Civil and Yard Structures Specifications

Consolidation Works at First and Second Container Terminals
King Abdulaziz Port in Dammam
Civil and Yard Structures Specifications

SA1980PMD-JAC-70-ERE-CE-00001 | P01
Saudi Global Ports Company

Consolidation Works at First and Second Container Terminals King Abdulaziz Port In
Dammam
Project No: SA1980PMD

Document Title: Civil and Yard Structures Specification
Document No.: SA1980PMD-JAC-70-ERE-CE-00003
Revision: S3-P01
Document Status: For Client Review and Approval
Date: March 2022
Client Name: Saudi Global Ports Company
Client No: -
Project Manager: Avni Buyukozer
Author: Murali Gunti/David Fanthorpe
File Name: SA1980PMD-JAC-70-ERE-CE-00003 – Civil and Yard Structures Specification
CH2M Saudi Ltd

8092 Legend Tower
Riyadh 12313-3735
Kingdom of Saudi Arabia
T +966.11.463.8720
F *966.11.463.8750
www.jacobs.com
© Copyright 2022 CH2M Saudi Limited .The concepts and information contained in this document are the property of Jacobs. Use or copying
of this document in whole or in part without the written permission of CH2M constitutes an infringement of copyright.
Limitation: This document has been prepared on behalf of, and for the exclusive use of Jacobs’ client, and is subject to, and issued in accordance with, the
provisions of the contract between Jacobs and the client. Jacobs accepts no liability or responsibility whatsoever for, or in respect of, any use of, or reliance
upon, this document by any third party.
Document history and status
Revision Date Description Author Checked Reviewed Approved
S3-P01 28/02/2022 For Client Review and Approval VS/DF/MTB MTB MG/DF AB
S3-P02 17/03/2022 Issued for Tender VS/DF/MTB MTB MG/DF AB
Contents
1 Introduction ...........................................................................................................................................................4
1.1 Background ............................................................................................................................................................4
1.2 Jacobs’ Role ...........................................................................................................................................................4
1.3 Reference Documents .........................................................................................................................................4
1.4 First Terminal Works ............................................................................................................................................5
1.5 Second Terminal Works ......................................................................................................................................6
2 Specification for Concrete ..................................................................................................................................8
2.1 Design Codes, Standards and Reference Documents ..................................................................................8
2.2 Concrete............................................................................................................................................................... 14
2.3 Materials .............................................................................................................................................................. 16
2.4 Aggregate ............................................................................................................................................................ 18
2.5 Reinforcement.................................................................................................................................................... 21
2.6 Water .................................................................................................................................................................... 22
2.7 Admixture............................................................................................................................................................ 23
2.8 Concrete Mix Design Requirements .............................................................................................................. 24
2.9 Placing.................................................................................................................................................................. 30
2.10 Formwork............................................................................................................................................................. 35
2.11 Reinforcement.................................................................................................................................................... 38
2.12 Mortar and Grouts ............................................................................................................................................. 39
2.13 Joints .................................................................................................................................................................... 41
2.14 Curing and Protection ...................................................................................................................................... 43
2.15 Finishes ................................................................................................................................................................ 44
2.16 Protection of Concrete ..................................................................................................................................... 47
2.17 Quality Records .................................................................................................................................................. 49
2.18 Actions in the Event of Non-compliance ..................................................................................................... 50
2.19 Repair and Remedial Works ............................................................................................................................ 50
3 Structural Steel Specification ......................................................................................................................... 51
3.1 Design Codes and Standards .......................................................................................................................... 51
3.2 Particular Requirements .................................................................................................................................. 53
3.3 Standard Requirements ................................................................................................................................... 55
3.4 QA/QC, Inspection, Testing and Commissioning....................................................................................... 72
3.5 Submittals ........................................................................................................................................................... 78
3.6 Shipping, Handling, Storage, and Installation ........................................................................................... 79
4 Pavement............................................................................................................................................................. 84
4.1 General ................................................................................................................................................................. 84
4.2 Design Codes, Client Parameters and References ..................................................................................... 84
4.3 Employer’s Requirements ............................................................................................................................... 84
4.4 Materials and Durability .................................................................................................................................. 85
4.5 Concrete Pavement Repair.............................................................................................................................. 86
5 TERMINAL LINE MARKING & SIGNAGE AND SAFETY BARRIERS............................................................ 91
5.1 Work Scope ......................................................................................................................................................... 91
5.2 Materials and Structural Form ....................................................................................................................... 91
5.3 Definition Dimensions and Layout ................................................................................................................ 92
5.4 Design Criteria .................................................................................................................................................... 92
5.5 Workmanship...................................................................................................................................................... 92
6 FENCING............................................................................................................................................................... 95
6.1 General ................................................................................................................................................................. 95
6.2 Materials and Structural Form ....................................................................................................................... 95
6.3 Definition Dimensions and Layout ................................................................................................................ 97
6.4 Design Criteria .................................................................................................................................................... 97
6.5 Workmanship...................................................................................................................................................... 97
7 SUSTAINABILITY PLAN AND ENVIRONMENTAL IMPACT OF MATERIALS ........................................... 98
7.1 SUSTAINABILITY PLAN .................................................................................................................................... 98
7.2 ENVIRONMENTAL IMPACT OF MATERIALS .................................................................................................. 98
Appendix A. PERMITTED PAVEMENT OPTIONS

Appendix B. BOND COATS, TACK COATS AND OTHER BITUMINOUS SPRAYS (SHEETS 1, 2 AND BINDER
DATA SHEET)
Appendix C. SERIES 700 ROAD PAVEMENTS – GENERAL
Appendix D. SERIES 800 ROAD PAVEMENTS — UNBOUND, CEMENT AND OTHER HYDRAULICALLY
BOUND MIXTURES
Appendix E. SERIES 900 ROAD PAVEMENTS – BITUMINOUS BOUND MATERIALS
Appendix F. SERIES 1000 CONCRETE PAVEMENTS
Appendix G. SERIES 100 CONTRACTOR TESTING
1 Introduction
1.1 Background
Saudi Global Port (SGP) intends to develop the First Container Terminal (“FT”) and the Second Container
Terminal (“ST”) in Dammam, Saudi Arabia by upgrading and expanding the terminal facilities. The current
project is the first phase in that upgrading.
Berths 23 and 24 on the FT are to be repaired and refurbished together with repair and reconstruction of
the yard pavement and the renovation of sixteen buildings.
On the ST the quay wall for an additional berth, berth 44, is to be constructed together with the provision of
an additional 3 hectares of pavement and infrastructure. There will also be new buildings and a further area
of 14 hectares to be reclaimed.
This project is intended to develop the port to accept the next generation of mega vessels while
incorporating sustainability to minimise the environmental impact of terminal operations. In addition, smart
port designs will be introduced to enhance SGP’ s benchmark productivity.
Figure 1.1: First and Second Terminal Masterplan
1.2 Jacobs’ Role

Saudi Global Ports (SGP) holds a 30-year operating concession for the First and Second container terminals
from the Saudi Port Authority (MAWANI). SGP have appointed Jacobs as their consulting civil engineer for
the design and documentation of the entire first phase of the development project.
1.3 Reference Documents

This specification is to be read in conjunction with the following documents:
• Volume 2 Specifications
o SA1980PMD-JAC-70-SPC-MR-00001-T1 Specification-P03
o SA1980PMD-JAC-80-SPC-MR-00001-T2 Specification-P03
o SA1980PMD-JAC-00-ERE-EL-00001_P03 Dry Utilities Specifications
o SA1980PMD-JAC-70-ERE-ME-00001_P02 - Wet Utilities Specification
• Volume 3 Contract Drawings
• Volume 5 Site Data and As-builts
1.4 First Terminal Works

Jacobs will undertake concept and detailed design of refurbishment and new works required for the
development of civil and pavement, and yard structures works in the First Terminal.
The marine works of the First Terminal comprise the repair and refurbishment of Berths 23 and 24 of total
length of 480m. The construction items under upgrading of the FT include (but are not limited to) the
following:
• Repairs to existing quay wall.
• Demolition, site clearances.
• Crane rail removal and re-installation.
• Repairs to existing concrete pavement
• Reefer Gantries,
• Approvals and permits.
The project will be constructed within an operational port environment and is directly adjacent to active
berths, a container yard and navigational manoeuvring areas.
This specification identifies the requirements for various elements of the yard including pavement, reefer
gantry, leaky container pits, wet and dry utilities manholes, Reefer wash area, Fence Foundations, Road
Barriers and light pole foundations.
Refurbishment works required on the First Terminal are to be developed by the Contractor upon completion
of the relevant assets and site surveys.
Upon review of the output of these surveys, where required the Contractor is required to develop solutions
to repair any damage / deterioration of the asset(s). All repairs are to be made in compliance with the as-
built detail drawings as per Volume 5 Site Data, Volume 3 Contract Drawings, and this specification. Where
a discrepancy between the as-built detail drawing and this specification document exists, the specification
shall take precedent.
All repairs and modifications proposed by the Contractor require approval by the Engineer prior to
undertaking the works.
Contract documents and drawings related to first terminal works are under the document control number
series beginning with SA1980PMD-JAC-10.
1.5 Second Terminal Works

Extension of the Second Terminal Civil and Yard Structure works is to be undertaken in compliance with this
specification and the drawings from Volume 3 Contract Drawings.
The contractor shall confirm the location of all existing assets relative to the proposed Second Terminal
Works. Upon confirmation of the location of existing services and civil works, the contractor shall verify the
proposed designs with respect to the alignment of pavement and depth of services. Where coordination
between existing services is required, a minimum of 300mm separation between services is to be maintained.
1.5.1 Second Terminal Options

1.5.1.1 Option 1 – 3Ha Option
It is proposed to develop the Second Terminal in two phases. The first option of development comprises a
3-hectare extension including 225 m of new berth.
Contract documents and drawings related to Second Terminal 3Ha works are under the document control
number series beginning with SA1980PMD-JAC-30.
1.5.1.2 Option 2 – 3Ha with Additional 14Ha Option
The second option of development comprises of a 3-hectare extension including 225 m of new berth and
14-hectare yard extension with revetment.
Contract documents and drawings related to Second Terminal 3Ha +14Ha works are under the document
control number series beginning with SA1980PMD-JAC-50.
2 Specification for Concrete
2.1 Design Codes, Standards and Reference Documents
2.1.1 General
This Specification is primarily written in accordance with the British and European Standards. However, this
doesn’t preclude the Contractor from following other National or International Standards of equivalent
standing, subject to the approval of the Client/Engineer.
The order of precedence, in case of conflict, shall be as given below:
• Employers Requirements (all parts)
• British Standards
• European Standards (EN)
• American Standards
• International Standards and Guidance
• Kingdom of Saudi Arabia Standards
The materials and construction of the Works covered by this Specification are required to comply in all
respects with the relevant Standards, Specifications and Codes of Practice, at the time of the effective
standards cut-off date indicated in the Contract (February 2021) except as explicitly varied by this
Specification. A list of Standards, Specifications and Codes of Practice referred is given in below sections.
2.1.2 Primary Design Codes and Standards

Table 2-1 to
Table 2-4 provide a list of the design codes, standards and guidelines that will be used during the design of
the works of the project.
Table 2-1: British Standards
Reference Title
BS 812-104 Method for qualitative and quantitative Petrographic examination of aggregates
BS 812-109 Methods for determination of moisture content
BS 812-111 Methods for the determination of ten per cent fines value (TFV)
Specification for bitumen-based coatings for cold application, suitable for use in
BS 3416
contact with potable water
BS 4449 Specification for carbon steel bars for reinforcement of concrete
BS 4482 Steel wire for the reinforcement of concrete products. Specification
BS 4483 Steel fabric for the reinforcement of concrete. Specification
BS EN 206 Concrete - Specification, performance, production and conformity
BS 8500-1 Concrete - Complementary British Standard to BS EN 206-1
BS 5606 Guide to accuracy in building
BS 6213 Selection of construction sealants
Reference Title
BS 6349 Maritime structures (multiple parts)
BS 6744 Stainless steel bars - reinforcement of concrete - requirements and test methods
BS EN 1990 Eurocode 0: Basis of structural design (multiple parts)
BS EN 1991 Eurocode 1: Action on structures (multiple parts)
BS EN 1992-1-1 Eurocode 2: Design of concrete structures. General rules and rules for buildings
Eurocode 2. Design of concrete structures. Concrete bridges. Design and detailing
BS EN 1992-2
rules
BS EN 1992-3 Eurocode 2. Design of concrete structures. Liquid retaining and containing structures
BS 8204-2 Screeds, bases and in situ floorings. Concrete wearing surfaces. Code of practice
BS 7213 Metal arc welding of steel for concrete reinforcement
BS EN ISO 17660 Welding of reinforcing steel (Multiple parts)
Spacers and chairs for steel reinforcement and their specification. Product
BS 7973-1
performance requirements
Spacers and chairs for steel reinforcement and their specification. Fixing and
BS 7973-2
application of spacers and chairs and tying of reinforcement
Specification for scheduling, dimensioning, bending, and cutting of steel
BS 8666
reinforcement for concrete
BS EN 12620 Aggregates for concrete
PD6682-1 Aggregates –Part 1: Aggregates for concrete - Guidance on the use of BS EN 12620
PD 6682-3 Aggregates –Part 3: Aggregates for mortar - Guidance on the use of BS EN 12620
BS EN 197-1 Cement. Composition, specifications, and conformity criteria for common cements
BS EN 197-2 Cement. Conformity evaluation
BS EN 450 Fly ash for concrete. Definitions, specification, and conformity criteria
BS EN 480 Admixtures for concrete, mortar, and grout. (Various parts)
Welding consumables – covered electrodes for manual metal arc welding of non-
BS EN 499
alloy and fine grain steels- classification
Welding consumables – Covered electrodes for manual metal arc welding of non-
BS EN ISO 2560
alloy and fine grain steels-Classification
BS EN 932 Tests for general properties of aggregates- (various parts)
BS EN 933-1 Determination of particle size distribution. Sieving method.
BS EN 933-3 Determination of particle shape
BS EN 933-7 Determination of shell content. Percentage of shells in coarse aggregate
Welding –recommendations for welding metallic materials- Part 1: General guidance
BS EN 1011-1
for arc welding
Tests for mechanical and physical properties of aggregates. Determination of the
BS EN 1097-1
resistance to wear (micro-Deval)
BS EN 1097-2 Methods for the determination of resistance to fragmentation
BS EN 1097-3 Determination of loose bulk density and voids
Reference Title
BS EN 1097-6 Determination of particle density and water absorption
Tests for mechanical and physical properties of aggregates. Determination of the
BS EN 1097-8
polished stone value
BS EN 1367-2 Magnesium sulphate soundness test
BS EN 1367-4 Determination of drying shrinkage
Products and systems for the protection and repair of concrete structures. Test
BS EN 13579
methods – drying test for hydrophobic impregnation
Products and systems for the protection and repair of concrete structures. Test
BS EN 13580
methods. Water absorption and resistance to alkali for hydrophobic impregnations.
Products and systems for the protection and repair of concrete structures (various
BS EN 1504
parts)
BS EN 1744-1 Tests for chemical properties of aggregates. Chemical analysis
Tests for chemical properties of aggregates. Determination of acid-soluble chloride
BS EN 1744-5
salts
Testing concrete in structures. Cored specimens. Taking, examining, and testing in
BS EN 12504-1
compression
BS 1881-122 Methods of testing concrete. Method for determination of water absorption
BS 1881-124 Methods for analysis of hardened concrete
BS 1881-204 Recommendations on the use of electromagnetic cover meters
BS 1881-206 Recommendations for determination of strain in concrete
BS 1881-208 Recommendations for the initial surface absorption of concrete
Mixing water for concrete –Specification sampling, testing, and assessing the
BS EN 1008 suitability of water, including water recovered from processes in the concrete industry,
as mixing water for concrete
Admixtures for concrete, mortar, and grout Part 2: concrete admixtures-Definitions,
BS EN 934-2
requirements, conformity, marking and labelling
BS EN 10088-1 Stainless steels. List of stainless steels
BS EN 12350-1 Testing fresh concrete – Part 1: sampling
BS EN 12350-2 Testing fresh concrete – Part 2: slump test
BS EN 12350-5 Testing fresh concrete – Part 5: flow table test
BS EN 12350-6 Testing fresh concrete – Part 6: Density
BS EN 12350-7 Testing fresh concrete. Air content – pressure methods
BS EN 12350-8, Testing fresh concrete - Part 8: Self-compacting concrete - Slump-flow test
BS EN 12350-9 Testing fresh concrete - Part 9: Self-compacting concrete - V-funnel test
BS EN 12350-10 Testing fresh concrete - Part 10: Self-compacting concrete - L box test
BS EN 12350-11 Testing fresh concrete - Part 11: Self-compacting concrete - Sieve segregation test
BS EN 12350-12 Testing fresh concrete - Part 12: Self-compacting concrete - J-ring test,
Reference Title
Testing concrete - Part 1: Shape, dimensions and other requirements for specimens
BS EN 12390-1
and moulds
BS EN 12390-2 Testing hardened concrete- Part 2: making and curing specimens for strength testing
BS EN 12390-3 Testing hardened concrete- Part 3: compressive strength testing of test specimens
Testing hardened concrete – Part 4: Compressive strength- specification for testing
BS EN 12390-4
machines
BS EN 12390-5 Testing hardened concrete – Part 5: flexural strength testing of test specimens
BS EN 12390-8 Testing of hardened concrete- Part 8: Depth of penetration of water under pressure
BS EN 13263-1 Silica fume for concrete. Definitions, requirements and conformity criteria
BS EN 13263-2 Silica fume for concrete. Conformity evaluation
BS EN 13791 Assessment of in-situ compressive strength in structures and precast components
Assessment of in-situ compressive strength in structures and precast components –
BS 6089
Complementary guidance to that given in BS EN 13791
Ground granulated blast furnace slag for use in concrete, mortar and grout -
BS EN 15167-1
definitions, specifications and conformity criteria
Ground granulated blast furnace slag for use in concrete, mortar and grout -
BS EN 15167-2
conformity evaluation
Metallic materials. Calibration of force-proving instruments used for the verification
BS EN ISO 376
of uniaxial testing machines
Method 326E:1995 Plastics. Determination of tensile properties. Test conditions for
BS EN ISO 527
films and sheets
Welding consumables. Covered electrodes for manual metal arc welding of non-alloy
BS EN ISO 2560
and fine grain steels. Classification
Paints and varnishes. Corrosion protection of steel structures by protective paint
BS EN ISO 12944
systems. Execution and supervision of paintwork
BS ISO 14654 Epoxy-coated steel for the reinforcement of concrete
Epoxy powder and sealing material for the coating of steel for the reinforcement of
BS ISO 14656
concrete
Rubber vulcanized or thermoplastic. Determination of tear strength. Small (Delft) test
BS ISO 34-2
pieces
BS EN ISO 9001 Quality management systems - Requirements
Table 2-2: Acceptable Alternative British Standards
Reference Title
BS 5328 Concrete (various parts)
BS 3892-1 Specification for pulverized-fuel ash for use with Portland cement
BS 4027 Specification for sulfate-resisting Portland cement
BS 812-2 Methods for the determination of density
Reference Title
BS 812-101 Guide to sampling and testing aggregates
BS 812-102 Methods for sampling.
BS 812-103 Method for determination of particle size distribution. Sediment test.
BS 812-103.1 Method for determination of particle size distribution. Sieve tests.
BS 812-103.2 Sedimentation test
BS 812-
Testing aggregates. Method for determination of particle shape – Flakiness index
Section 105.1
BS 812- Testing aggregates. Method for determination of particle shape – Elongation index
Section105.2 of coarse aggregate
BS 812-121 Method for the determination of soundness
BS 812-123 Method of determination of alkali-silica reactivity
BS 812, Part 117 Testing aggregates – Method for determination of water-soluble chloride salts
BS 882 Specification for aggregates from natural sources for concrete
BS 1881-101 Method of sampling fresh concrete on site
BS 1881-102 Method for the determination of slump
BS 1881-108 Method for making test cubes from fresh concrete
BS 1881-111 Method of normal curing test of test specimens (20°C method)
BS 1881-116 Method for determination of compressive strength of concrete cubes
BS 1881-128 Methods for analysis of fresh concrete
BS 3148 Methods of test for water for making concrete
BS 5075 Admixtures
BS 6699 Specification for ground granulated blast furnace slag for use with Portland cement
Welding consumables – covered electrodes for manual metal arc welding of non-
BS EN 499
alloy and fine grain steels- classification
Welding consumables. Covered electrodes for manual metal arc welding of non-
BS EN ISO 2560
alloy and fine grain steels. Classification
Table 2-3: Acceptable American Standards
Reference Title
Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete
ASTM A 615
Reinforcement
Standard Practice for Making and Curing
ASTM C 31
Concrete Test specimens in the Field
ASTM C 33 Standard Specification for Concrete Aggregates
Standard Test Method for Compressive
ASTM C 39
Strength of Cylindrical Concrete Specimens
Standard Test Method for Organic Impurities in
ASTM C 40
Fine Aggregates for concrete
Standard Test Method for Organic Impurities in
ASTM C 87
Fine Aggregate on strength of mortar
Reference Title
Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate for
ASTM C 88
Magnesium Sulfate
ASTM C 94 Standard Specification for Ready-Mixed Concrete
ASTM C 117 Standard Test Method for Materials Finer than 75 µm
ASTM C 127 Standard Test Method for Specific Gravity and Absorption of Coarse Aggregate
ASTM C 128 Standard Test Method for Specific Gravity and Absorption of Fine Aggregates
Standard Test Method for Resistance to Degradation of Small Size Coarse
ASTM C 131
Aggregate
ASTM C 136 Standard Test method for Sieve Analysis of Fine and Coarse Aggregate
ASTM C142 Standard Test method for clay lumps and friable particles in aggregates
ASTM C 143 Standard Test Method for Slump of Hydraulic Cement Concrete
ASTM C 150 Standard Specification for Portland Cement
ASTM C 172 Standard Practice for Sampling Freshly Mixed Concrete
ASTM C 232 Standard Test methods for bleeding of concrete
ASTM C 260 Standard Specification for air-entraining admixtures for concrete
ASTM C 494 Standard Specification for Chemical Admixtures for Concrete
ASTM C856 Standard Practice for the petrographic examination of hardened concrete
ASTM C 1152 Standard Test Method for Acid-Soluble Chloride in Mortar and Concrete
ASTM C1260 Standard Test for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)
Standard Test Method for Rapid Assessment of Static Segregation Resistance of
ASTM C1712
Self-Consolidating Concrete Using Penetration Test
ASTM D 36 Test method for softening point of bitumen (ring-and-ball apparatus)
ASTM D 543 Test method for resistance of plastics to chemical reagents
ASTM D 570 Test method for water absorption of plastics
ASTM D 638 Test method for tensile properties of plastics
ASTM D 751 Test method for coated fabrics
ASTM D 1000 Test methods for pressure-sensitive adhesive coated tapes
ASTM D 1004 Test method for initial tear resistance of plastic film and sheeting
ASTM D 5385 Test method for hydrostatic pressure resistance of waterproof membranes
ASTM E96 Test methods for water vapor transmission of materials
Test methods for water vapor retarders used in contact with earth under concrete
ASTM E154
slabs, on walls, or as ground cover
Standard Test Method for determining the effects of chemical admixtures on
ASTM G109 corrosion of embedded steel reinforcement in concrete exposed to chloride
Environments
Table 2-4: Guideline Documents

Reference Title
AASHTO T277 Electrical Indication of Concrete’s ability to resist chloride ion penetration
ASTM C1202
ACI 305R Hot Weather Concreting
BRE Special Digest 1 Concrete in Aggressive Ground, 2005
BRE Digest 330 Alkali-silica reaction in concrete- Part2 Detailed guidance for new construction,
2004
NT Build 492 NT Build 492, Concrete, mortar, and cement-based repair materials: chloride
migration coefficients from non-steady-state migration experiments. Nord Test
Method, 1999
NT Build 443 NT Build 443, Concrete, Hardened: Accelerated chloride penetration, Nord Test
Method, 1995
CIRIA Report 135 CIRIA Report 135, Concreting deep lifts and large volume pours, 1995
CIRIA Report 136 CIRIA Report 136, Formwork striking times: criteria, prediction and method of
assessment, 1995
CIRIA C577 - Concrete Guide to the construction of reinforced concrete in the Arabian Peninsula
Society Special
Publication CS 136
Concrete Society Guide to the design of concrete structures in the Arabian Peninsula
Special Publication CS
163
Concrete Advice Sheet Assessment of in-situ concrete strength using data obtained from core testing
147
Diagnosis of alkali- British Cement Association, Diagnosis of alkali-silica reaction, 1992
silica reaction
Ifsttar, Technics and Recommendations for preventing disorders due to Delayed Ettringite Formation,
methods, GTI5-A Marne-la-Vallée: Ifsttar, Technics and methods, GTI5-A, 2018
Rilem CPC 11.3 Rilem CPC 11.3 Absorption of water by immersion under vacuum.
Self-compacting European guidelines for self-compacting concrete: Specification, production, and
concrete use, EFNARC, 2005
2.2 Concrete
2.2.1 General
Concrete as a material shall be provided in accordance with this Specification. The requirements set out in
the Specification are directed to the achievement of durability as well as strength. The principal exposure
risks are the ingress of chloride ions, damage by sulphates and salt crystallisation, carbonation, impact, and
abrasion.
Concrete for marine works and structures shall be as per Marine Specifications SA1980PMD-JAC-70-SPC-
MR-00001 and SA1980PMD-JAC-80-SPC-MR-00001. Concrete for Pavement works shall be as per Section
4 of this specifications.
2.2.2 Service Conditions

The environmental exposure conditions and design life are classified in accordance with BS 6349-1-4, and
BS 8500-1 below:
Table 2-5: Design life, Exposure class and Maximum design crack width
Maximum design
Location Exposure Class Working Life (years)
crack width (mm)
Airborne Chlorides2 0.30
Landside 50
XS1, XC3/4
Landside (buildings 0.40
Mild3 50
internal elements)
Marine Tidal and Splash 0.30
50
Above LAT-3.0m XS3, XC3/4
Marine Submerged 0.30
50
Below LAT-3.0m XS2, XC2
Buried (Marine (below 0.30
3
dredged level) or Landside XS2, DC-3/AC-3, S-3 50
(below finish level))
Water-retaining Structures XC3/4 50 0.10
Notes
1
Structures >1 km from coast
2
Elements not in direct contact with saline water
3
Guide to the design of concrete structures in the Arabian Peninsula (CS 163)
The working life shall be 50 years without major repairs, where major repairs would include breaking out and
reinstating concrete due to reinforcement corrosion. The serviceability limit state for durability, considered
for the design life (50 years) of the structure is ‘corrosion initiation’.
All reinforced concrete shall be designed to resist chloride induced corrosion. Secondary cementitious
materials (such as ground granulated blast furnace slag, fly ash and/or silica fume) and low water-cement
ratios shall be used. In addition, specified curing and cover requirements shall be rigidly enforced.
All concrete in contact with the ground shall be designed to resist sulphate attack and salt crystallisation.
Secondary cementitious materials and low water-cement ratios shall be used. Surface protection in the form
of membranes and coatings shall be employed apart from piles and quay walls.
2.2.3 Precast Concrete

(a) The Contractor shall submit for review details of arrangements for casting, handling and placing
precast units. For each type of item, the minimum required concrete strength for lifting without
damage shall be calculated. The equivalent in-situ compressive strength or maturity shall be
tabulated. These shall include safety factors in accordance with CIRIA Report 136.
(b) Contractor shall cast samples of precast elements for approval, and approved element samples shall
be retained on site as the control standard for subsequent precast element production.
(c) Precast concrete units shall be cast on manufactured beds. The beds shall not be liable to settlement
and shall have smooth, hard and level surfaces. Each unit shall be marked with a serial number and
date of casting.
(d) Quay wall blocks shall not be moved until the representative cylinders or cubes reach adequate
compressive strength for handling and shall not be placed until the specimens representing them
reach the specified 28-day Characteristic Strength. For precast concrete slabs (such as for the new
capping beam), the concrete strength at the time of lifting shall be considered in the design and once
lifted, can be placed at their final location however additional loading (from concreting) shall not
occur before they have attained their 28-day characteristic strength.
(e) Precast elements shall be cast within the following dimensional tolerance (a) in plan +3mm to 0mm
(b) in height +3mm to 0mm. Furthermore, no face of an element shall deviate by more than 3mm
from a straight line 3m long laid on the face.
(f) When Contractor intends to purchase factory-made precast concrete items, trial mixes may be
dispensed with, provided that evidence is given to satisfy the Engineer that the factory produces
concrete which complies with this Specification. The evidence shall include details of mix proportions,
water-cement ratios, workability/consistence, compressive strength and third-party accreditation.
(g) Precast items shall comply with the relevant British Standard. In addition, concrete manholes units,
pipes and fittings shall be subject to routine water absorption testing Table H1 of Annex A of BS EN
1916.
(h) Bedding mortar shall be dry pack bedding mortar with cement to sand ratio of 1:3 comprised of clean
dune sand and approximately 550 kg/m3 of cement with water dosed accordingly to achieve a stiff
mixture.
2.3 Materials
2.3.1 Cementitious Materials
The cementitious materials to be used throughout the Works shall be obtained from manufacturers
approved in writing by the Engineer and shall be as described under one of the following headings:
(a) Portland Cement (CEM l) complying with BS EN 197 or ASTM C150 but containing not less than
4% and not more than 9% proportion by mass of tri-calcium aluminate (C3A).
(b) Sulphate Resisting Portland Cement (SRPC) complying with either ASTM C150 Type V.
Alternatively, the cementitious combination can comply to the relevant clauses of BS EN 197 for
sulphate resistance (‘SR’) classification.
(c) Pulverised fuel ash (PFA) complying with BS EN 450-1.
(d) Silica fume (SF) complying with BS EN 13263 as un-densified powder or a slurry.
2.3.2 Silica Fume

Silica fume shall not contain more than 0.2% silica metal by mass or any deleterious materials, such as
carbon, quartz, rust, and cellulose fibres. The materials must originate from silicon plants producing silicon
or ferrosilicon with silicon contents higher than 85%. The suitability of the silica fume shall be ascertained
by testing to confirm to BS EN 13263 and that its properties are compliant with this specification, including
the limits presented in the table below.
Table 2-6: Silica Fume Properties
Parameter Requirement
Silica Fume Powder
SiO2 ≥ 85%
Loss on Ignition ≤ 5%
Fineness ≥ 12,000 m2/kg
Activity index > 95% after 28 days
Carbon content ≤ 2%
Alkali level as Na2O equivalent ≤ 2%
Relative density ≥ 2.2
Moisture content ≤ 3%
Silica Fume Slurry
pH 5.5 ± 1
Water content 50% ± 2%
Relative density 1.3-1.4
Silica fume shall be incorporated as a slurry or, where this is not available, in powder form. Where silica fume
is incorporated as a powder, the Contractor shall take necessary measures, during concrete mixing, to ensure
the silica fume has been fully dispersed.
Attention is drawn to the health hazards associated with silica fume, particularly in the powdered form, and
the need to adopt protective systems to reduce dust generation and the potential risk of hydrogen evolution
due to silica metal contamination.
2.3.3 Cementitious Materials Certification and Testing

Cementitious materials shall be certified by the manufacturer as complying with the requirements of the
appropriate Standard(s). Before ordering cement, the Contractor shall submit details of the proposed
supplier and information on the proposed methods of transport, storage and certification for approval and
show that the quantity and quality required can be attained and maintained throughout the construction
period.
Representative samples of the proposed cement are to be taken and forwarded to an independent
laboratory approved by the Employer for analysis before the source is approved.
Having obtained approval, the Contractor shall not change the agreed arrangements without permission.
Each consignment of cementitious materials shall be accompanied by a certificate showing the place of
manufacture and the results of standard tests carried out on each day’s bulk production included in the
consignment.
Cementitious type for each mix shall be as shown in the table of concrete mixes.
2.3.3.1 Portland Cement Testing
Tests on Portland cement, sulphate resisting Portland cement and Portland-pozzolan cement shall be
carried out for the properties listed in the following table to assess with test methods and limits to the
relevant parts of the BS EN 196 as appropriate. This shall continue for each consignment is completely used.
Non- compliant cement shall be rejected and removed from site immediately.
Table 2-7: Testing Frequency of Portland Cement
Properties Frequency
Strength Initial and monthly
Fineness Initial and monthly
Setting Time Initial and monthly
Soundness Initial and monthly
Loss on Ignition Initial and monthly
Insoluble Residue Initial and monthly
Alkali content as Na2O Equivalent Initial
Chloride Content Initial
Tri-calcium Aluminate Content Initial
SiO2, MgO, AI2O3, Fe2O3, CaO, SO3 contents Initial
2.3.3.2 Pulverised Fuel Ash (PFA) Testing
PFA shall be tested for the following parameters:
i. Strength,
ii. Setting time.
iii. Fineness.
iv. Moisture content.

2.3.3.3 Silica Fume (SF) Testing
Silica fume shall be tested monthly for the following parameters:
i. Activity index.
ii. pH (slurry).
iii. Water content (slurry),
iv. Relative density (slurry).
2.3.4 Delivery and Storage of Cementitious Materials

Deliveries of cementitious materials shall be made in undamaged, dry, sealed bags or purpose made bulk
delivery vehicles. Bagged materials shall be stored in dry, weather tight structures with a raised floor, or in
suitable silos. Bagged cement shall not be stored higher than 10 bags at a temperature of not less than 8°C.
Different consignments (if bagged) and binder types shall be stored separately and used in the order in
which they are received. No bags of cement shall be used unless the manufacturer's seals are intact at the
time of mixing and the bags are marked with the source, material type, consignment reference and date of
manufacture.
Cementitious materials shall be fresh when delivered to site and shall be free-flowing and free of lumps
when used. Any cementitious binders stored on site longer than one month may be required for retest. If on
retesting the cement does not conform to the Specification, the whole of the remaining part of that
consignment shall be rejected.
The temperature of the cementitious materials shall not exceed 65°C at the time of incorporation into a
concrete mix.
2.4 Aggregate
2.4.1 General
Aggregate shall comply with the requirements of BS EN 12620 and PD 6682 and shall be of normal weight
and from natural sources. The Contractor shall obtain approval of proposed aggregate sources and shall
select suitable aggregate and samples of sand and stone for specified testing before obtaining aggregate.
Laboratory tests according to the British Standard, American Standard or the equivalent British or CEN
Standard shall be made at regular intervals to confirm the suitability of aggregate.
2.4.2 Quality and Testing

Aggregate shall be free from clay, loam and soft soil, shale or decomposed stone, organic matter, other
impurities, or any matter likely to affect durability of concrete and shall be hard and dense. The aggregate
for exposed concrete shall be supplied from sources known to be free of staining impurities such as coal,
lignite, iron pyrites, etc.
The following criteria shall be ascertained by testing to assess the suitability of the aggregate.
Table 2-8: Aggregate Testing Frequency
Aggregate Testing Frequency

Frequency of Testing
Test Reference Testing Standard Once per Period of Days
Coarse Fine
Moisture content BS EN 1097-5 2/day 3/day
Grading1 BS EN 933-1 1 1
Shell content1 BS EN 933-7 1 1
1
Fines content BS EN 933-1 1 1
Specific gravity and water absorption BS EN 1097-6 7 7
Flakiness Index BS EN 933-3 7 -

Acid soluble sulfate and chloride BS EN 1744 -1 2 2
content1
Clay lumps ASTM C142 14 14
Organic impurities ASTM C40 & C87 - 56
10% Fines Value BS 812- 111 56 -
Resistance to fragmentation BS EN 1097-2 Initial and every 90 days
Resistance to abrasion BS EN 1097-8 Annex A Initial and every 90 days
Resistance to wear BS 1097 -1 Initial and every 90 days

Soundness (Magnesium sulphate) BS EN 1367-2 Initial and every 90 days
Potential alkali reactivity Clause 2.3.2 Initial and every 90 days
Drying shrinkage BS EN 1367-4 Initial and every 90 days
Note:
1. After 3 months period of successful test results, the testing frequency of Grading, Shell content,
Fines content and Acid soluble sulfate and chloride content testing may be relaxed to 7 days,
subject to agreement with the Engineer.
Table 2-9: Aggregate Testing Limits
EN 12620 category
Properties
Requirements
Grading (BS EN933-1)2 4/20 or 2/14
Coarse aggregate (graded) Coarse aggregate (single-sized) 10/20 or 6.3/14 or 4/10
Fine aggregate 0/4 or 0/2
EN 12620 category
Properties
Requirements
Uncrushed gravel FI50
Crushed rock or crushed gravel FI35
Shell Content (%) (BS EN 933- 7)
Fine aggregate ≤10% by mass (2.36-5mm)
Coarse aggregate ≤2% by mass (>2.36mm)
Fines (BS EN933-1)
≤1.5
Uncrushed, partially crushed, or crushed gravel coarse aggregate.
Gravel all-in aggregate
≤3
Crushed Rock all-in aggregate
≤11
Crushed rock coarse aggregate
≤4
Uncrushed partially crushed or crushed gravel sand
≤3
Crushed rock sand ≤10
Clay Lumps (%) (ASTM C40 & C87) ≤2
Coarse aggregate ≤1
Fine aggregate
Organic impurities ASTM C40 & C87 Color plate ≤ 3 Setting within 30
Fine aggregate minutes
Strength ≥ 95%
10% Fines Value (BS 812- 111) ≥ 100 kN
Coarse aggregate
Resistance to fragmentation (BS EN1097-2) LA30
Resistance to abrasion (BS EN1097-8, Annex A) ≤ 15
Coarse aggregate
Resistance to wear (BS EN1097-1) ≤ 35
Coarse aggregate
Soundness (Magnesium sulphate) (BS EN 1367-2) MS18
Acid-soluble sulfate content (BS EN1744-1)1
Aggregates (other than air-cooled blastfurnace slag) AS0.2
Acid soluble chloride content (BS EN 1744-1)1
Reinforced concrete ≤0.05%
Pre-stressed concrete ≤0.01%
Water absorption (BS EN1097-6) ≤2%
Drying shrinkage (BS EN1367-4) ≤0.075%
Potential alkali reactivity Clause 2.4.3
Coarse and fine aggregate
2.4.3 Alkali-Reactivity Potential

Aggregate shall not contain any materials that are reactive with alkalis in the aggregate itself or in the
cement, the mixing water or in water in contact with the finished concrete or mortar in amounts sufficient to
cause excessive localised or general expansion of the concrete or mortar. Annex B of BS 8500-
2:2015+A1:2016 shall be used as the main mitigation guideline for Alkali-Aggregate Reaction (AAR).
The Contractor shall initially assess an aggregate source by petrographic examination in accordance with BS
EN 932-3 and testing in accordance with ASTM C289. If potential reactivity is indicated, then accelerated
mortar bar tests in accordance with ASTM C1260 shall be carried out. Expansion values in excess of 0.1%
at 14 days shall be taken as deleterious.
2.4.4 Storage of Aggregates

Aggregate shall be stored in concrete-based bins with the base laid to falls to provide drainage away from
the storage area or on stages to prevent intermixing and the inclusion of dirt and foreign materials. Each
size of aggregate shall be stored separately.
Storage bins shall be emptied and cleaned regularly.
2.4.5 Aggregate for Control of Early-age Thermal Cracking

To control of the risk of early-age thermal cracking in sections with a minimum thickness greater than 0.5
m, the selection of coarse aggregate shall be from a rock type having a coefficient of thermal expansion less
than 10 x 10-6 / °C, such as limestone or similar approved.
2.5 Reinforcement
2.5.1 Steel for Reinforcement
Reinforcement for use in reinforced concrete shall comply where appropriate with BS 4449, BS 4482, BS
4483, BS 6744, and BS 8666.
High-yield deformed bars shall be Grade B500 complying with BS 4449, unless otherwise approved. The
minimum Modulus of Elasticity for any reinforcing steel bar shall be not less than 200 kN/mm².
Epoxy coated reinforcement shall not be used.
2.5.2 Tying Wire

Tying wire shall be black annealed mild steel of diameter approximately 1.5 mm. Tying wire shall have the
same minimum concrete cover as detailed for reinforcement. Stainless steel 1.2mm diameter shall be used
for stainless steel reinforcement.
2.5.3 Testing
Prior to approval the Contractor shall provide copies of the manufacturer's certificates of test results relating
to the steel reinforcement to be supplied and shall additionally provide independent test results obtained
from an approved laboratory. Samples of each bar size shall be selected randomly from each consignment
of reinforcement delivered to the site. One sample shall be taken per 5,000m length of bars delivered to
site. The samples shall be tested in accordance with BS 4449 for chemical and mechanical properties.
2.5.4 Stainless Steel

Where required stainless steel reinforcement shall be hot rolled austenitic stainless-steel Type 1.4436 to BS
EN 10088-1, with a minimum tensile strength of 510N/mm 2. Test certificates and product analysis
certificates shall be provided.
Dowels shall be made from Steel Designation 1.4429 or 1.4436 and Grade 200 or 500 steel bars complying
with BS 6744.
2.5.5 Storage of Reinforcement
Reinforcement shall be stored above ground on a concrete slab under cover and racked as necessary for
protection from contamination and to avoid deformation of the bars. Similar provision shall be made in the
reinforcement bending area.
Individual bundles of reinforcing bars shall be durably marked to identify source, batch number, type and
diameter. Reinforcement must not be roughly handled, dropped from a height, or subjected to shock loading
or mechanical damage.
At the time of placing concrete, reinforcement shall be clean and free of corrosive pitting, loose mill scale,
loose rust, ice, oil, and other substances which may adversely affect the reinforcement concrete, or bond
between the two. Any reinforcement that becomes contaminated shall be abrasive blasted with an approved
blasting media or high pressure jetted using water complying with Clause 2.6.
2.6 Water
2.6.1 Water General
The Contractor shall make his own arrangements and obtain approval for the provision of fresh water for the
manufacture and curing of concrete.
2.6.2 Quality
Water to be used for mixing and curing concrete and mortar shall be fresh and free from sediment and
dissolved or suspended matter that may be harmful and shall comply with the requirements of BS EN 1008.
It shall be fresh, clean, potable, and free from any substances that may be deleterious to concrete or steel.
The pH of water used in concrete shall be not less than 5.0 or more than 8.0. The use of water recovered
from washing out the plant shall be in accordance with Annex A of BS EN 1008. A deemed-to-satisfy
condition shall be that water comes from a desalinated, un-chlorinated drinking water supply. Water
samples from other sources of supply shall be taken for analysis before any concrete work is commenced,
and at monthly intervals thereafter throughout the duration of the Contract. If the samples are unacceptable
Contractor shall either change to a new supply or take steps to improve the existing source, as approved.
Under no circumstance shall seawater be used for mixing or curing concrete.
The Contractor shall avoid water being contaminated by earthy, vegetable, or organic matter, acid or alkaline
substances, substances or other deleterious matter in solution or suspension that, in the opinion of the
Employer, will impair the strength or durability of the concrete.
2.6.3 Sulphate and Chloride Content

The sulphate (SO4) content shall not exceed 500ppm, the chloride ion content shall not exceed 500ppm
and the alkali content shall not exceed 600ppm. Tests to establish the contents shall be carried out at
monthly intervals.
The concrete mix shall also comply with the overall limits for chloride, sulphate and alkalis given elsewhere
in this specification.
2.6.4 Ice
Ice may be added to the water; however, it must conform to the above and where the ice is flaked or crushed,
and it must be stored in such a manner as to prevent thawing and refreezing into larger pieces. The method
of mixing shall ensure that the ice is fully dispersed and melted during the mixing cycle.
2.7 Admixture
2.7.1 Admixture General
Where approved or specified, admixtures complying with BS EN 934-2 or ASTM C494 shall be used as a
means of:
• Achieving workability with the lowest appropriate water-cement ratio in order to achieve durability
• Controlling and retarding setting
• Reducing bleeding and associated plastic settlement and cracking
• Reducing the risk of scaling and damage due to Delayed Ettringite Formation
• Inhibiting corrosion of embedded steel
• Controlling wash-out in underwater concrete.
Admixtures other than those specified herein shall only be used provided that the prior approval of the
Employer has been obtained and any information or test results required by him have been provided and
are to his satisfaction.
Admixtures containing chlorides or other corrosive agents shall not be used.
If Contractor proposes to use admixtures, he shall submit full detail of the proposed materials to the
Engineer for approval including but not limited to the following:
i. Long and short-term effect of the admixture on concrete including the effects of different types of
cement and aggregate.
ii. Effects of over and under dosage.
iii. Whether the admixture entrains air of its effect on air content.
iv. Storage life and any special storage requirements.
v. Safety precautions in handling.
vi. Compatibility with other admixtures and different types of cements and aggregates.
vii. Compliance with the appropriate Standards,
viii. Available on-site technical service.
Very strict control is to be maintained to ensure that the correct quantity of admixture is used at all times.
The equipment to be used for dispensing and the method of incorporating the admixture in the concrete
shall be to the approval of the Employer.
Admixtures shall be stored in strict accordance with manufacturer’s instructions. Admixtures which have
been stored outside the recommended conditions or in excess of the recommended storage period shall
be removed from site. Admixtures shall be agitated prior to the start of each day’s concrete production.
2.7.2 Corrosion Inhibitor

If the Contractor proposes to use corrosion inhibitors, these shall be in a liquid form suitable for addition to
concrete during batching. The suitability of the inhibitor, compatibility with other products in the concrete
and dosage shall be confirmed in writing by the manufacturer. This shall include composition and detailed
longterm independent test data that conclusively substantiates the products ability. This should include as
a minimum test data to ASTM G109.
Upon request, the Contractor shall submit test method(s) that determine the plastic and hardened
concentration of the active component in the corrosion inhibitor.
2.7.3 Polypropylene Fibres
Polypropylene fibre reinforcement for the control of plastic shrinkage shall be 100% virgin polypropylene
fibres specifically manufactured for use as a concrete reinforcement and so certified by the manufacturer. It
shall contain no reprocessed olefin materials. The fibre dosage shall ensure a minimum fibre area of 200m2
per cubic metre of concrete unless the manufacturer warrants the effectiveness of a lower dosage level. The
nominal length of each fibre shall be 12mm and the nominal fibre thickness shall be 18-32 microns.
2.8 Concrete Mix Design Requirements

2.8.1 Schedule of Concrete Mixes
Concrete shall be as shown in the Table of Mixes below.
The criteria given in the Table of Mixes are designed to produce concrete of the required strength and
durability.
The Design Characteristic Strength values are for concrete which has been cured at a temperature of 20°C ±
2°C and are the values below which no more than 5% of the test results fall.
Table 2-10: Table of Mixes (reinforced concrete)
Reference C45A C45A

Typical Use Landside concrete Landside concrete
structures (buried), structures (exposed to
Landside crane beam, airborne chlorides),
Water-retaining Onshore
structures, Onshore Superstructures
substructures
Type of Mix Designed Designed
Design 28-day Characteristic strength
(Cube)1 (N/mm2) 45 45
Cylinder /Cube strength 35/45 35/45
(N/mm2)
Cement / Combination Type IIIA (50-60% GGBS) IIIA (50-60% GGBS)
+ 5-10% SF + 5-10% SF
IIB-V (25-30% FA) IIB-V (25-30% FA)

+5-10% SF +5-10% SF
Minimum Cementitious Content (kg/m3) 380 380
Maximum Cement Content (kg/m3) 450 450
Maximum free Water/ Cement Ratio2 0.40 0.40
Maximum Aggregate Size (mm) 20 20

Required Admixtures
BS EN 934 or ASTM C494
Other Additives SF3 SF3

Reference C45A C45A
Temperature Range for Fresh Concrete (°C) 5-32 5-32
Target Workability Class (i.e., Consistency S3 S3

Class)4
Minimum Cover (mm) 65 50 (exposed to weather)
30 (for indoor elements)
Control Testing Frequency (m3)6 30 30
Special Requirements Control of temperature Control of temperature
rise (Section 2.9.7)5 rise (Section 2.9.7)5
Durability testing (Section Durability testing
2.8.4.1) (Section 2.8.4.1)
Notes:
1. The Design Characteristic Strength values are for concrete which has been cured for 28 days
at a temperature of 20°C ± 2°C and are the values below which no more than 5% of the test
results are expected to fall. Contractor may take extra samples for testing at 56 days in case
of 28 days strength failure.
2. The free water-cement ratio shall include water contained in the admixtures and the cement
combination shall include silica fume.
3. Up to 8% silica fume by mass of cement may be incorporated to improve fresh and
hardened concrete properties.
4. To be confirmed by the Contractor. Each truckload shall be tested for consistence.
Consistence testing shall be undertaken at time intervals to show the mix has adequate
workability retention under the ambient conditions. The tolerance shall be in accordance
with Annex B of BS 8500-1.
5. To mitigate risk of thermal cracking and delayed Ettringite formation.
6. Testing frequency, for reinforced and unreinforced concrete, may be relaxed to 50 m 3 and
100 m3 respectively, once successful 28 days strength results have been established for a
period of at least 2 months, subject to agreement with the Engineer.
The concrete elements will be designed using the nominal steel cover. The nominal cover is defined as the
minimum cover distance from the surface of the concrete to any steel reinforcement plus a tolerance. The
fixing tolerance to be considered (assuming good control) in detailing the location of reinforcement is as
follows:
• Reinforced concrete: -0/ +10 mm
• Precast concrete: -0/ +5 mm
• Piles/ low control substructure/ in contact with ground: -0/ +50 mm
• Piles/ low control substructure/ with temporary casing: -0/ +25 mm
2.8.2 Quality and Testing

Concrete shall comply with BS EN 206. Sampling for test purposes shall comply with BS EN 12350-1. The
making and curing of specimens shall comply with BS EN 12390-2.
Before placing concrete, the Contractor shall obtain acceptance of the mixes proposed for each grade of
concrete and the average target strengths. The mixes shall be designed to achieve the necessary workability
for the Contractor to place and compact the concrete with the equipment proposed for use.
The mean strength shall exceed the characteristic strength by a margin of at least 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.
2.8.3 Control of Chlorides, Sulphates and Alkalis

2.8.3.1 Chlorides in Concrete
a) The total estimated chloride ion content as a percentage by mass of the cement or combination in the
mix shall not exceed the following limits:
i. For reinforced concrete: 0.20%
ii. For mass concrete: 0.50%
b) The Contractor shall test the constituents of the concrete to establish these contents as provided for
elsewhere in this specification.
c) Every 2 weeks, for all mixes, tests to BS 1881: Part 124 for chloride content shall be made on the
hardened concrete test specimens. The following values are acceptable:
i. 95% of the test results less than 0.20% and no result greater than 0.25% chloride ion by mass of
cement or combination.
ii. 95% of the test results less than 0.5% no result greater than 0.65% chloride ion by mass of
cement or combination.
d) All the above limits shall apply in addition to the limits for individual constituents of the mix given
2.8.3.2 Sulphates in Concrete
a) The total estimated sulphate content (SO3) of the mix, calculated from the constituents including that
present in the cement, shall not exceed 3.6% by mass of cement or combination in the mix.
b) Every 2 weeks, for all mixes, tests to BS 1881 Part 124 shall be made on the hardened concrete test
specimens to determine the total sulphate content. The following values are acceptable.
i. 95% of the test results less than 3.6%, no results greater than 4% by mass of cement or
combination.
c) The above limits shall apply in addition to the limits for individual constituents of the mix given
2.8.3.3 Alkalis in Concrete
The total alkali content of the concrete calculated in accordance with BRE Digest 330 shall not exceed
3.0kg/m3 unless approved by the Engineer. The alkali content shall allow for all the constituents and shall
be calculated every month or whenever there is a change of the origin of the constituent materials.
2.8.4 Trial Mix
2.8.4.1 Laboratory Trial Mixes
Preliminary laboratory tests shall be carried out to determine the mixes to satisfy the Specification with the
available materials.
Trial mixes shall be tested to determine the following properties of mixes proposed for initial field tests
(average of two determinations):
• Bleeding in accordance with ASTM C232 (non-vibrating): 1% maximum
• Air content if applicable in accordance with BS EN 12350-7.
• Workability/ Consistency and slump retention time. Tests shall be undertaken at time intervals to show
the mix has adequate workability under the expected ambient conditions.
• Fresh and hardened concrete densities
• Water/cement ratio
• Visual Stability Index (VSI)
• Setting time (BS EN 934-2)
• Compressive strength 1, 3, 7 and 28 days (BS EN 12390-3).
For un-reinforced concrete durability tests (i) to (iii) shall be undertaken as indicated in the table below. For
reinforced concrete durability tests (i) to (vi) shall be undertaken. If the values obtained in trials do not meet
the specified limits the mixes shall be re-designed, and the trials re-commenced.
Table 2-11: Durability Test Compliance
Limit on average of three

Test Method Age (Days)
determinations
(i) Water penetration test BS EN 12390-8 28 ≤ 20mm
(ii) Water absorption (30 minutes) BS1881, Part 122) 28 ≤ 1.75%
(iii) Initial surface absorption (30 minutes) BS1881, Part 208 28 ≤0.15ml/m2/s
(iv) Rapid chloride permeability test AASHTO T277 28 ≤ 1000 coulombs
(v) Porosity test RILEM CPC 11.3 28 ≤ 10%

3.0 x10-12 m2/s1 (and
(vi) Chloride migration coefficient NTB 492 28 maximum single value of
3.5X10-12 m2/s)
2.8.4.2 Initial Field Tests

Trial mixes shall be prepared under full-scale site conditions and tested in accordance with the relevant
parts of BS EN 12350 and BS EN 12390.
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, two for test at 7 days, two at 28 days and two for testing at 56 days.
The mean workability/ consistency of the trial mixes shall comply with the target value, allowing for the
permitted tolerances given in BS EN 206. The compressive strength shall be considered satisfactory if the
strength of the cubes tested after 28 days show compliance with both the workability and specified
Characteristic Strength using the criteria in BS EN 206.
Further trial mixes shall be made if the range (the maximum minus the minimum of the two 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:
• Bleeding in accordance with ASTM C232 (non-vibrating): 1% maximum
• Air content if applicable.
• Consistence (workability).
• Fresh and hardened concrete densities.
• Durability test requirements
2.8.5 Quality Control

2.8.5.1 Site Records
a) Complete, correlated records for sampling and testing shall be maintained to include as a minimum:
i. Sampling, site tests and identification numbers of specimens tested in the laboratory.
ii. Location of the parts of the structure represented by each sample.
iii. Location in the structure of the batch from which each sample is taken.
2.8.5.2 Fresh Concrete

a) A visual examination of each batch of concrete delivered to site shall be undertaken by suitably
experienced and qualified personnel. Free water-cement ratio for each batch delivered shall be checked
from complete and accurate autographic records, showing aggregate moisture corrections. Where
autographic records are not available then a microwave test shall be undertaken in accordance with BS
1881, Part 128.
b) Slump, flow table, or slump flow workability / consistency tests shall be carried out at the site of the
pour or at the delivery checkpoint on each truckload of concrete delivered. The consistence shall be as
per the mix design within the permitted tolerances given in BS EN 206.
c) Temperature measurements of the concrete at placing shall be carried out on each batch of concrete if
the ambient temperature lies outside the range 10 to 32°C.
d) Random monitoring of the plastic density of the concrete shall be carried out weekly, using a calibrated
container in accordance with BS EN 12350-6.
2.8.5.3 Hardened Concrete

a) One sample for hardened concrete tests shall be taken from concrete delivered to site, at the frequency
given in the Table of Mixes (Section 2.8.1) and whenever doubts are raised regarding the quality of the
concrete. The sampling shall be in accordance with BS EN 12390-2. The cubes / cylinders shall be made
at the point and time of placing.
b) From each sample two cubes shall be made for compressive testing at 28 days and one for testing at 7
days for control purposes. The 28-day strength shall be assessed for compliance in accordance with BS
EN 206 and BS 8500-1. The concrete shall be judged against the identity testing criteria in Table B.1 of
BS EN 206 on each defined volume of concrete.
c) The control testing frequency for the durability properties of the concrete mixes shall be every 500m 3
of concrete used in the works and compliance assessed in accordance with Table 2-11.
d) Samples associated with a non-compliance shall be retained for examination for a period of three
months.
2.8.5.4 Site Laboratory

a) Test specimens 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. The
method of compacting test specimens shall be as approved.
b) The testing machine shall be housed in a laboratory and calibrated to BS EN ISO 376 when delivered;
the calibration shall include the use of the Foote strain gauge and be verified at 3- monthly maximum
intervals.
2.8.6 Batching and Mixing

2.8.6.1 Machinery
a) The batching and mixing of concrete shall comply with ASTM C94.
b) Batching shall be by weigh-batching machines equipped with accuracy checks for the weighing
mechanism. The machines shall be cleaned, checked, and adjusted regularly as approved.
c) Mixing shall be by a forced action machine. All mixers shall be properly maintained in good working
order in every respect. For each mixer proposed, the Contractor shall provide a copy of the
manufacturer's specification and statement of performance capability.
d) Measuring equipment shall be checked and calibrated at the start of field trials and at weekly intervals
thereafter. The necessary test weights shall be kept available on site.
e) Scales shall be checked over their complete range by a specialist every three months. A calibrated
container shall be used to check the accuracy of admixture dispensers once each month.
f) All concrete mixers shall be inspected for wear and a check undertaken of mixer uniformity in
accordance with ASTM C94.
2.8.6.2 Accuracy of Batching

a) The tolerance of batching constituent materials shall not exceed the limits given in Table 21 of BS EN
206.
b) The batch masses of fine and coarse aggregate shall be adjusted to allow for the free water contained
in them. The quantity of water added to each batch shall be adjusted by the quantity of free water
contained in the fine and coarse aggregate and the liquid content of any admixture. The moisture
content of the fine aggregate shall be measured continuously in the hopper by an approved device.
The amount of admixture shall also be measured.
2.8.6.3 Records
(a) The water supply to the batching plant shall have a metering system to control and record the
amount of water added. Water shall not be added on site.
(b) Superplasticiser may be added to the concrete on site, but the addition of admixtures shall only
be carried out by authorized personnel and shall be recorded and signed on site placement records
to show the amount incorporated and the workability/ consistency of the concrete before and after
the addition.
(c) The batching plant shall have an automated (autographic) system for recording the batch masses
for each delivery.
(d) A daily concrete report shall be provided detailing the quantities of each cementitious material
and admixture used, the total volume of concrete batched for each mix and section of the works,
the free moisture in each size of aggregate and the target batch masses for each mix produced.
The autographic records for each delivery shall be appended.
(e) Each load of concrete shall be accompanied by a delivery note that indicates the:
i. Unique batch number.
ii. Delivery location.
iii. Mix reference.
iv. Target workability/consistence.
v. Time at which water was added.
vi. Truck number.
vii. Drivers name and signature.

viii. Recipient’s name and signature.
2.8.6.4 Ready-mix Concrete
Ready-mixed concrete shall comply with the requirements specified herein and those of BS EN 206 and BS
8500. Ready-mixed concrete plants shall hold current accreditation to an approved quality scheme. Ready-
mixed concrete, plants and mixer trucks shall be subject to acceptance. Truck-type concrete mixers shall be
subject to mixer uniformity tests to ASTM C94.
2.9 Placing
2.9.1 Placing General
The Contractor shall obtain the approval of the Employer to his proposed sequence for placing concrete
including the limits of individual pours and the height of lifts. The Contractor through approved trials and
calculations to minimise thermal and shrinkage strains in the concrete shall arrange the sequence and limits
for placing the concrete.
Concrete shall be placed in the position and sequence indicated on the Drawings, or as directed by the
Engineer. Placing shall not be commenced until the fixing and condition of reinforcement and items to be
embedded, and the condition of the containing surfaces or formwork has been approved. 24 hours
notification shall be given of the intention to place concrete.
The size and sequence of pours shall be arranged to control the risk of shrinkage and thermal cracking. The
size and sequence of pours shall be arranged to control the risk of shrinkage and thermal cracking in
accordance with the guidance in CIRIA Report C660.
The following precautions are outline within the specification and shall be strictly adhered to by the
Contractor:
• Limits on the aggregate and cement type and cement content to be used and a requirement to make
appropriate use of admixtures (Clauses 9.1 and 11.1)
• Restrictions on sulphate content of the cement and the concrete
• Limits on the placing, peak and differential temperature

• For sections over 0.6 m minimum dimension, monitoring temperatures within trial pours and the works
and extracting cores for testing and examination in case the specified temperature limits are exceeded
Concrete shall be transported by means, which prevent contamination (by dust, rain, etc.) segregation or
loss of ingredients, and shall be transported and placed without delay.
Concrete shall be placed directly in its final position without segregation or displacement of the
reinforcement, embedded items, and formwork. Concrete shall not be placed in water, except by tremie,
using best practice techniques for underwater placement of concrete.
The maximum permissible crack widths, for visual inspection and repair, 28 days after completion of curing,
shall be 0.1mm for marine structures of reinforced concrete in tidal/splash zone and water-retaining
structures and 0.2mm for other structures. Contractor shall provide the facilities to enable the full surface
area to be inspected and cracks to be measured at times to be agreed and shall be responsible for repairing,
sealing, or replacing the concrete, as agreed with Engineer. All remedial work shall be to the Contractor’s
cost.
2.9.2 Placing Equipment

(a) Concrete may be placed directly from a truck mixer or other transporting equipment. The chutes
attached to this equipment may be used if the clear free fall from the end of the chute is no greater
than 2m and that the slope of the chute does not exceed 1V:1H. When transferring concrete vertically
from higher to lower elevations, drop pipes (trunking) shall be used.
(b) Concrete buckets and skips may be used provided that the equipment is designed to discharge
concrete of the slump required, the discharge gates are tight against escaping grout when closed and
that any free fall of concrete does not exceed 1.0m.
(c) The delivery pipe shall be steel or heavy-duty flexible hose of at least 150mm ID (internal diameter).
The pump shall be of adequate capacity and power to ensure delivery of a continuous supply of
concrete. Full details of all pumping equipment proposed for use shall be submitted to the Engineer
for review and approval.
(d) Underwater concrete shall be placed by tremie. The tremie pipe shall be of at least 200mm internal
diameter and of rigid construction. Method statement for tremie concreting shall be submitted to
Engineer for review and approval at least a month before Contractor intends to commence the tremie
concrete.
(e) Whenever the supply of concrete to the pump is interrupted for more than one hour, the chutes,
pumps, pipes and any other means of distribution shall be thoroughly flushed out with water and
cleaned and shall be flushed with water immediately prior to the resumption of concreting.
(f) All wash water used shall be discharged outside the formwork and clear of any freshly placed concrete.
When pumping is complete, the concrete remaining in the pipeline shall be ejected without
contaminating the concrete in place. At all times when pumping concrete, the Contractor shall provide
adequate alternative arrangements for placing the concrete in case of a breakdown of the pumping
equipment.
2.9.3 Basic Site Checks

(a) Before placing concrete on the ground, the formation shall be compacted as specified and a screed of
blinding concrete shall be applied to form a surface for construction. Water seepage shall be stopped
or channelled away from the work and protective membranes installed.
(b) Surfaces to receive concrete shall be cleaned immediately before placing concrete. Surfaces shall be
clean with no debris, tying wire clippings, fastenings, or free water. Absorbent surfaces shall be wetted
to a saturated surface dry condition immediately prior to concrete placement.
(c) Before concreting is commenced the reinforcement and other embedded items shall be thoroughly
cleaned of all deleterious matter including concrete splash from previous concreting operations.
(d) Contractor shall take every precaution to ensure that contamination due to windborne dust, organic
or chemical products from ongoing operations surrounding the works does not occur.
(e) All forms and falsework shall be carefully examined for access and safety and the space to be
occupied by the concrete thoroughly cleaned out. Where considered necessary by the Engineer, joints
between panels of formwork shall be filled with an acceptable material.
(f) Concrete shall be completely discharged within 90 minutes of water being added to the mix unless
the use of hydration control admixtures is shown by trials to permit extension of this time with no
detriment to concrete properties.
(g) The concrete at the time of placing shall have the target workability/ consistency within permitted
tolerances. Water shall not be added on site unless approved by the Engineer.
(h) Peak temperature of the concrete during curing shall not exceed 65°C (or 70 °C where at least 25%
FA have been incorporated in the concrete).
(i) Placing in each section of the works shall be continuous between construction joints. The Contractor
shall make provision for standby equipment and for emergency measures in the event that concrete
placement is suspended for more than 30 minutes. These measures shall include erection of vertical
stop ends and formation of a construction joint or removal of the concrete already placed. Concrete
with cold joints shall be treated as non-compliant.
(j) Contractor shall provide full time on worksite a fully qualified Quality Control Engineer who shall be
responsible for the quality control of the concrete and the work. Several quality control supervisors
shall report to the Quality Control Engineer, one who shall be experienced in concrete quality control
and who duties shall include day to day supervision of the concrete constituents and the concrete
mixing, placing, sampling, testing and record keeping operations.
2.9.4 Pour Records

(a) Autographic records and a record book shall always be kept on Site by the Contractor and be available
for inspection by the Engineer. The records shall contain the following information relating to each
delivery of concrete to the Site:
i. Registration number of the truck, name of concrete supplier and location of batching plant.
ii. Time of introduction of cement and water to the mix.
iii. Time of arrival of truck at the concrete pour location and times when concrete discharge and
compaction were completed.
iv. Strength Class of concrete and actual mix proportions including admixtures.
v. Position in which concrete batch is to be placed.
vi. Whether test cylinders/ cubes were taken from the load and sample reference numbers.
vii. Workability test results.
viii. Concrete temperature at time of start and completion of discharge.

(b) In addition to the above, the Contractor shall maintain an accurate and up to date record showing dates,
times, weather, and temperature conditions when each part of the work was concreted.
2.9.5 Placing in Inclement Weather

Placing shall not take place in the open during high winds, storms, or heavy rains. If such conditions are
likely to occur, the Contractor shall provide protection for the materials, plant, and formwork so that work
may proceed. If strong winds are prevalent, protection from driving rain and dust shall be provided.
2.9.6 Hot Weather Concreting

(a) When the air temperature rises above 32°C then special hot weather precautions shall be taken. No
concreting shall be carried out on a rising thermometer above 40°C nor on a falling thermometer
above 43°C.
(b) The placing temperature of concrete shall not exceed 32°C. A lower placing temperature than 32°C
may be required to control the risk of early age thermal cracking and delayed ettringite formation.
(c) ACI 305 ‘Hot Weather Concreting’ shall be followed. The following measures inter alia may be
required to control the placing temperature:
i. Shade aggregate, cement silos, water tanks and concrete plant.
ii. Paint concrete plant white.
iii. Run concrete plant with flake ice before mixing or transporting concrete.
iv. Use chillers to cool the mixing water.
v. Add flake ice as a proportion of the mixing water.
vi. Carry out concreting during the cooler parts of the day or during the night.
vii. Use of liquid nitrogen.
viii. Spray aggregate stockpiles, chutes, formwork, and reinforcement with clean water.
(d) Contractor shall supply suitable maximum/ minimum thermometers and record the shade and sun
temperatures at locations where concrete is being placed. In addition, the Contractor shall also
record wind speed and relative humidity at the place of concreting.
(e) The Contractor shall take all necessary measures to prevent plastic shrinkage cracking. These
measures shall include avoiding placing concrete under environmental conditions when plastic
shrinkage is likely to occur.
2.9.7 Placing in Thick Sections

(a) Contractor shall undertake special precautions when casting sections with a minimum thickness
greater than 0.60m and sections that are required to be water retaining or watertight.
(b) Contractor shall submit a detailed method statement to the Engineer for review defining his
proposed arrangement to avoid the effects of thermal cracking and temperature differentials. The
method statement shall include but not be limited to, the size and sequence of pours, concrete
temperature-monitoring system of pours, formwork type and removal time, and calculations for
temperature and strain development at internal and surface locations, considering heat of
hydration, ambient radiation and temperature, and physical restraints.
(c) Contractor shall undertake trial pours under conditions representative of those anticipated during
the works for all concrete sections greater than 0.60m minimum dimension. Thermocouples shallbe
used to monitor the ambient, concrete placing, core, and surface temperature values. The
Contractor shall take precautions to limit the peak temperature of the concrete to 65°C (or 70 °C
where at least 25% FA have been incorporated in the concrete).The maximum temperature
differential between the form or face of the concrete (estimated by thermocouples place 30 to
50mm below the concrete surface) and the centre of the pour shall be 20°C (or 25°C where the
thermal expansion coefficient of the concrete is controlled to less than 10x10-6/°C) unless the
Contractor’s detailed method statement and trial pour demonstrate otherwise. The precautions
considered shall include the use of plywood formwork, the insulation of surfaces, protection of
newly cast surfaces from solar radiation and the avoidance of evaporation and cold-water curing
leading to thermal shock.
(d) Cores shall be removed from any parts of the works that fail to comply with the limits on total
sulphate or peak temperature. The cores shall be subject to sulphate testing to BS 1881: Part 124,
petrographic examination, and expansion testing at 38°C to modified BCA expansion testing
method (Diagnosis of alkali-silica reaction, British Cement Association, 1992).
2.9.8 Placing at Night

If approval has been given for placing at night or in dark interiors, adequate lighting shall be provided
where mixing, transportation and placing are in progress.
2.9.9 Placing Underwater

Underwater concreting shall be undertaken in accordance with the guidance in Concrete Society
Technical Report 35. There shall be a minimum disturbance of the water and running water and wave
wash shall be controlled. Tremie pipes, or other approved placing equipment, shall be used. Measures to
minimise segregation of the concrete and avoid delay during placing shall be taken. During concreting
the pipe shall remain buried in the concrete and the pipe must not be emptied until the pour is complete.
2.9.10 Compaction
2.9.10.1 Compaction General
(a) Concrete shall be thoroughly compacted in its final position, whichever is lesser:
i. Within two hours of water being added to the cement at the batcher, or
ii. Loss of workability of concrete does not allow satisfactory placement of concrete.
(b) Partially set concrete shall not be used in the Works.
(c) Poker vibrators shall be operated such that each layer of concrete is well compacted and is
thoroughly intermixed with the previously placed layer at the joint line and shall be withdrawn
from the concrete in a manner that does not form voids. Vibration shall be applied continuously
during the placing of each batch of concrete until the expulsion of air has practically ceased and in
a manner that does not promote segregation of the ingredients.
(d) Vibration shall not to be applied directly or indirectly to concrete after the initial set has taken
place.
(e) Poker vibrators shall not be used to make concrete flow horizontally into position, except where
necessary to achieve full compaction under void formers and cast-in accessories and at vertical
joints. Compaction shall continue until the expulsion of air has virtually ceased, and in a manner
which does not promote segregation of the ingredients.
(f) Slabs 100mm thick or less shall be compacted by vibrating beams or other approved techniques and
not by internal vibrators.
(g) The formation of cold joints shall not be permitted.
(h) Concrete for bored piles shall be designed to flow freely and pass through the reinforcing cage
without vibration, segregation, and bleeding such that the reinforcement is fully encapsulated, and
the minimum cover of compacted homogenous concrete is achieved.
2.9.10.2 Vibrator
(a) Sufficient numbers and types of vibrators, including back-up, shall be maintained on site to suit the
rate of pouring, consistency, and location of concrete. Concrete placing shall cease in the event of
a total breakdown of the vibration equipment and shall be reduced with partial failure of the
equipment. Concrete that has not been properly compacted shall be rejected.
(b) External vibrators shall be used only on review and acceptance from the Engineer.
(c) The top surface of pours shall be inspected approximately 30 minutes after concrete has been
finished. Should there be any evidence of plastic settlement cracking, the affected concrete shallbe
re-vibrated whilst plastic by a method approved by the Engineer’s representative. Contractor shall
take appropriate measures to reduce the possibility of cracking in further pours.
2.10 Formwork
2.10.1 Formwork General
(a) Formwork shall be designed and constructed in accordance with the recommendations of ACI 347
or similar approved standard and shall ensure that the finished concrete members conform
accurately to the dimensions, lines and elevations shown on the Construction Drawings and to the
specified tolerances given in BS 5606.
(b) The Contractor shall obtain approval of the methods and materials proposed. Details of formwork
for special finishes shall be approved before materials are ordered.
(c) Formwork shall be designed and constructed to withstand the worst combination of the following,
without producing deformation of the finished concrete in excess of the specified tolerances:
i. Total weight of formwork, reinforcement, and concrete.
ii. Construction loads including dynamic effects of placing, compacting and construction traffic.
iii. Wind loads.
(d) The faces of formwork shall be clean, free from protrusions, adhering grout and other
imperfections or defects and shall be removable without disturbing the concrete.
(e) Top formwork shall be provided to slopes of 15 degrees or more from horizontal.
(f) Formwork panels shall have true edges for accurate alignment and shall be fixed with either
vertical or horizontal joints. Joints shall be close fitting and shall not permit leakage of grout, nor
steps and ridges in exposed surfaces.
2.10.2 Rough Formwork
Rough formwork shall be butt-jointed, seasoned, sawn timber.
2.10.3 Fine Finish Formwork

Fine finish formwork shall be used for all concrete surfaces unless detailed otherwise on the
Construction Drawings. This finish shall be obtained from forms designed to produce a hard-smooth
surface with true, clean arrases.
2.10.4 Form Ties

(a) Form ties shall be factory fabricated removable ties that will neither allow formwork deflection nor
spall the concrete when removed. The ties shall be provided with backing plates to distribute loads
evenly to the formwork. Snap-off metal ties shall not be used.
(b) Bolt or tie systems which, when removed, leave a hole through the member, shall not be permitted
in liquid retaining structures. Ties shall be fitted with devices that will leave holes in the concrete
surface not less than 6mm or more than 25mm in diameter. Bolts and rods that are to be
completely withdrawn from the finished concrete shall be coated with an approved non-staining
bond breaker prior to concreting.
(c) Tie cavities shall be roughened and filled with approved non-shrink concrete or epoxy mortar.
(d) Removable ties shall be located so that the specified cover to reinforcement is maintained to all
surfaces including that of the tie-holes. If ties are left in, the cover to the part of the tie which
remains in the concrete shall be as specified for the reinforcement or as approved by the Engineer.
2.10.5 Box Outs

Box-outs for forming holes and voids shall be constructed to be easily removable without damaging
theconcrete during removal. They shall be properly vented to permit the escape of entrapped air and
shall be capable of being sealed subsequently to prevent the loss of grout.
The use of polystyrene blocks for forming holes shall not be allowed unless used purely as a void filler
within rigidly constructed boxes.
2.10.6 Openings
Temporary openings in formwork to assist in inspection and cleaning-out of the form and placing and
compaction of the concrete shall be formed in accordance with the guidance in CIRIA Report 135 such
that they can be completely sealed to prevent grout loss.
2.10.7 Formwork Props

(a) The Contractor shall submit a method statement including proposals for prop bearings and
sequence of propping/ re-propping and back propping at least 14 days before commencement of
concreting. Formwork props shall prevent deflection and damage to the structure. Carry down props
to bearings should be strong enough to provide adequate support throughout concreting
operations.
(b) All props shall be supported on adequate sole plates and shall not bear directly on or against
previous Permanent Works concrete. They shall be capable of being released gently without shock
to the supported formwork. No appliance for supporting the formwork shall be built into the
permanent structure.
2.10.8 Chamfers
Where chamfers are required, the fillets shall be cut to provide an even line. All outward projecting 90-
degree corners shall have a 25mm x 25mm chamfer unless shown otherwise on the Construction
Drawings.
2.10.9 Treatment
(a) Forms, other than retained-in-place metal forms, shall be coated with form oil (mould oil) or form
release agent before the concrete is placed. The coatings shall be approved commercial
formulations of satisfactory and proven performance.
(b) Release agents that are suitable for use with the type(s) of formwork, formed finishes and specified
applied finishes shall be used. The same type and make of release agent shall be used throughout the
entire area of any one finish and shall be applied evenly to form faces, from top downwards, and
to horizontal surfaces last. The minimum amount necessary shall be used to obtain a clean release
and prevent excessive local collection.
(c) Release agents shall not bond with, stain, or adversely affect the concrete surfaces and shall not
impair subsequent treatment of concrete surfaces depending upon the bond or adhesion, nor
impede the wetting of surfaces to be cured with water or curing agent. Forms for unexposed
surfaces that are to be treated with a waterproof membrane shall be moistened with water
immediately before placing concrete. Surplus oil on form surfaces, reinforcing steel and
construction joints shall be removed before placing the concrete.
(d) Release agent shall be prevented from touching the reinforcement, hardened concrete, other
materials not part of the form face, and permanent forms.
(e) Surface retarders shall not be used for formed faces unless as part of any construction joint details,
or where otherwise agreed in writing with the Engineer in advance.
(f) Controlled permeability formwork may be used to reduce the incidence of blowholes and the need
for preparation of surfaces to received coatings. The controlled permeability formwork will have a
current British Board of Agreement certificate or equivalent independent third-party certification
demonstrating its suitability for the intended application.
2.10.10 Formwork removal

(a) Formwork shall be removed in a manner not to damage the concrete, at times to suit the
requirements for its curing, and to prevent restraint that may arise from elastic shortening,
shrinkage, or creep. Formwork shall not be removed until the concrete has sufficient strength to
support itself.
(b) Soffit forms, centres and props may be removed when the member has sufficient strength and
stiffness to carry itself and any loading without unacceptable stresses or deflections. Load shall not
be applied to a member until it can be demonstrated that it has sufficient strength and stiffness.
(c) Where it is intended to re-use formwork, it shall be thoroughly cleaned and made good by the
Contractor to the satisfaction of the Engineer.
(d) External loading shall not be applied until the concrete has reached the 28-day characteristic
strength.
(e) Formwork striking times shall be determined in accordance with CIRIA Report No 136 Formwork
Striking Times – Criteria Prediction and Methods of Assessment.
(f) Proposals by the Contractor for the striking of formwork shall be submitted to the Engineer for
review prior to the commencement of concrete production for the main works.
2.10.11 Permanent formwork

Permanent formwork of GRP pipe is to be used where indicated on the drawings. The minimum wall
thickness of the GRP shall be 5.0 mm.
2.11 Reinforcement
2.11.1 Reinforcement General
(a) Steel reinforcement shall be cut, bent, and fixed in accordance with BS4449, BS4483 or BS6744.
(b) Cutting and bending of reinforcement shall be carried out in accordance with approved schedules and
to BS 8666. Re-bending shall be rejected, minor adjustments shall require Engineer approval,
temperatures below 5°C: Obtain instructions, temperatures greater than 100°C: Prohibited.
(c) Cutting shall be carried out with an approved cropping machine.
(d) On-site facilities shall be provided for bending reinforcement to deal with approved minor
adjustments.
(e) Reinforcement temporarily projecting from the concrete at joints shall not be bent out of position
without approval. In this event the reinforcement shall be bent over a suitably sized former to prevent
any damage or over-stressing.
(f) Any bars showing signs of cracking or brittleness, after bending or re-bending, shall be rejected.
2.11.2 Fixing
(a) Reinforcement shall be fixed into cages or mats by binding the intersections and laps with tying wire
or approved fixing clips in accordance with BS 7973. The fixings shall be of sufficient quantity to
ensure that the reinforcement is held securely in place during construction and concreting. Use of
additional steel for support of temporary works shall be permitted subject to the review of the
Engineer.
(b) Links shall be taut so that bars are braced, and the inside of their curved parts shall be in contact with
the bars being connected. Tying wires shall be twisted tight with pliers and the free ends shall be bent
inwards.
(c) Reinforcement shall be subject to abrasive blasting using approved media complying with BS 7079 to
remove rust, oil, grease, salts and other deleterious matter. Repeated cleaning 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.
(d) Contact between ordinary carbon steel and stainless embedded steel shall be avoided.
(e) During concreting of all reinforced work, a competent steel fixer shall be in attendance throughout to
ensure that the reinforcement and other embedded items are securely and accurately positioned prior
to concrete placement.
2.11.3 Welding
(a) Electric arc welding may be used, if approved, for joining bars. Covered-alloy or shielded-arc
electrodes shall conform to BS EN 499. Workmanship shall be to BS EN 1011-1. Welders shall have
certification (less than 12 months old) or shall undertake welder approval trials to demonstrate their
competence. Joints shall be butt-welded with standard double-V or double-U welds.
(b) All temporary or non-structural welding shall be subject to the same welding procedures as structural
welding.
(c) The Contractor shall submit written welding procedures, and Inspection and Testing Plans, to the
Engineer for all welding operations, including welder approver trials. Items to be included in the
procedure shall be in accordance with BS EN 17660-1.
(d) All welding shall be carried out in accordance with BS EN 17660-1 and BS EN 1011-1 and shall fulfil
the quality requirements specified in BS EN ISO 3834-3.
(e) The Contractor shall take precautions to avoid stray arcing between electrode or electrode holder and
the workpiece or adjacent bars. Welding return leads shall be connected to the workpiece by means
which prevent damage by sparking. Reinforcement damaged by arc strike shall not be incorporated in
the Works. All slag and spatter shall be removed from the weld and adjacent surfaces.
2.11.4 Spacers
(a) Where required to support and retain the reinforcement in its correct position, the Contractor shall
provide templates, stools, or other supports. Target or nominal cover to reinforcement shall be in
accordance with this Specification. Cover shall be maintained over ties, stirrups, and lap splices.
(b) Approved type(s) of cover spacers shall be used, which will adequately support the reinforcement,
adequately resist displacement, not cause indentation of the formwork and shall be made from:
Plastics (perforated to at least 25% of their area), or Concrete (strength and durability to match
surrounding concrete). Spacers and chairs shall be in accordance with BS 7973-1. Cover spacers shall
be staggered on adjacent parallel bars and shall not be closer than 300mm centres.
(c) Steel chairs shall not be used. Where precast concrete spacer blocks are used, they shall be of
equivalent strength and durability as the concrete in the element and of a thickness consistent with
the required cover.
(d) If the formed surface is exposed to view, the precast concrete support block shall be the same quality,
texture and color as the finished surface.
2.11.5 Cover
(a) The minimum concrete cover values to the steel reinforcement shall be as indicated in Table of Mixes
(Section 2.8.1). Note that the concrete elements will be designed using the nominal steel cover which
is the minimum concrete cover plus a fixing tolerance depending on the method of construction (refer
to Section 2.8.1).
(b) Concrete cover checks shall be carried out after concreting using a cover meter in accordance with BS
1881-204 over at least 10% of accessible surfaces at a 1m spacing prior to covering up to confirm
the minimum cover and reinforcement fixing tolerance. The measured cover values to all steel shall
not be less than the minimum cover value given Table of Mixes. The results of the survey shall be
submitted to Engineer for review and acceptance prior to any covering up.
(c) The cover values above shall apply to all surfaces exposed to the ambient environment, including
surfaces within expansion joints and joints between diaphragm wall panels.
2.12 Mortar and Grouts

2.12.1 Material for Cement-based Mortars and Grouts
The materials used for making cement-based mortar and grout are cement (OPC), lime, sand, water,
plasticizers.
Cement, sand, water, and plasticizers shall comply with Sections 4.1(a), 5, 7 and 8 of this specification
respectively. Lime shall be non-hydraulic or semi-hydraulic calcium lime complying with the requirements
of BS EN 459-1.
2.12.2 Cement-based Mortars Mixes

Cement-based mortar to be used in the Works shall comply with the requirements for the grades given in
Table 2-12. The actual grades to be used in any location shall be as indicated on the Drawings or elsewhere
in this Specification or as directed by the Engineer.
Table 2-12: Cement-based Mortar Grades
Mix Proportions
Mortar Grade Cement Type
Cement: Lime: Sand Cement: Sand
Portland Cement 1: 0: 2
P2 -
(OPC)
P3 -
(OPC)
P6 1: 6
(OPC)
Note:
1. Lime is measured as lime putty
2. The quantity of water used in the mixes shall be only sufficient to produce a workable mortar for the
intended use.
3. The above provision shall also apply where either “dry-pack” or “pouring” mortars are required.
2.12.3 Expanding Agent for Cement-based Grouts

Expanding agents for use with cement-based grout mixes shall be subject to the Engineer’s prior approval
before being used in the Works. Information submitted for the approval of expanding agents shall include
full details of the manufacturer’s brand name, chemical composition, and the proportions in which the
agent would be used in any grout mix. No expanding agent containing any chloride shall be used.
2.12.4 Cement-based Grout Mixes

Unless otherwise specified or indicated on the Drawings, cement-based grouts shall be as follows:
• For grout thickness not exceeding 25 mm
o Cement grout with a suitable proportion of expanding agent, all mixed as thickly as possible
consistent with fluidity, with a controlled proportion of water.
• For grout thickness exceeding 25 mm but not exceeding 50 mm

o 1-part cement to 2 parts sand with a suitable proportion of expanding agent, all mixed, as thickly
as possible, consistent with fluidity, with a controlled proportion of water.
2.12.5 Mixing of Cement-based Mortars and Grouts
Mortars and grouts shall be mixed in a mechanical batch mixer for not less than 3 minutes or as directedby
the Engineer. In any event mixing shall continue until a thorough dispersion of materials has been achieved
and the mass is uniform in colour and consistency. After mixing all grout shall be passed through a 5 mm
sieve to remove lumps.
Hand mixing of mortar may be permitted by the Engineer for small batches provided the quantities of
materials and water are accurately controlled. Hand mixing of small batches shall be continuous until the
mortar is completely and uniformly mixed to the Engineer’s satisfaction.
No re-tempering of mortars or grouts in which the cement has begun to set will be allowed.
2.12.6 Epoxy-resin-based Mortars and Grouts

Epoxy-resin-based mortars and grouts shall be subject to the Engineer’s prior approval before being used
in the Works.
For general purpose use, epoxy resin-based grout shall be free flowing and shall be capable of grouting gaps
of up to 50 mm in depth in a single operation. It shall also have high early strength, non-shrink
characteristics.
Epoxy mortar shall have high strength characteristics.
All epoxy resin-based mortars and grouts shall be stored, mixed, and used strictly in accordance with the
manufacturer’s instructions, together with the requirements laid down in the following clauses. No such
material shall be used after the expiry of the manufacturer’s specified “shelf life”.
2.12.6.1 Preparation for Placing Epoxy-resin-based Mortars and Grouts
Concrete surfaces against which epoxy mortars and grouts are to be placed shall be lightly sand blasted to
remove laitance and left free from dust, grease, mould oil and other contamination. Similarly, base plates
to be bedded on epoxy mortar or grout shall be cleaned of all loose rust, dirt, oil, grease, and paint. In
addition, all surfaces shall be dry unless the mortar or grout is a special formulation designed for useon wet
surfaces.
Unless otherwise approved or directed, epoxy-resin-based mortars and grouts shall not be placed against
cement-based materials until 28 days after these materials have been cast.
2.13 Joints
2.13.1 Construction Joints
(a) Construction joints shall be located, and the sequence of placing arranged to minimize shrinkage and
thermal strains in the concrete.
(b) Concrete placing shall not be interrupted, except where joints occur, and shall continue after normal
hours, if necessary, to achieve this.
(c) Joints shall be formed square to the work with keyways included.
(d) Horizontal joints shall be generally at least 500mm above ground level and 500mm above high water
level in marine locations.
(e) Upon removal of the formwork the joint face shall be inspected, and if the soundness of the concrete
is not approved the Contractor shall investigate and remedy defects.
(f) Before placing is resumed at a joint, the set surface shall be roughened to remove laitance and expose
the aggregate; the concrete shall have gained sufficient strength to ensure that aggregate is not in
any way damaged or loosened within the matrix. If damaging materials have come into contact with
the surface of the joint the concrete shall be cut back, and the roughened surface cleaned by
compressed air or water jets and brushed and watered immediately before placing to ensure a
saturated surface-dry condition.
(g) Chemical surface-retarders shall not be used without approval.
(h) Construction joints shall be sealed with an approved sealant on de-bonding tape at external and
liquid-contact faces.
(i) Construction joints in water-retaining structures shall incorporate an approved waterstop and
construction joint details shall be submitted to Engineer for review.
(j) Formwork to provide stop ends for vertical joints in reinforced concrete shall be firmly fixed and
scribed around the reinforcement. Such concrete that passes through the stops shall after setting by
hacked off and removed. Alternatively, expanded metal mesh may be used, the mesh being removed
with care within 24 hours of casting.
2.13.2 Design Joints

(a) Expansion and contraction joints shall be shown on the Construction Drawings.
(b) A contraction joint in a non-water-retaining structure shall form a plane of discontinuity in the
member. The concrete face first cast shall be painted with two coats of approved rubberized bitumen
paint before the adjacent concrete is placed. The adjacent concrete shall include a groove against the
joint for sealant. The exposed edges shall be sealed with an approved sealant on de-bonding tape.
(c) If a contraction joint is likely to be contaminated, the joint shall be sealed immediately with an
approved free-flowing sealing fluid as soon as the formwork has been removed.
(d) An expansion joint in a non-water-retaining structure shall be formed as for a contraction joint, but
non-absorbent closed-cell polyethylene joint filler shall be included so that the adjacent concrete
members can expand.
(e) A design joint in a water-retaining or water-tight structure shall include a continuous waterstop strip
of copper, rubber, rubber and steel or PVC fixed across the joint. The concrete shall be free from
honeycombing and worked against the embedded part of the strip. Projecting portions of the strip
shall be protected from damage during operations and, in the case of rubber and plastic, from light
and heat.
(f) Bituminous paint shall be applied to the lips of the loop of copper waterstop, and the loop filled with
bituminous compound before embedding in the concrete.
(g) The method of joining waterstops shall be in accordance with the manufacturer's instructions.
2.13.3 Joint Fillers

Expansion joint filler shall be pre-formed bitumen bonded cork board 25mm thick and shall compress
to 50% of thickness and shall recover to not less than 70% of its original thickness.
2.13.4 Joint Sealants

(a) Joint sealants shall be selected in accordance with BS 6213 and shall be confirmed by the manufacturer
in writing as suitable for the intended application, including the environment. Data sheets shall be
provided for the proposed material indicating the movement accommodation factor.
(b) Expansion joint fillers and primers shall be compatible with and obtained from the same manufacturer
as the adjacent sealant.
(c) Joints shall be primed and sealed in accordance with the manufacturer’s instructions.
2.14 Curing and Protection

2.14.1 General
(a) The Contractor shall prepare and submit a detailed method statement for wet curing of concrete and
maintaining the curing regime to the standards and times specified. All necessary supports and
coverings shall be provided to form enclosed conditions to provide shade and support the necessary
hessian and polythene.
(b) Concrete shall be protected from sunshine and drying winds by approved shading and wind- breaks,
and from cold, rain or running water, from placing for a period of 10 days for wet curing only and 7
days for wet curing followed by application of a suitable curing compound subject to Engineer’s review
and approval. During this period the following measures shall be taken to prevent the loss of moisture
and to minimise thermal stresses caused by the difference in temperature between the surface of the
concrete and the core of the concrete mass.
i. Horizontal surfaces:
• Polythene sheeting shall be placed immediately after finishing.
• After final set has taken place, the polythene shall be replaced by wet hessian covered with
polythene; the hessian shall be kept permanently damp for a minimum period of 7 days or until
such time as further concrete is cast on the surface. Where appropriate, surfaces shall be
completely ponded.
• After 7 days the hessian and polythene shall be removed, and an approved aluminised or white
resin-based or water-based curing compound applied. The rate of application shall be as
recommended by the manufacturer.
• Alternative methods of curing must be approved before use where special finishes are required.
ii. Vertical surfaces:
• Polythene over wet hessian shall be secured to the surfaces immediately after removal of the
formwork. The hessian shall be kept permanently damp.
• The hessian and polythene shall be retained for at least 7 days after casting and an approved
aluminized or white resin-based or water-based curing compound applied.
(c) Water used during curing operations shall comply with Section 2.6. Alternative curing methods to
continuous water curing, such as the use of a spray-on curing membrane, must be approved before
use and shall be applied strictly in accordance with the manufacturer’s recommendations. Curing
membranes shall be applied within 30 minutes of casting. The membrane shall have an efficiency of
at least 90% and shall be compatible with any coating and waterproofing compounds to be
subsequently applied to the surface of the concrete.
2.14.2 Contamination
Concrete shall be protected from contamination by sea or brackish water, oil, fuel, and other deleterious
materials for a minimum period of 30 days after placing.
2.14.3 Insulating Formwork
Insulating formwork and insulating blankets shall be left in place until the peak temperature in the
concrete has been reached. The temperature differential between the concrete and the ambient
temperature at the time of formwork removal shall not exceed 20°C.
2.14.4 Protection of Joints

Rebates formed to receive sealant and the surfaces of construction joints shall be protected from curing
compound by wet hessian to ensure proper curing of the joint surface and adjacent concrete. The
protection shall remain in place until the joint surface is sealed.
2.15 Finishes
2.15.1 Finishes General
The finished faces of concrete shall be sound, even coloured, even textured and free from defects.
Unless otherwise indicated on drawings, the following finishes shall be produced.
2.15.2 Formed Concrete Finishes

Formed concrete surface finishes shall be as follows:
Class F1
This finish is formed for surfaces at construction joints. The surface produced shall be free from voids,
honeycombing or other large blemishes, steps, sharp protrusions, or local hollows. The shutters shall be
removed as soon as possible without disturbing the concrete or reinforcement and the surface be well
brushed or hosed down to remove all excess laitance and fine aggregate. Coarse aggregate is to be left
exposed but undisturbed.
Class F2
This finish is for surfaces that are permanently exposed to view. The surface produced by the formwork
shall be free from voids, honeycombing or other large blemishes. Any small blemishes shall be carefully
filled immediately after the removal of the formwork and other marked imperfections such as fins or steps
shall be made good. To achieve this finish wrought timber boards, plywood sheets, steel panels or such
other material as is approved by the Engineer shall be used. In large panels, the panels shall be arranged
in an approved uniform pattern with vertical or horizontal joints, unless otherwise directed. Joints shall be
carefully filled or sealed before concreting. The same type and brand of shutter release agent shall be
used throughout the Contract on surfaces of a structure where a Class F2 finish has been specified.
Class F2P
This finish is similar to Class F2 except that in addition to the requirements for Class F2 the formwork is to
be lined with a proprietary controlled permeability formwork liner as specified in Section 2.10.9 (f). The
same type and brand of controlled permeability formwork liner shall be used throughout the Contract on
surfaces where a Class F2P finish has been specified.
Class F3
This finish is for surfaces not permanently exposed to view. The surface produced shall be free from voids,
honeycombing or other large blemishes, steps, sharp protrusions, or local hollows. The formwork may be
sawn boards, metal panels or other approved suitable material. The finished faces of concrete shall be
sound, even coloured, even textured and free from defects. Unless otherwise indicated on drawings, the
following finishes shall be produced.
Any remedial treatment to formed surfaces shall be agreed with the Engineer following inspection
immediately after removing the formwork and shall be carried out without delay unless otherwise
specified or directed. Any concrete, the surface of which has been treated before being inspected by the
Engineer or has been treated by unapproved methods, shall be liable to rejection.
Normally, the only form of treatment which will be allowed for Class F2 concrete finish after removal of
the formwork will be the filling of minor surface blemishes with a specially prepared approved cement
and fine aggregate paste and/or rubbing down with abrasive blocks and water to produce a smooth
surface followed by a thorough washing down with water.
Apart from the filling of minor surface blemishes, as provided for above, plastering of defective concrete
shall not be permitted. Any defective concrete finish will be rejected, and the Engineer may order the
defects to be cut out and repaired or may reject the entire section incorporating the defective concrete
finish.
All cement and fine aggregate pastes used for remedying formed concrete surfaces shall be designed to
produce, as near as is possible and to the satisfaction of the Engineer, a good color match with the main
body of concrete.
2.15.3 Un-formed Concrete Finishes

Unformed concrete finishes shall be as follows:
Screeded Finish - Class U1
• A screeded finish shall be applied where indicated on the Drawings.
• The concrete shall be levelled and screeded to produce a uniform surface to the profile shown on the
Drawings.
Floated Finish - Class U2
• A floated finish shall be applied where indicated on the Drawings. Steel floats shall be used unless
otherwise approved or directed.
• Floating shall be done as soon as the concrete has hardened sufficiently and may be done by hand or
machine. Care shall be taken that the concrete is worked not more than is necessary to produce a
uniform surface free from screed marks which is finished level or to the falls specified on the drawings.
Brushed Finish - Class U3
• A brushed finish shall be applied to all unformed upper surfaces of concrete unless noted otherwise
on the Drawings.
• The surfaces shall be finished to the levels and falls shown on the Drawings and shall first be floated
as for Class U2 finish and then it shall be brushed with a stiff brush, as directed, to give a good running
surface. A 100 mm wide strip at the edge of the slab and adjacent to all joints shall be finished smooth
with a steel float.
• The requirements for the surface finish of rigid concrete pavements shall be a brushed finish as
defined above, subject to the approval of the Engineer.
2.15.4 Cutting and Pinning

The Contractor shall carry out necessary cutting and pinning including the cutting of splays, cutting away
for and pinning in lugs, bolts, sleeves for pipes and all other fittings, raking out joints for skirting and
flashings, and all labor necessary for the proper completion of the block work, including the required
making good to finishes.
All cutting and pinning through concrete shall be watertight finished.
The concrete partition walls of the cellars in the electrical main station and substations shall have
openings of 600 mm for inspection use.
2.15.5 Concrete Surfaces without Formwork

(a) On upward-facing surfaces which do not require formwork or special finish the finish shall be produced
by proper placing and compacting operations alone.
(b) For a fair finish, screeding shall be used, carried out by sliding and tamping a screed board running on
the top edges of the formwork, or on screeding guides, to give a dense concrete skin.
(c) For a fine finish, screeding shall be used as described, then left until the concrete has stiffened and
the film of moisture has disappeared. A steel or wooden float shall then be used for a glossy or
sandpaper surface as required. Working shall be the minimum compatible with a good finish. The
surface shall be protected from water drops.
(d) The surface of capping blocks, transition slabs and crane beams shall have a brushed finish.
2.15.6 Wire-Brushed Finish

After removal of the formwork the surface of the concrete shall be abraded by stiff wire brushes and
water to remove the cement laitance and expose the aggregate.
2.15.7 Bush-Hammered Finish

The surface shall be abraded by carborundum stones to remove irregularities. Within three weeks, the
surface shall be bush hammered to remove the cement laitance and expose the aggregate. Approved
bush hammers shall be worked to within 12mm of corners and arises; the remaining 12mm shall be
hand-chiselled to match. Bush hammers shall be operated perpendicularly to the surface and the
remaining exposed aggregates shall not be loose or fractured. The treated surface shall be washed
with water and stiffly brushed. The exposed aggregate shall be clean and free from film.
2.15.8 Chemical Retarders

Chemical surface retarders, if approved, may be used to produce an exposed aggregate finish, and the
Contractor shall demonstrate that the durability of the concrete surface is not reduced.
2.15.9 Carborundum Finish

Carborundum finish shall be achieved by sprinkling carborundum grit on the unset surface and working-
in by wooden float. The grit shall vary in size between BS 1.18mm mesh and BS 0.60mm mesh and
shall be distributed from a BS 1.18mm hand-screen at the rate of 2.15kg/m2.
2.15.10 Specimen Panels of Concrete

The Contractor shall produce specimen panels of finished concrete for approval. The approved panels
shall be retained by the Engineer and used to determine the acceptability of concrete finishes in the
Works.
2.15.11 Tolerances
Except as detailed elsewhere in this specification, the tolerances of concrete surfaces shall be in
accordance with the following:
i. Foundations and other in-situ buried concrete: BS 5606

ii. Exposed concrete: BS 5606
iii. Placing of precast concrete: BS 8110
2.16 Protection of Concrete

2.16.1 Protective Coating/Membranes
2.16.1.1 Concrete in Contact with the Ground
(a) All landside concrete (except blinding) in contact with the ground shall have protection. In-situ
concrete shall be protected by tanking membranes (requirements detailed in Section 2.16.1.3and
2.16.1.6). Precast concrete shall be protected by cold- applied, polymer-modified, liquid applied
membranes (requirements detailed in Section 2.16.2). For partially buried structures, the protection
shall extend 500mm above ground level.
(b) Tanking materials or coatings must be durable and provide protection of the concrete from contact
with water for the duration of their service life (as per manufacturer recommendation). Materials are
to be selected to provide a service life of between12 to 15 years life to first major maintenance. In
cases where the membrane or coating is not accessible for maintenance such as buried elements,
beyond the point of material service life, the concrete mix is adequate to achieve the specified design
life to the required performance level.
(c) The surfaces to receive coating shall be prepared in accordance with the manufacturer’s instructions.
(d) Prior to backfilling membranes and coatings shall be protected from damage by hardboard or other
approved material.
(e) Grade slabs: Grade slabs shall be laid on 1000 gauge polythene sheet.
2.16.1.2 Sumps
The internal surfaces of sumps in contact with chemicals or brackish water shall be protected by two
components water-based epoxy and cementitious modified polymer coating, Masterseal 525 from
BASF, Nitocote EP403 from Fosroc, Cemprotec E942 from Flexcrete, or similar approved.
2.16.1.3 Protective Membrane

(a) Protective membrane for concrete structures shall be the Bituthene 4000 system from Grace
Construction Products or similar approved.
(b) A method statement shall be submitted for installation and testing of the membrane. This shall be in
strict accordance with the manufacturer’s recommendations.
2.16.1.4 Holiday Spark Testing

After removal of shutters and seaming of studliner, “holiday spark testing” shall be carried out in
accordance with manufacturer’s requirements.
2.16.1.5 Warranty
A 10-year warranty shall be provided for the membrane in respect of workmanship and materials.
2.16.1.6 Protective Covering for Tanking Membrane
(a) The protective covering shall be Hydroduct 220 from Grace Construction Products, or similar
approved, expanded polystyrene boards 25mm thick or 6mm polystyrene that has a minimum
compressive strength of 55KN/m2. If extruded polystyrene protection board is used backfill shall not
contain sharp rock or aggregate over 50mm is size.
(b) The protective covering shall be secured using Bituthene Protection Board adhesive or Hydroduct tape
in accordance with the manufacturer’s recommendations.
2.16.2 Liquid Applied Waterproofing Membranes

2.16.2.1 Preparation
(a) Concrete to be waterproofed shall be free of all grease, oil, wax and any contaminants that might
affect adhesion. Before installation of the protection material, all receiving surfaces shall be firm, dry,
and clean from mud, grease, dirt and loose materials. The surface shall be relatively even and free
from any sharp edges, stones or aggregates or other protuberances and hollows.
(b) Laitance and loose surface material should be removed by high-pressure water jet or grit blasting.
Large blowholes or other surface defects shall be filled and repaired with a cementitious based
material approved by the supplier of the waterproofing. In addition, there shall be strict adherence to
any other application requirements specified by the materials manufacturer.
(c) Liquid membranes shall not be applied to surfaces subject to a negative hydrostatic pressure. Prior to
application of the waterproofing the prepared concrete shall be thoroughly dampened with clean
water. No standing water is acceptable, but the surface should remain visibly damp.
2.16.2.2 Application
(a) A first coat of waterproofing material should be applied at 1mm thick and spray application is
recommended although brush or trowel application is possible. Application shall comply with the
recommendations from the supplier. After the recommended cure / drying time, a second coat of
waterproofing shall be applied at 1mm thick.
(b) Freshly applied waterproofing must be protected against rain, strong sunlight and strong winds unless
effectively cured. Protection boards shall be used to protect the waterproofing from backfilling.
(c) The waterproofing should be applied in accordance with the supplier’s recommendations only and at
the minimum thickness specified above.
2.16.3 Concrete Coatings

2.16.3.1 General
Concrete coatings shall be applied in strict accordance with the manufacturer’s instructions. The coating
shall be applied in two coats preferably of differing colours to give a total minimum dry film thickness
of 1mm.
2.16.3.2 Storage
(a) All coating materials shall be kept in the manufacturer’s original containers with labels and sealsintact.
All paints and coating materials shall be kept in a covered, well-ventilated, and clean storage area.
Each container shall clearly display the name of the coating manufacturer, colour,type of coating, batch
number and shelf life. Where required, special storage requirements shall be displayed and complied
with.
(b) Coatings and paint that have deteriorated during storage, or have exceeded their shelf life, or have
livered or gelled, shall not be used. Thixotropic materials may be stirred to obtain normal consistency.
Coatings shall not be thinned except in the quantities specifically recommended by the coating
manufacturer.
2.16.3.3 Application
(a) Coatings shall be applied in accordance with the coating manufacturer's recommendations.
(b) The surface to receive the coating shall be thoroughly soaked with clean water for 24 hours until
uniformly saturated without any standing water.
(c) The Contractor shall follow the recommendations contained in the coating manufacturer's data sheets
on overcoating intervals and curing.
2.16.3.4 Inspection and Testing

(a) The Contractor shall be responsible for the production of inspection and testing procedures and
specifications.
(b) All stages of surface preparation and coating work shall be subject to inspection by the Contractor’s
qualified QA/QC inspection personnel. All inspection and test results shall be documented and shall
be approved by the Engineer. The documentation shall include daily record sheets.
(c) The following minimum test equipment shall be provided and maintained at the site of the works by the
Contractor.
i. Maximum and minimum thermometer.

i. Magnetic steel thermometer.
ii. Hygrometer.
iii. Dew point tables.
iv. Wet film thickness comb (8No.).
v. Elcometer adhesion tester (0 to 280 kg/cm2) and core cutter.
(d) Each coat shall be visually inspected for pin-holing and adhesion. Any necessary filling or re- coating
or other remedial work shall be undertaken before application of subsequent coats or covering up.
(e) Inspection and supervision shall be as detailed in BS EN ISO 12944. A total quality management
approach will be required of the Contractor at every stage of the project with regard to protective
coatings, The Quality Assurance system shall be in accordance with BS EN ISO 9000.
(f) The Contractor shall develop requirements for the following inspections and checks as a minimum:
i. Pre-qualification of materials and processes including repair methods.
ii. Inspection for surface defects and contaminants and their removal.
iii. Checking or testing of all incoming materials prior to use.
iv. Application and thickness control of all coats.
v. Curing of coating materials.
vi. Control and effectiveness of repairs.
2.17 Quality Records

(a) The Engineer shall have full access to the execution of laboratory work. trials and testing. The
Contractor shall also supply such samples as the Engineer may require for independent testing.
(b) Laboratories used for independent testing shall have quality management procedures in place in
accordance with BS EN ISO 9001. Test laboratory services shall be proposed by the Contractor prior
to the commencement of the works and approved by the Engineer.
2.18 Actions in the Event of Non-compliance
(a) In the event of a failure to comply with the Specification the Contractor shall report the matter in
accordance with the contractual procedures, then any of the following actions may be instructed:
(b) Work should stop.
(c) Investigation of the non-compliance.
(d) Redesign of the concrete mix.
(e) improving quality control.
(f) Cutting and testing specimens from placed concrete.
(g) Durability testing of placed concrete.
(h) Load-testing relevant structural units.
(i) Non-destructive testing of placed concrete.
(j) Breaking-out and replacing concrete.
(k) In the event of (v) the Contractor shall cut specimens from approved locations. Cores shall be tested
and assessed in accordance with BS EN 12504-1 and BS EN 13791.
(l) The Engineer may issue instructions for the work to be stopped until reasons for the failure have been
established; possible consequences assessed, and appropriate preventative and remedial measures
taken. Wherever a non-compliance has been identified (even if the work is eventually accepted) the
corrective actions arising will be at the expense of the Contractor and will not be considered as
grounds for extension of time.
2.19 Repair and Remedial Works

(a) Methods and details for carrying out remedial work to damage and defects shall be submitted in the
form of a detailed method statement for the review of the Engineer.
(b) In general, repairs and remedial methods shall be based on the use of proprietary polymer modified
cementitious materials.
(c) No remedial work, or covering up, shall be undertaken until the struck concrete face has been
inspected and approved by the Engineer.
(d) The location and nature of all repairs and remedial works shall be recorded and a copy of the records
handed over at completion.
(e) The impact of the repairs upon durability shall be assessed by the Contractor and included as an
addendum to the Durability Assessment Report.
3 Structural Steel Specification
3.1 Design Codes and Standards
3.1.1 General
This Specification is written in accordance with the British and European Standards which provide the basis
to achieving in order to indicate the required quality of the plant, fittings, and finishing. This does not
preclude Contractor from quoting to other National or International Standards of equivalent standing which
should be clearly identified, at the time of tendering. English language copies of the proposed standards
shall be submitted. This requirement applies when an official English language version is not available.
The order of precedence, in case of conflict, shall be as given below:
• British Standards,
• European Standards (EN)
• American Standards,
• International Standards and Guidance.
The materials and construction of the Works covered by this Specification are required to comply in all
respects with the relevant Standards, Specifications and Codes of Practice, at the time of the effective
standards cut-off date indicated in the Contract (February 2021) except as explicitly varied by this
Specification. A list of Standards, Specifications and Codes of Practice referred is given in below sections.
3.1.2 Primary Design Codes and Standards

Industry and other standards which are applicable to this document are listed below. This project shall be
designed and implemented in accordance with the latest revision of listed Standards.
Table 3-1: Design Codes and Standards
Design Code Reference Description

BS EN 1993 Design of Steel Structures
BS EN 1090-1:2009 Execution of steel structures and aluminium structures. Requirements for conformity
+A1 assessment of structural components
BS EN 10025-2 Hot rolled products of structural steels. Technical delivery conditions for non-alloy
structural steels
BS EN 10210-1 Hot finished structural hollow sections of non-alloy and fine grain steels. Technical
delivery requirements
BS EN 10029 Hot-rolled steel plates 3 mm thick or above. Tolerances on dimensions and shape
BS EN 10088-1 Stainless steels: Part 1: List of stainless steels
BS EN 10088-2 Stainless steels: Part 2: Technical delivery conditions for sheet/plate and strip of
corrosion resisting steels for general purposes
BS EN 10088-3 Stainless steels: Part 3: Technical delivery conditions for semi-finished products bars
rods wires, sections and bright product of corrosion resisting steel for general
purposes.
BS EN 1011-1 Welding. Recommendations for welding of metallic materials. General guidance for arc
welding
BS EN 1011-2 Welding. Recommendations for welding of metallic materials. Arc welding of ferritic
steels
BS EN ISO 9692-1 Welding and allied processes. Types of joint preparation. Manual metal arc Welding,
gas-shielded metal arc welding, gas welding, TIG welding and beam welding of steels.
BS EN ISO 9692-2 Welding and allied processes. Joint preparation. Submerged arc welding of Steels.
BS EN ISO 4032 Hexagon regular nuts (style 1). Product grades A and B.
BS EN ISO 4034 Hexagon regular nuts (style 1). Product grade C.
BS EN ISO 7091 Plain washers. Normal series. Product grade C.
BS EN 1090-1:2009 Execution of steel structures and aluminium structures. Requirements for conformity
+A1: 2011 assessment of structural components.
BS EN 1563 Founding. Spheroidal graphite cast irons.
BS EN ISO 2560 Welding consumables. Covered electrodes for manual metal arc welding of non- alloy
and fine grain steels. Classification
BS EN ISO 5817 Welding - Fusion-welded joints in steel, nickel, titanium, and their alloys (beam welding
excluded) - Quality levels for imperfections
BS EN ISO 8501 Preparation of steel substrates before application of paints and related products
BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles
BS EN ISO 3506-1 Mechanical properties of corrosion-resistant stainless-steel fasteners. Bolts, screws,
and studs
BS EN ISO 15614 Specification and qualification of welding procedures for metallic materials. Welding
Procedure test
BS EN ISO 12944 Corrosion protection of steel structures by protective paint systems
BS EN ISO 14730-1 Railway Applications. Track. Aluminothermic welding of rails. Approval of welding
processes
BS 7079 General introduction to standards for preparation of steel substrates before
application of paints and related products.
BS 4921 Specification for sherardized coatings on iron or steel
BS 3382-1 Specification for electroplated coatings on threaded components. Cadmium on steel
components. Zinc on steel components
BS 3382-2 Specification for electroplated coatings on threaded components. Cadmium on steel
components. Zinc on steel components
BS 7371-6 Coatings on metal fasteners. Specification for hot dipped galvanized coatings
BS 4190 ISO metric black hexagon bolts, screws and nuts.
BS 6349 -1-1 Maritime works – Part 1-1: General – Code of practice for planning and design for
operations
BS 6349 -1- 4 Maritime works - Part 1-4: General – Code of practice for materials
BS 6349-2 Maritime works - Part 2: Code of practice for the design of quay walls, jetties and
dolphins
BS 6349-3 Maritime works - Part 3: Code of practice for the design of shipyard and locks.
BS 6349 - 4 Maritime works - Part 4: Code of practice for design of fendering and mooring systems
PIANC Report No. WG33 PIANC Report of Working Group 33, “Guidelines for Design
(2002)
of Fender Systems: 2002’
BS 6349-3 Code of Practice for the design of Shipyards and sea locks
ISO 12488-1:2005 Cranes – Tolerances for Wheels and Travel and Traversing Tracks – Part-1: General
DIN 536-1 Crane rails; hot rolled flat bottom crane rails (type A); dimensions, section parameters
and steel grades
EN 1090-1 Execution of steel structures and aluminium structures Part 1: Requirements for
conformity assessment of structural components
EN 1090-2 Execution of steel structures and aluminium structures Part 2: Technical requirements
for the execution of steel structures
Table 3-2: Acceptable Alternative American Standards

AISC 360-10 Specification for structural steel Buildings
ASTM A6/A6M Standard Specification for General Requirements for Rolled Structural Steel Bars,
Plates, Shapes, and Sheet Piling
ASTM A36/ A36M Standard Specification for Carbon Structural Steel
ASTM A53 / A53M Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and
Seamless
ASTM A500 / A500M Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural
Tubing in Rounds and Shape
ASTM A572/ A572M Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural
Steel
ASTM A992/ A992M Standard Specification for Structural Steel Shapes
AWS D1.1/D1.1M-15 Structural Welding Code – Steel
AWS A5.1/5.1M-12 Specification for Carbon Steel Electrodes for Shielded Metal Arc
Welding
ASTM A240 / A240M Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate,
Sheet, and Strip for Pressure Vessels and for General Applications
ASTM A789 / A789M Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless-Steel
Tubing for General Service
ASTM A790 / A790M Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless-Steel
Pipe
ASTM A653 / A653M Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-
Coated (Galvannealed) by the Hot-Dip Process
3.2 Particular Requirements

3.2.1 Design Requirements
3.2.1.1 General
Material grades and minimum yield strength requirements shall be in accordance with material properties
indicated in Section 3.3.1.
Bolts shall be designed on the basis that the threads will be included in the shear plane. Holding down and
fixing arrangements shall be sized, designed, and supplied by the CONTRACTOR. Cast in fixings are preferred
compared to post drilled fixings and shall be used wherever possible.
The CONTRACTOR shall review all base foundation and fixing details to ensure that they are adequate for
the maximum loads plus safety margin that can be applied (under both operational and potential failure
modes which may occur).
CONTRACTOR shall perform calculations for connection design, prepare fabrication drawings including 3D
models and submit to the Engineer for review and approval.
3.2.1.2 Structural Steel
The structural steel grade parameters adopted in the design of each type of element are presented in the
table below.
Table 3-1 Structural Steel Grade
Element Grade
Structural Steel (hot rolled sections) Grade 275 to BS EN 10025 (minimum)

Grade 1.4404 to BS EN 10088-2 and 3
Or
Super duplex stainless-steel type UNS S32520,
Stainless Steel
S32750, S32760 or S32550 in accordance with
ASTM A240/A240M, A789/A789M or
A790/A790M
Stainless steel anchors Grade A4 Class 80 to BS EN ISO 3506-1 and 2
Circular hollow sections (structural members, other than Grade 275 to BS EN 10025 (minimum)
piles)
Structural steel grating Grade 275
Grade 4.6, 8.8 or 10.9 to BS EN ISO 898-1 or
Anchor Bolts
equivalent ASTM A 307 and ASTM A 354-BD
For all types of structural steel:
• Density: 78.5 kN/m3
• Young’s modulus, E = 205,000 MPa
• Coefficient of thermal expansion: 12 x 10-6 / ºC
3.2.2 Durability Requirements

3.2.2.1 General
This section contains design related measures that will be taken to ensure the durability of the structures.
Durability requirement for concrete and corrosion protection shall be based on the design life.
The design life denotes the duration that the facility will continue to be in service, and assumes that adequate
regular inspections and maintenance, but not major repairs or rebuilding, will take place throughout the
term.
3.2.2.2 Durability – Structural Steel
The durability of various structural steel elements of the marine structures and facilities is ensured by one
or combination of the following measures.
• Painting: All structural steelwork related to crane beam structure, quay furniture, wharf structures or
any external surfaces steelwork shall be coated with a coating protection system in accordance with
BS EN ISO 12944-5:2018. The coating systems applied shall provide durability giving the minimum
period of 15 years to first maintenance. First maintenance is defined as the re-application of a paint
protection system in areas where the coating has failed.
• Sacrificial thickness: Refer below Table 3-3. Structures requiring a corrosion allowance will include
all structural members except handrails, guardrails, toe plates, grating, and the like, and also
conforming stainless steel members. A minimum corrosion allowance of 1mm per wetted face shall
be considered on all steel plate and sections of marine structures.
For other structural steel elements like quay furniture on top of quay wall, the painting design life of 15
years and corrosion allowance for the remaining 35 years is sufficient for meeting the design service life
of 50 years.
Table 3-3: Minimum Total Corrosion Allowance for Structural Design
Zone Level Range Thickness loss due to corrosion (mm)

10year period 25years period 35year period
Atmospheric Zone Above +1.25m CD 0.020 mm/year 0.020 mm/year 0.020 mm/year
x 10 = 0.20 x 25 = 0.50 x 35 = 0.70
Splash Zone Between + 0.6m CD and 0.075 mm/year 0.075 mm/year 0.075 mm/year
+1.25m CD x 10 = 0.75 x 25 = 1.875 x 35 = 2.625
Intertidal Zone Between +0.4m CD and 0.035 mm/year 0.035 mm/year 0.035 mm/year
+0.6m CD x 10 = 0.35 x 25 = 0.875 x 35 = 1.225
Low Water Zone Between -1.00m CD and 0.075 mm/year 0.075 mm/year 0.075 mm/year
+0.4m CD x 10 = 0.75 x 10 = 1.875 x 35 = 2.625
Permanent Between 1.0m below 0.035 mm/year 0.035 mm/year 0.035 mm/year
Immersion Zone dredge level (varies) and - x 10 = 0.35 x 25 = 0.875 x 35 = 1.225
1.00m CD
Buried Zone (below Below 1.0m dredge level 0.024 mm/year 0.024 mm/year 0.024 mm/year
seabed) x 10 = 0.24 x 25 = 0.60 x 35 =0.84
Notes:
1. In absence of exact corrosion rates at site, the corrosion rates used for calculating the corrosion thickness
is based on the corrosion rates indicated in Section 4.4 of BS EN 1993-5.
2. Exposure zone classification is in accordance with BS EN ISO 12944-5:2018.
As an alternative to paint protective finishes, galvanising shall be considered for use to the structural steel
sections in all bolted construction, subject to agreement by the Engineer.
3.3 Standard Requirements

The following details and requirements in this section of the specification are common for all structural
elements indicated in this Specification.
3.3.1 Materials
3.3.1.1 General
CONTRACTOR shall supply all materials, tools, and equipment, and all else required for the successful
completion of the work, which shall be the most suitable for the duty concerned and selected for long life
and minimum maintenance in the climatic conditions specified.
CONTRACTOR supplied material shall be new and unused and free from imperfections.
In general, the minimum allowable thickness of any structural steel is to be 8 mm.
Special materials, coating protection or increased material thickness shall be used where structural elements
are subject to severe corrosion or wear. Corrosion protection shall be in accordance with the requirements
specified in Section 3.2.2.2.
Where connecting dissimilar metals will cause galvanic corrosion, a suitable insulation material shall be
provided between the metals. Only galvanized fasteners shall be used to connect galvanized structural
members. Coated fasteners shall be used for painted structural members.
Steel plates rolled and hollow sections and similar products used for structural and other purposes shall
comply with BS EN 10025-1 and BS EN 10025-2 or BS EN 1020-1 or ASTM A572, Grade 50 and ASTM
A500, Grade C in accordance with Volume 2 Employer’s requirements.
Hot rolled structural steel sections shall comply with BS 4-1, BS EN 10210-1, BS EN 10210-2, BS EN 10056-
1, and BS EN 10056-2. Steel tubes shall comply with BS EN 10296-1 and BS EN 10297-1 or ASTM A53.
Where stainless steel is applicable, steel tubes shall comply with BS EN 10296-2 and BS EN 10297-2 or
ASTM A312. in accordance with Volume 2 Employer’s requirements.
The procurement, fabrication, welding, mechanical fastening, surface treatment, transportation, erection,
inspection, and documentation of steelwork shall be carried out in accordance with the requirements of EN
1090-1 and EN 1090-2. All work shall be undertaken to execution class EXC3.
Galvanised steel sheet for purlins and side rails shall be in accordance with BS EN 10326. Profiled sheet for
composite floor slabs shall be galvanised steel sheet to BS EN 10346 with a Z275 coating or ASTM A653
All cast iron shall be spheroidal graphite cast iron to BS EN 1563.
The CONTRACTOR shall ensure that before assembly begins, all plates are flat, and all rolled sections are
straight. Bent or sharp kinked material shall be rejected. Straightening, when necessary, shall be carried out
by methods that do not impair the metallurgical integrity of the material. Any defective materials shall be
replaced by the CONTRACTOR at no cost to the Employer.
When shaping a component by bending, pressing, or forging either by hot or cold process, its properties
must not fall below those specified in BS EN 1090-2 and TR10347 for EXC3 class steel.
3.3.1.2 Stainless Steel
All stainless-steel plate and sections shall be Grade 1.4404 to BS EN 10088-2 and 3. All stainless-steel
fixings shall be Grade A4, Class 80 to BS EN ISO 3506-1 and 2.
Particular attention shall be paid in the design and manufacture of the work to prevent corrosion due to
contact between dissimilar metals and provision of isolating nylon washers. Particular attention shall also
be paid during manufacture of the work to prevent the formation of “white rust” on galvanised components.
3.3.1.3 Welding Consumables
Consumables for use in metal arc welding shall comply with BS EN ISO 14171, BS EN ISO 14174, BS EN ISO
2560, BS EN ISO 14341, or BS EN ISO 17632 as appropriate and stored and kept in a controlled atmosphere
described in BS EN 1011-1.
3.3.1.4 Fasteners
Bolts shall be 20mm diameter Grade 8.8 in accordance with BS EN ISO 3506-1 except for cold rolled purlins,
cold rolled side rails, or stairs, ladders, and handrails when diameter 16mm shall be used. Nuts shall be
Class 8.8 in accordance with BS EN ISO 4032 or if galvanised shall be Class 10 in accordance with BS EN ISO
4034 EN ISO 4032. Stainless steel bolts shall be grade 1.4436 A4 Class 80 in accordance with BS EN 10088-
3.
Any stainless steel holding down, and fixing nuts, bolts and washers shall be stainless-steel Grade A4, Class
80 to BS EN ISO 3506-1 and 2 or of higher strength.
3.3.1.5 Shear Studs
Proprietary shear studs shall be in accordance with BS EN ISO 13918 with the following properties after
being formed:
Minimum yield strength: Grade 50 (350 N/mm2)
Minimum ultimate tensile: Grade 65 (450 N/mm2)
3.3.1.6 Protective Treatment Materials
For protective treatment material requirements, refer to Section 3.3.4.
3.3.1.7 Open Steel Flooring
A. Steel Grating
Steel grating shall be galvanized in accordance with BS EN ISO 1461. Top surface of bearing bars shall be
plain unless serrated is specified. Grating stair treads shall have abrasive- or chequered-plate nosing.
B. GRP Grating
Contractor can as an alternative propose GRP Gratings of approved pattern and designed for the design
loads and spans.
Floor grating shall be of the open grid pattern of GRP material and thickness to be determined by calculation
based on spans as shown in relevant design drawings and loading requirement. GRP gratings shall be
designed according to Supplier’s recommendations along with BS 4592 (all parts). GRP grating vendor shall
provide their standard details for approval by Engineer.
Open grid GRP flooring to be fastened to supporting steel beams with grating clips as detailed and
manufactured by the GRP grating Supplier. Clips shall be supplied as sets by Supplier and consist of bolts,
nuts and washers made from 316 stainless steel material. Type of grating, clips and bolt material are subject
to Engineer’s approval.
Grating shall be attached to supporting steelwork with galvanized and painted clips / fixtures. A nominal
gap of 8 mm is to be provided between installed panels.
Holes or cut-outs in floor panels shall have perimeter stiffening strips or toe plates and shall be supported
from framing below.
3.3.1.8 Solid Plate Flooring
Where required for safety reason and as shown in design drawings, flooring shall be made of solid floor plate
with a raised pattern affording a non-slip surface. Minimum thickness of floor plate shall be 6 mm exclusive
of pattern.
13 mm diameter drainage holes staggered at 600 mm centres shall be provided in floor plates with a
minimum of one hole per panel.
Removable floor plates shall be attached to supporting steelwork with galvanized and painted countersunk
bolts. A nominal gap of 8 mm is to be provided between installed panels.
3.3.1.9 Platforms, Ladders, Stairs and Handrail
Platform gratings, stair treads and ladders shall be of either steel or GRP / GRE material of approved pattern
and designed for the specified loads, as indicated on Design Drawings.
Maximum rise for a single unbroken flight of stairs shall be within acceptable limits (16 steps maximum).
A single run shall have the same slope. Maximum stairway slope shall not exceed 35 degrees for main stairs,
and 38 degrees for secondary stairs.
Maximum stair riser height shall not exceed 180 mm and minimum tread width shall be 280 mm. Minimum
widths between stair stringers shall be 800 mm for secondary stairs, and 1000 mm for main stairs.
All ladders shall be caged except when 2.3 m clearance under cage cannot be maintained. Single stage
ladders shall be no longer than 9.0 m. Multiple stage ladders shall be staggered at 6.0 m.
Except for berthing ladders used on cope side, ladders and safety cages in other areas shall be of either steel
or GRP / GRE.
Unless otherwise noted herein or the drawings, safety gates, hand rail members (top and mid rails), hand
rail posts, insert plates and ladder supporting clips shall be hot dip galvanized to a coating weight of 610
g/m² in accordance with BS EN ISO 1461 and painted.
Ladders shall be preferably side-step ladders. Ladders shall be supported by attachments near the top of
the ladder.
Hand railing shall be constructed of steel pipe. All handrail members (top and mid rails) and handrail posts
shall be minimum of circular hollow section CHS 42.4 mm (outer dia. x 3.2 mm thk). Railings shall enclose
all platforms and stairways.
Railings shall be easily removable where required for periodic maintenance of equipment or facilities.
Toe plates of 100mm x 6mm flat shall be provided on walkways and platforms along all edges protected by
handrails, under the bottom treads of all stairways which rise from landings, and around floor openings for
permanent equipment, when the clearance between the edges of the flooring is greater than 50 mm. Toe
plates must be omitted across ladder openings.
3.3.2 Fabrication
3.3.2.1 General
Unless otherwise specified or shown, fabrication of structural steel shall conform to the requirements of BS
EN 1090-1, BS EN 1090-2, and BS EN 1993 except as modified herein. The following requirements shall
also be considered:
• All structural steelworks shall be shop fabricated in sections consistent with shipping and erection
limitation. No field cutting, or fabrication will be permitted. All parts necessary for the complete
field assembly and erection of the structural steelwork are to be furnished and suitably identified.
• Splices other than those shown on the drawings must be approved in writing by the Engineer. In
general, but particularly for hollow sections, sections shall not be allowed to be manufactured by
welding together shorter sections with a transverse weld.
• All members and connections shall be closely fitted and finished true to line and in precise
position required to permit accurate erection and proper joining of parts in the field.
• Access shall be provided for inspection of material and fabrication at reasonable times at
all work areas including the CONTRACTOR’s shops and yard. The Engineer’s representative
will inspect all steelwork fabrication prior to painting or other protective treatments being
applied by the CONTRACTOR and unless the Engineer in each specific case waives the inspection,
such surface coatings shall not be applied prior to the approval of the Engineer. The CONTRACTOR
shall give the Employer/Engineer not less than two (2) working day’s written notice of intention to
proceed with the application of protective coatings to any steel work fabrication.
• The CONTRACTOR shall not sub-contract any part of the fabrication of steelwork without prior
approval of the Engineer.
• Materials of up to 16 mm in thickness may be sheared. Material of greater thickness may not be
sheared but shall be machined or machine flame cut. Sheared edges, which are later to be formed
by bending, are to have 1.5 mm removed by machining.
• Bolt holes shall be drilled, punching is not allowed. Slotted holes shall be formed by drilling two
holes and completed by cutting.
• Fabricated components shall be stacked clear of the ground, kept clean and supported in such a
manner as to avoid permanent distortion. If possible, accumulation of water from rain or
condensation shall be avoided. Individual components shall be stacked and marked in such a way
as to ensure that they can be identified.
• Sufficient components shall be checked for dimensional accuracy and conformity to drawing to
prove that the manufacturing process is working satisfactorily.
• The exact sections, shapes, thickness, sizes, weights, and details of construction indicated on the
drawings shall be supplied. Substitutions of sections or modifications of details shall be made only
when approved by the Employer/Engineer in writing.
• Where a bend is to be made, the material shall be maintained below 600°C throughout the bending
operations and then air cooled if required. The CONTRACTOR shall use a calibrated temperature
measuring or indicating device for this purpose. Details and proof of calibration of the measuring
device proposed shall be submitted to the Engineer’s approval.
• Cambering of rolled steel members shall be achieved by approved mechanical means.
• Any squaring or notching at ends of beam or girders shall be with radius on inner corner and shall
meet the guidelines of SCI P358.
• Fabricator shall submit all 3-D steel models to Contractor in agreed format to check any fouling
with adjacent equipment or steel before starting fabrication.
• Fabricator shall submit all general arrangement drawings which are extracted from 3-D models
before starting their fabrication drawings for Contractor review.
• Intermediate transverse stiffeners shall be provided for built-up members to prevent web from
buckling. Stiffeners shall be in pairs and shall be connected to either side of the web.
• The intermediate transverse stiffener shall be connected to the web by continuous fillet welds.
• Intermediate transverse stiffener shall be fitted tight to the flanges to exclude water after painting.
• Load bearing stiffeners shall be provided at locations with high local concentrated loads where the
compressive capacity of the webs has been exceeded.
• The load bearing stiffeners shall be designed to prevent local buckling and crushing of the web.
• The load bearing stiffener shall be fitted against the loaded flange by continuous welds.
• The ends of the bearing stiffeners shall be milled/ground for even bearing to flange.
• Stiffeners shall be cut short, fitted against the compression flange, and welded to the web.
• Continuous fillet weld shall be used to attach load bearing stiffeners to the web, and this shall be
on both sides.
• Contractor shall prepare and submit fabrication drawings to Engineer for approval.
3.3.2.2 Bolted Connections
All bolted connections shall conform to BS EN 15048-1, BS EN 14399-1, or BS EN 1090-2, as appropriate
and the following requirements:
• Bolt material shall be in accordance with the requirements specified in Section 4.1.5.
• Bolts shall be snug tightened (non-preloaded) Gr 8.8 bearing type connections, unless otherwise
noted on the drawings. Ladder, stair tread, purlin, girt, door frame and handrail connections may
be made with standard machine bolts, conforming to BS EN ISO 3506-1. It shall be limited in size
to 16mm diameter or smaller.
• A minimum number of bolts in a framed beam connection shall be two bolts.
• Holes for bolts shall be drilled. Flame cutting of holes is not permitted. Holes may be punched full
size in mild steel up to 12 mm in thickness. No punching is allowed for high tensile steel. Mild steel
of thickness greater than 12mm may be punched 3 mm under size and reamed to full size.
• The diameter of the die for hole punching shall not exceed the diameter of the punching by more
than 5% of the punch diameter. Finished holes shall be true and present a uniform bearing surface.
• All bolts shall be hot dip galvanized unless indicated. All galvanized bolts shall be supplied with a
pre-applied lubricant coating.
• All gusset plates shall be 10 mm except where otherwise noted on the drawing.
• The CONTRACTOR shall furnish all field fasteners as required for erection and 5% extra for waste,
loss, etc.
• The CONTRACTOR shall ensure, for bolted beam to column connections, that close control is
maintained in cutting to length and squaring beam ends such that end plates at each end are
parallel and end plates are welded to the beams to produce the minimum distortion in the end
plates. The CONTRACTOR shall furnish shims approved by the Engineer to all joints where gaps
appear between mating surfaces due to fabrication or mill tolerances. Plate thicknesses shown on
drawings are minimum plate thickness after any milling has been carried out to remove distortion.
• Where Load Indicating Washers are noted on the drawings for bearing type joints, The
CONTRACTOR is to observe the following:
o The washers are to be assembled with the protrusions bearing against the underside of the bolt
head, or in applications where it is necessary to rotate the bolt head rather than the nut in
tightening,
o The load indication washer shall be fitted under the nut in conjunction with a nut face washer
with the protrusions bearing against the washer.
3.3.2.3 Moment Connections
Moment connections shall conform to the requirements of SCI P398 and BS EN 1993-1-8.
3.3.2.4 Spliced Connections
Shop splice shall not be permitted without the prior approval of Engineer. In case of approval, only one splice
per member to be approved, less stress critical location shall be selected, the shop splice shall develop 100
percent of the member capacity.
Splice connection design shall conform to the requirements of SCI P358 and BS EN 1993-1-8.
The joint rotation caused by bolt slips, shall not be permitted in the design of the splice connections.
Rail splices and crane girder splices shall not coincide with each other.
3.3.2.5 Measurement
All measurement shall be made by a steel tape related to a standard tape which has been certified to be
correct at 20°C. The tape and steel to be measured shall be at the same temperature and proper precautions
shall be taken to tension the tape correctly.
3.3.3 Welding
3.3.3.1 General
All welding shall conform to the requirements of AWS Structural Steel Welding Code (AWS D1.1) or BS EN
1011-1, the guidance given in BS EN 1011-2 as appropriate, together with the special requirements and
provisions noted on the Drawings and this specification. Welding shall be by electric arc welding electrodes
shall be E70XX and comply with AWS A5.1 and AWS A5.5 unless noted otherwise. Other than work shown
on the shop drawings as site work, structural steel shall not be welded on site.
Butt welds shall be qualified as complete penetration butt welds and 100 percent weld soundness to be
established by radiographic or ultrasonic inspection.
Welds not designated on drawings shall be 6 mm continuous fillet welds. All welded joints shall be
completely seal welded.
Site welding will normally not be allowed. However, if approved in special circumstances, the following shall
be adhered to:
• The site welding plant shall be of ample capacity to provide the required current to each welding
point without appreciable fluctuations.
• The welding procedure for making each joint shall be approved by the Engineer before the work is
started and the CONTRACTOR shall make such trial welds as directed to demonstrate the
soundness of the proposed method and the competence of workmen.
• Welding of clip angles or other items to tanks is not permitted.
For structural members with full penetration corner or T-joints between plates both thicker than 18 mm,
procedures to minimize the risk of lamellar tearing shall be provided for approval by the Engineer.
3.3.3.2 Electrodes for Welding
The Contractor shall obtain approval from the Engineer of the types of electrodes proposed for use.
Welding electrodes shall be of matching chemical composition to the parent metal in compliance with BS
EN 499 and shall give a weld deposit with mechanical properties not less than the minimum specified for
the parent metal.
Hydrogen controlled electrodes shall be used for butt welding of steel over 25mm thick.
3.3.3.3 Welding Personnel
All welding shall be carried out by welders and welding operators tested to meet the requirements of AWS
standards or BS EN ISO 9606-1. The CONTRACTOR shall submit welder qualifications and weld procedures
to the Engineer’s for acceptance prior to the commencement of production.
Welders who have failed a repeat acceptance test shall not be permitted to weld. Welders who fail any
periodic test shall be given another test as soon as practicable and shall be deployed on welding only after
passing such a retest.
3.3.3.4 Welding Procedures
The CONTRACTOR shall submit all relevant Welding Procedure Specifications for each weld procedure for
inspection and acceptance by Engineer. When requested by Engineer, the referenced Procedure
Qualification Records shall also be submitted. When requested by Engineer, the records of all welders and
welding operator qualification tests shall be made available. All welding procedures shall be the
responsibility of the CONTRACTOR and shall be such as to minimise distortion or restraint. When required
by the Employer/Engineer, the CONTRACTOR shall submit for review all welding procedures in accordance
with BS EN ISO 15609-1.
The welding procedures shall also comply with the guidance of BS EN 1011-2 Annex C, Method A to avoid
hydrogen cracking.
Provision shall be made for procedure trials to be carried out in accordance with BS EN ISO 15614-1. The
trials shall include specimen weld details for the actual construction which shall be welded in a manner
simulating the most unfavourable situation which may occur. Where prefabrication primers are to be applied
to the work before fabrication, they shall similarly be applied to the samples before trials are made.
All welding procedures specifying pre heat weld treatment must indicate the following:
• Preheat Temperature (maximum and minimum)
• Heat Rate (maximum)
• Holding Temperature (maximum and minimum)
• Holding Time
• Cooling Rate (maximum)
All preheating procedures shall be submitted to the Engineer for review.
Pre-heating shall be carried out when directed by the Engineer and when the following conditions
exist:
• The temperature of the parent metal is at or below 10°C.
• All repairs.
• Any incomplete weld which has been allowed to cool.
Transverse welds to form members of the required length shall be complete penetration butt welds
as defined in AWSD D1.1 or BS-EN.
Welding to steel castings shall be based on production tests that accurately model site conditions.
The welding of different stainless-steel types to each other or to other steels, such as carbon steels, shall
be subject to procedure trials and agreed with Engineer.
Before welding commences the CONTRACTOR shall ensure there is no paint within 75 mm of the surface
to be welded with the exception of wash primers for blast cleaned steel declared by their VENDOR’s to be
suitable for welding.
All welds shall be designed to seal the joints between sections completely unless specified otherwise by
Engineer. The requirements for seal welds where appropriate shall either be shown on the drawing or
specified in the Specification for the component.
Details of any temporary attachments including the methods to be used to remove them shall be submitted
to Engineer for approval.
All fillet welds shall be continuous and where sealing runs are adopted; they shall have the appropriate
corrosion allowance. All welds shall be smooth in preparation for painting.
All main butt welds shall have complete penetration, shall be made between prepared fusion faces and
when possible, shall be welded from both sides.
In the fabrication of built-up assemblies, all butt welds in each component part shall be completed before
final assembly.
Where butt welds are to be ground flush, there shall be no loss of parent metal.
Peening of welds resulting in deformation of the weld surface shall only be carried out with the express
permission of Employer/Engineer. All spatters shall be cleaned off and all slag removed on completion of
the weld and before examination by the welding inspector.
Welding operations shall be completed before any final machining or other fitting work is carried out.
Procedures shall be adopted to enable welds to be traced to the welder by whom they were made.
All electrodes used shall be in accordance with the relevant clauses in BS EN 1090 and BS EN ISO 2560
and shall have the approval of Lloyds Register of Shipping.
The CONTRACTOR shall carry out weld examination in accordance with BS EN 1090-2 with acceptance
criteria to BS EN ISO 5817, Quality Level B, and the following additional requirements.
Sections of welds that are shown by radiographic or ultra-sonic methods to have any group of inclusions
in line where the sum of the longest dimensions of all such imperfections is greater than T (where T is the
thickness of the thinner plate joined) in a length of 6T shall be judged unacceptable except where each of
the individual spaces between imperfections is greater than three times the length of the longer of the
adjacent imperfections.
When the length of the radiograph is less than 6T, the permissible sum of the length of all inclusions shall
be proportionally less than T providing the limits of the deficient welding are clearly defined.
Transverse welds to form members of the required length shall be complete penetration butt welds as
defined in BS EN ISO 1011-1 and BS EN ISO 1011-2.
Projecting welded gussets to be kept to a minimum to avoid damage during transportation and to avoid
fouling with proposed pipe/equipment penetrations.
3.3.3.5 Weld Quality
All welds shall be continuous unless shown otherwise on the Drawings and there shall be thorough fusion
between weld metal and base metal between successive passes in the weld. All craters shall be filled to the
full cross section of the weld.
Arc strikes outside the area of permanent welds shall be avoided. Cracks or blemishes resulting from arc
strikes shall be ground to a smooth contour and undergo NDT to ensure soundness.
Additional weld metal to compensate for deficiency in size of weld shall be deposited using an electrode
preferably smaller than that used in making the original weld and preferably not more than 6 mm in
diameter. The surfaces shall be thoroughly cleaned before welding.
For all cases, the electrode and electrode wire used shall be such that the welds can be made to the standard
required of this Specification.
Electrodes that have been wet shall not be used, whether dried or not. Welding flux that has become damp
shall not be dried or reused. Flux fused in the welding process shall not be ground or reused. Flux shall be
dry and free of contamination from dirt, mill scale, rust, or other foreign material.
Electrode wire shall be clean and free from rust, oil, grease, and any other deleterious substances.
Electrode wire and flux shall be stored in their original containers or other properly identified container in a
dry and weatherproof location.
Welds connecting members having a cross sectional thickness of 25 mm or more shall be made with low
hydrogen electrodes. Low hydrogen electrodes need not be used for root bead or hot pass.
3.3.3.6 Site Welding
Subject to prior approval, use of site welding as an alternative to bolted connections shall be considered,
subject to the approval of Engineer.
The extent of testing for site-welded joints shall be 100% inspected by radiography RT and magnetic particle
examination MT or penetrant examination PT in accordance with the acceptance criteria specified in BS EN
ISO 5817/ API Standard 1104.
Initially 100% of each butt weld shall be inspected. At the discretion of Engineer, the number of inspections
may subsequently be reduced. Furthermore, at the discretion of Engineer the radiographic examination RT
may be substituted by ultrasonic examination UT
Defective welds shall be cut out, remade, and retested until approved.
3.3.3.7 Workmanship
Copies of certificates for all welders shall be supplied to Engineer and the welder of any joint shall be shown
to be qualified for the position and type of weld proposed in the welding procedures.
Welding procedures for all welding at moment carrying connections shall be approved by an Independent
Inspection Authority and submitted for approval by Engineer prior to work commencing.
All welds shall be inspected and tested in accordance with this Specification. If the in-house inspection and
testing arrangements are not carried out to an accredited Quality System, then all inspections and tests must
be carried out by an Independent Inspection Authority at the CONTRACTOR’s expense.
Details of any proposed Inspection Authority or evidence of accreditation must be submitted during tender
stage and approved by Engineer.
3.3.4 Protective Treatment

3.3.4.1 General
This section covers the minimum requirements for materials, surface preparation, application, and
inspection of paint protective coating systems for all the marine structural steel works other than piping for
products or services and fixtures and proprietary equipment.
For shop-coated components, a copy of the Surface Preparation and Coating Inspection form or approved
equivalent shall be included with the shipping documentation. For field coated components the Surface
Preparation and Coating Inspection Form shall be submitted at the end of each shift.
3.3.4.2 Coating Materials
The coating systems used shall meet or exceed the requirements of the protective coating schedule (Refer
Section 3.3.4.8). The CONTRACTOR may propose alternative protective coating systems to the approval of
the Engineer. The contents of the submission shall include:
• Technical details in the form of data sheets and specifications.
• Methods of application and repair.
• Warranty and written confirmation that the system proposed and all coating materials to be used are
suitable for the particular environmental category and life to first maintenance in this Specification, are
compatible with each other and shall provide supporting technical justification with reference to
relevant design standards.
• Estimate of maintenance-free life.
• Estimate of cost including break-down of material, labour, plant, and equipment to rehabilitate or
replace the system at the end of the maintenance free period.
• Completed projects list and testimonials.
Paint coating materials shall be delivered to the place of application in the VENDOR’s unopened, original
containers bearing a legible product designation, batch number, and date of manufacture. Wherever
possible, coating materials to be from one manufacturing batch. Wherever possible, coating materials to be
from one manufacturing batch. Where more than one batch is to be used, keep separate, allocate to distinct
parts or areas of the work, and inform the Engineer accordingly.
Paint or protective coating must be non-conductive and not interact with the CP system provided as
indicated in this Specification.
Temperature sensitive and self-polymerization paint materials must be stored in air-conditioned storage
area to maintain the temperature as recommended in the Manufacturer's data sheet.
The coating materials shall be used within the Manufacturer’s published shelf life.
Containers of coatings shall be clearly marked, and containers and components shall only be opened for
immediate use.
3.3.4.3 Sampling and Testing
Samples for testing may be taken both from the sealed containers and from the workmen’s’ kettles on the
works. Any work coated with materials, the samples from which prove unsatisfactory, shall be cleaned off
and re-executed, and work on which the paint is found to be unduly thin shall be repainted, until the
minimum thickness specified is achieved.
The coating application procedure trials applicable to the steelwork are to be the initial element of works on
the Site. The trials will demonstrate the method proposed for applying the system, coverage, coating
thickness, colour and final appearance of the coating. Technical representatives shall monitor these works
and agree the final procedures. The coated element(s) when accepted, shall form the standard against
which the corresponding coating in the works shall be judged. All issues are expected to be resolved at this
point. Adequate time for these procedure trials shall be allowed.
No changes to the materials and/ or methods of application used in the painting trials shall be permitted
during the main works unless agreed by the Engineer.
3.3.4.4 Application Equipment
The CONTRACTOR shall comply with Environmental Management procedures and government regulation
for control of abrasives and any paint over spray, drips, or spills to prevent their release into the environment.
The CONTRACTOR shall also comply with procedures and requirements specifically relating to the Employer
Requirements to Environmental Impact Mitigation Strategies.
Equipment provided shall be capable of regulating and controlling the work environment to the specified
environmental conditions, to perform the work according to the Program of Works approved by the
Engineer.
Application equipment shall be equivalent to the equipment recommended by the coating VENDOR and
shall be suitable to apply the coating as specified.
Equipment with air supply lines shall be equipped with filters/traps to remove moisture and oil as close to
the point of use as possible. These traps shall be in addition to oil and water extractors mounted on the
compressor. The cleanliness of compressed air shall be established before each coating application by
holding a clean piece of white blotter paper or a white cloth approximately 500 mm from the air supply,
downstream of moisture and oil separators while air is blowing on the paper or cloth for 1 minute. If oil or
water deposits are left on the paper, then the in-line oil and water traps shall be replaced or adjusted until
this requirement is met.
3.3.4.5 Surface Preparation
Pre-degrease surface preparation of all welds, corners, etc shall be undertaken to ensure a compatible
surface finish is achieved for coating prior to surface degreasing and grit blasting.
Surface cleaning and removal of all debris associated with welding and construction shall be undertaken
prior to surface degreasing and grit blasting.
Full visual inspection and approval to proceed shall be required for the surface preparation prior to surface
degreasing. Records of this inspection shall be kept and submitted to the CONTRACTOR.
All steel surfaces shall be degreased using suitable solvent free emulsifying detergents and clean potable
drinking water.
Degreasing shall commence at the highest part of the structures and proceed to the lowest part of the
structures to prevent contamination of the degreased areas.
Full visual inspection and approval to proceed shall be required for the surface preparation prior to surface
degreasing. Records of this inspection shall be kept and submitted to the CONTRACTOR.
Abrasive grit blasting will be undertaken using hard sharp angular grit in accordance with BS EN ISO 11124
or BS EN ISO 11126.
The final surface of the steel immediately prior to application of the first coat in any coating system shall
comply with ISO 8501 – 1 Sa 2½ minimum. A sharp angular profile is required which provides a surface
profile amplitude of 50-85 microns, average shall be 75 microns.
Abrasive used shall be Australian Garnet or steel shot and shall be capable of providing a sharp, angular
blast profile of 50-85 microns amplitude.
All steelworks shall be prepared to preparation P2 in accordance with BS EN ISO 8501-1, with edges to
preparation grade P3 in accordance with BS EN ISO 8501-3.
The amplitude of the blast profile shall be at least as coarse as Segment 2 but no coarser than Segment 3
when assessed in accordance with ISO 8503-2 (this is at least ‘MEDIUM G’ profile grade). Direct
measurement of amplitude can be undertaken using ISO 8503-5 or other agreed method. At no point shall
the measured amplitude be less than 50 microns.
Cast iron shall be prepared in accordance with BS ISO 27831.
The presence of levels of soluble salts above 20 mg/sq.m., assessed using methods detailed in ISO 8502-
5/6/9, or equivalent (or the SCM 400 Salt Contamination/Conductivity Meter) shall not be permitted. Fresh
water washing shall be carried out if needed to remove excess soluble salts.
If open blasting is employed every effort shall be made to contain the spent grit within the work area.
Suitable sheeting shall be used in order to allow spent grit to be collected.
All residual dust shall be removed from blast cleaned areas using a soft dusting brush, vacuum, or clean dry
compressed air just before coating application. Assessment of residual dust levels shall be carried out in
accordance with ISO 8502-3 Part B, residual dust levels shall not be worse than Class 2.
Coating shall be applied within 4 hours of surface preparation by blast cleaning being completed and before
the blast cleaned surface shows any sign of deterioration.
3.3.4.6 Metal Defects
Any weld spatter, rough weld caps, sharp edges or other metal defects exposed after surface preparation on
all surfaces which are not in accordance with the requirements of BS EN 10163 for quality of finished surface
shall be rectified accordingly.
Surface defects in hot rolled hollow sections revealed during surface preparation which are not in
accordance with the requirements of BS EN 10210-1 shall be rectified accordingly.
Areas of treated metal defects shall be finally prepared in accordance with the requirements of this
Specification.
3.3.4.7 Conditions for Application of Coating
All coatings shall be applied under cover so that they are protected from exposure to rain, wind, dew, dust,
direct sunlight, sea water, salt, etc.
Work shall not be performed in the following circumstances:
• If the surface is wet or likely to become wet after blasting, before or during application of prime
coating or top coating.
• On surfaces where condensation is likely to form, i.e., where the surface temperature of the steel is
less than 3°C above the dew point of the surrounding air.
• When the relative humidity of the surrounding air is greater than 85%.
• Adverse weather conditions exist such as, but not restricted to, the following:
o Wind is strong enough to blow sand, salt spray, or other foreign matter onto the surface being
painted.
o Wind is strong enough to cause dry spray or to disturb the spray pattern when application is
otherwise seriously by spray gun.
o Care shall be taken to ensure that spent abrasive material and other foreign matter is not
allowed to impinge on and adhere to freshly coated surfaces.
3.3.4.8 Coating Selection
The CONTRACTOR shall be responsible for providing the protective coatings in line with the specifications
as set forward in the schedule below.
The protective treatments are scheduled as follows:
Table 3-4: Protective Treatment Types
Protective
Treatment Description Dry Film Thickness (DFT) Requirements
Type
A. Minimum system thickness shall be 375 microns Dry Film
Thickness (DFT).
B. Blast Clean to BS 7079 – Part A1: 2009 (ISO 8501, Part 1:2007)
Sa 2.5 quality to achieve a coarse surface roughness of 50 to 85
microns.
Steelwork C. Primer: one coat of Zinc rich Epoxy Primer at 50 to 60 microns
Exposed to per coat.
A
Atmospheric
D. Intermediate Coats: two coats of 2-pack Epoxy High Build MIO
Zone Only
at 125 microns per coat minimum.
E. An additional stripe coat of MIO shall be applied to the relevant
areas.
F. Decorative Coat: one coat of Polyurethane gloss finish at
50 microns per coat.
A. Blast Clean to BS 7079 – Part A1: 2009 (ISO 8501, Part 1:2007)
Sa 2.5 quality to achieve a coarse surface roughness of 50 to 85
microns.
Immersed, B. Primer: one coat of 2-pack Epoxy Zinc Phosphate Primer at 25
Splash and microns per coat.
tidal zones in C. Intermediate coats: two coats of Glass Flake Epoxy at 500
B accordance
microns per coat minimum.
with
D. An additional stripe coat of the glass flake epoxy shall be
Employer
applied to relevant areas.
requirements
E. Where cathodic protection is installed, all painted steel work
below the splash zone shall be bonded into the cathodic
protection system.
All stainless
C None
steel works
Alternative coating systems to the above may be proposed, provided the proposal complies with the
requirements of this Specification. The CONTRACTOR shall obtain approval from the Engineer for the
alternative coating systems prior to works commencing.
Table 3-5: Protective Treatment Schedule
Protective Treatment Items
- Service pit covers, gully gratings and frames, Buffer stopper, tie
Type A Downs, storm anchors
- Bollards
- Coating Connections where stainless steel is not specified, including

cast-in threaded bars and anchor plates
- Fender Chains
Type B
- Fender Panel Brackets
- Fender Panels
- Steel tubular piles (from top to 1m below seabed level)
3.3.4.9 Schedule of Colour Finishes

The schedule of colour finishes shall be furnished in the method statement and submitted for Engineer’s
approval.
3.3.4.10 Coating Application
The first coating shall be applied to the cleaned surface within four (4) hours of completion of blasting and
shall be completed on that day before the dew point is reached.
Prior to applying each coat, all edges, angles, welds, and all areas difficult to coat shall be stripe painted.
Coating application shall not commence unless the requirements of surface preparation are met. All
coatings shall be applied in strict accordance with the VENDOR’s recommendations.
3.3.4.11 Method of Application
The coating shall be mixed with mechanical equipment immediately prior to application in strict accordance
with the Manufacturer’s instructions and then transferred to agitated pressure pots where appropriate and
kept in motion so that the pigment is kept in suspension until application is complete. Mixing of partial kits
is unacceptable. All solvents used for thinning shall be as recommended by the Coating Manufacturer.
Paint that has been mixed for a period longer than the VENDOR’s recommendations shall not be used.
The coating shall be applied using compressed air or airless spray equipment in strict accordance with the
Coating Manufacturer’s requirements. Small areas may be coated using a short-haired bristle brush. The
coating shall be smooth and uniform without runs, beads, pinholes, or other imperfections. Areas of
excessive film build that exhibit mud cracking or areas with defects of a sudden local nature which result in
insufficient film build shall be blast cleaned and feathered a minimum of 100 mm back to sound surrounding
coating and then re-coated in accordance with the Specification.
At all times the paints shall be used strictly in accordance with the Manufacturer’s instructions. The
CONTRACTOR shall employ, at the CONTRACTOR’s cost, a representative of the Coating Manufacturer to
advise and assist in obtaining consistently high-quality coatings.
Mixing of paints from two different VENDOR’s is prohibited.
The coating supplier’s recommendations regarding minimum and maximum over-coating intervals shall be
strictly followed.
3.3.4.12 Repair and Reinstatement of Damaged Paint Coatings
Where a coated surface must be repaired to provide a continuous coating, the area shall be washed
thoroughly with potable water and then re-profiled to the original surface preparation, so that none of the
damaged coating remains. The surrounding coating shall then be feathered for a minimum distance of 100
mm and the subsequent repair applied to overlap the edge of the feathering by a further minimum 100 mm,
unless otherwise specified by the Coating Manufacturer.
Dust and debris shall be removed from the substrate prior to coating application.
Test the coating for holes when it’s fully cured. Any defects shall be repaired and re-tested for assurance
3.3.4.13 Certification of Coatings
The CONTRACTOR shall provide a Conformance Report demonstrating compliance with the requirements
of the specification at every stage of the works as it progresses.
The Coating Manufacturer shall be present to witness a minimum of three complete work lots from blasting
through to final coating for the purposes of:
• Providing training to the CONTRACTOR’s personnel as necessary.
• Providing approval in writing for all aspects of the CONTRACTOR’s painting operation.
• Assessing a suitable works inspection frequency.
• A minimum of 5% of all work lots shall be inspected and signed off by the coating supplier.
3.3.5 Galvanizing
3.3.5.1 General
Galvanised coatings shall meet the durability requirements specified in Section 3.3.4.8.
Galvanizing shall be carried out in accordance with BS EN IS0 1461 and only after fabrication is complete.
All welds shall be cleaned and dressed and all surface defects including cracks, surface laminations, weld
spatter, deep pitting, fins at saw cuts, burrs and sharp edges shall be removed by filling or grinding.
Steelwork required to be galvanised shall be pickled in dilute hydrochloric acid, washed, fluxed and stove,
and then coated with zinc by dipping in a bath of molten zinc.
Components shall be immersed in the bath only for a period sufficient to attain the temperature of the bath
and shall be withdrawn at a speed which ensures that the galvanised coating shall be a minimum of:
• For all general marine structures (except marked below): 85 microns DFT on each surface and
therefore in accordance with a C5 Very High durability corrosivity to BS EN ISO 14713-1 and BS EN
ISO 14713-2.
Components shall be covered evenly on all surfaces and shall be free from pin holes, lumps of galvanizing
materials and all other defects.
Lightweight gauge metalwork shall be galvanised by the hot dip process as specified in BS 3083 or BS EN
10143.
Before application of a specified paint treatment, galvanised steelwork shall be cleaned, degreased, and
treated in accordance with the paint VENDOR’s recommendations.
Small areas of the galvanised coating damaged during transit or removed by cutting, drilling, or welding
shall be treated by the use of low melting point zinc alloy repair rods or powder specifically made for that
purpose in accordance with the VENDOR’s specification or a technique acceptable to and approved by the
Works CONTRACTOR in accordance with BS EN ISO 1461.
3.3.5.2 Contact Prevention
Contact between galvanised steel members and aluminium surfaces or between galvanised and un-
galvanised steel members shall be prevented by means of approved insulating washers and grommets.
3.3.5.3 Inspection
All galvanised components shall be subjected to 100% post-galvanizing visual inspection.
The results of the post-galvanizing inspection shall be recorded. These records shall be made available to
the Engineer on request.
If evidence of cracking is identified, then the component and all similarly shaped components fabricated
with similar materials and weld details shall be identified and quarantined as non-conforming products. A
photographic record of the cracking shall be made, and such further investigation as required by the Works
CONTRACTOR shall then be undertaken to establish the scope and origin of the problem. The results of such
further investigation shall be submitted for Engineer’s approval. Quarantined components may only be
repaired for use in the Works Engineer’s approval.
3.3.5.4 Vent Hole and Vent Hole Sealing
The CONTRACTOR shall agree with the Works CONTRACTOR the position of vent and drainage holes in
hollow components as described in BS EN ISO 14713, and any requirements for subsequent sealing using
an approved bung or proprietary metal filler.
3.3.5.5 Painting Galvanised Steel
Before over-coating hot dip galvanized surfaces, any contamination including by oil, grease, dirt or any other
materials detrimental to coating adhesion shall be removed. Cleaning agents shall be approved by the paint
VENDOR. Heavy deposits of grease shall be removed by scraper before degreasing takes place. Zinc
corrosion products shall be removed using warm water and a stiff bristle brush, and the surface of the
substrate allowed to dry thoroughly.
Clean potable water which does not leave harmful residues on the surface shall be used for wet cleaning and
rinsing.
Surface preparation shall be continued until the required standard has been achieved.
Immediately before application of each coat of paint, inspection and approval is required to ensure that the
surfaces to be painted meet the required standard of preparation and are free from harmful residues and
detrimental contamination, including water, moisture, condensation, oil, grease, mortar, concrete, dust, grit,
paint degradation products, chlorides, and sulphides.
Joints, splices, and fasteners shall be sealed.
Galvanized surfaces shall be sweep blasted before application of the coating system. A chloride free abrasive
shall be used for sweep blasting. A fine surface finish in accordance with BS EN ISO 8503-2 is required.
Sweep blasting shall produce a matt and etched finish without removing more than 10 µm of zinc thickness.
The abrasive size used shall be 0.2-0.5 mm, and the air pressure shall be 40 psi to 50 psi (2.7 bar to 3.3 bar).
After completion of surface preparation and prior to any coating work, the surfaces shall be thoroughly
cleaned of dust to comply with level 2 BS EN ISO 8502-3.
The first coat of a protective coating system shall be applied within 1 hour of sweep blast-cleaning.
Where the surface preparation or painting application requirements of this specification differ from those of
the approved paint VENDOR, the paint VENDOR’s requirements shall take precedence, subject to the
approval of the Engineer.
Preparation may use a Mordant Wash or T-Wash. If this is to be used it shall be endorsed by the coating
supplier. Mordant Wash shall not be used on weathered galvanizing. New galvanized steelwork that is to be
treated with Mordant Wash shall not have any passivation treatment applied by the galvanizer. The Mordant
Wash shall be applied until an even black coloration is produced over the entire galvanized surface. The
Mordant Wash shall not be allowed to pool. When an even black coloration does not occur with a single
application of Mordant Wash, the surface shall be further washed, degreased, and abraded with a non-
metallic abrasive pad followed by further applications of Mordant Wash until the required finish is achieved.
Any loose corrosion products and excess Mordant Wash shall be removed from the treated surfaces prior to
the protective treatment application by fresh water washing. The Mordant Wash treated surface shall be
allowed to dry thoroughly.
Any damage or repair required to the painted system, or the painted galvanised system shall follow strict
guidelines and recommendations from the paint supplier and the galvanizer.
3.3.6 Joints and Connections

3.3.6.1 High Strength Friction Grip (HSFG) Bolted Joints
The interfaces of all HSFG bolted joints shall be cleaned as specified, left unpainted masked off to protect
them until the joint is bolted up. Blast primer or metal spray as appropriate shall be taken 10 mm to 20 mm
inside the perimeter of the joint area.
Subsequent paint coats shall be stopped off progressively at intervals of 75 mm from the bolted joint. Before
the joint is made the facing, surfaces shall be lightly hand wire- brushed to give a clean surface free of
corrosion products and any foreign matter. Immediately after the joint has been made the primed steelwork
shall be hand wire brushed and the specified painting systems completed.
Seal edges with a polysulphide sealant.
3.3.6.2 Other Bolted Joints
For shop joints the blast primer shall be applied to parent and joint material. The joint shall be assembled
immediately after the first undercoat of the painting system has been applied to the parent and contact
surfaces.
For site joints all surfaces, excepting those of fasteners, shall receive in the shop the paint system which is
applied to the parent surfaces.
Seal edged with a polysulphide sealant.
3.3.6.3 Welded Joints
The CONTRACTOR shall ensure that areas within 200 mm of known site welds shall not be painted until all
welding and testing is completed. Where this is not practicable, the CONTRACTOR shall ensure that the paint
coat is removed by grinding and each coat is stepped back to enable preparation of fusion faces for welding.
Welds and surfaces which have been affected by welding shall receive the preparation and protective
systems which are applied to the parent surfaces. Where paints other than blast primers are to be applied to
the parent surfaces before the making of a joint, they shall be stepped back at 50 mm intervals commencing
at 200 mm from welded joints and at 10 mm from the perimeter of all other joints.
3.3.6.4 Treatment of Completed Joints
Within 14 days of the joints having been made and passed inspection, the parent and joint materials,
exposed parts of bolts, nuts and washers, weld and weld affected areas shall be prepared and painted.
All bolted joints shall be sealed against the ingress of moisture. Before painting commences gaps at joints
shall be plugged with approved filler. The perimeter of all joints shall be sealed with subsequent coats of
paint.
3.3.7 Other General Requirements
3.3.7.1 Order of Materials
CONTRACTOR shall submit duplicate copies of all sub-contract orders for materials and machinery parts to
Engineer’s approval, plus any drawings or sketches referred to at the time of placing the order.
The orders shall contain such excerpts from this Specification as are applicable and each part shall be clearly
identified in order that reviewing engineer can easily locate the part in the plant or system.
Orders for steel shall be endorsed “The maker’s analysis of each cast of steel is required.”
3.3.7.2 Workmanship and Safety
Workmanship throughout shall be of the highest possible standard, and all work shall be performed by
workmen skilled in their particular trades.
The surfaces of all plates or members intended to be jointed together shall be in contact over the whole
areas and where necessary all stiffeners shall bear tightly both at the top and at the bottom.
Keys shall be accurately fitted in an approved manner and shall have stops to prevent slackening or
accidental disengagement except where the position of a key makes the fitting of a stop unnecessary.
Erection and installation of major steel work shall be performed in a safe manner. A thorough Risk
Assessment shall be prepared before any erection or installation is undertaken. A copy shall be submitted
to Engineer’s approval in advance.
In the absence of any Safety Regulations directly applicable to the work specified, the equipment shall be
designed and furnished at least to the standards required by the national statutory requirements.
CONTRACTOR shall ensure that the finished plant is safe for the purpose specified and that safe systems of
operating, in keeping with best modern practice, are provided under the Contract.
3.4 QA/QC, Inspection, Testing and Commissioning

3.4.1 Quality Assurance and Control
The CONTRACTOR shall implement a Quality Management System to the approval of Engineer. All works
shall be planned, organized, controlled, and executed in accordance with the quality requirements.
3.4.2 Inspection and Testing

3.4.2.1 General
At all stages of fabrication and treatment, the steelwork shall be subject to inspection by Engineer. Any work
not to the satisfaction of Engineer shall be immediately rectified at the CONTRACTOR’s expense.
Approval given to steelwork at an earlier stage of fabrication or supply shall not preclude rejection of any
steelwork either before, during, or after erection.
Testing and Inspection shall be in accordance with the specification.
All work may be subject to inspection and approval by Engineer for conformity with the Specification.
Inspection and approval by Engineer shall in no way relieve CONTRACTOR of the responsibility for
compliance with the Specification.
CONTRACTOR shall provide all test certificates.
3.4.2.2 During Manufacturing
(a) General
Material tests required during manufacture shall be in accordance with the appropriate Standard
Specification or as otherwise approved or specified herein.
Tests shall be performed, and test certificates shall be provided or obtained and submitted from the
VENDORS, for the materials to be used in the project.
The tests shall include the following, in accordance with relevant BS/EN ISO standards or as appropriate:
• Chemical analysis.
• Tensile strength tests.
• Impact tests.
• Bend tests.
• Lamination tests.
• NDT Tests.
The tests shall be carried out by an approved testing authority, if appropriate, and notice shall be given of
the intended execution of any such tests.
If any sample fails a test the consignment it represents may be rejected in part or in whole. If necessary,
additional tests shall be carried out by an Inspection Authority selected by Employer/Engineer in the event
of apparent discrepancy between submitted certificates and actual condition of the supplied material.
Copies of test reports shall be submitted for Engineer’s approval.
The CONTRACTOR shall fully check all items to ensure they comply with the shop drawings and the
requirements of this Specification. This checking shall be done at least one (1) day prior to shipment.
Material and workmanship shall be available for inspection at all times by the Engineer.
• Fabricated steel required to have yield strength greater than the base grade shall be marked to identify
its specification. Such identification shall be visible on the steelwork prior to shipment to the
CONTRACTOR’s plant.
Shop assembly of the trial erection of structures will be the subject of inspection to Engineer’s satisfaction.
Dimensional checks shall be undertaken as necessary, and records shall be submitted to Engineer as part of
the quality assurance plan.
Engineer shall have right of access to witness all tests.
A. Inspection of Surfaces and Coatings
The CONTRACTOR shall be responsible for carrying out all inspection and quality control testing in
accordance with this Specification. Personnel undertaking inspection and quality control testing shall be
suitably trained and hold applicable and current certification. Certification to Level II under the Institute of
Corrosion Scheme or equivalent is required. The Engineer reserves the right to undertake any monitoring,
inspection and testing he determines is required for confirmation of compliance with the Specification. The
CONTRACTOR shall hold certification showing quality systems compliant with ISO 9002.
All inspection and quality control shall be carried out in accordance with procedures and an Inspection and
Quality Plan approved by the Engineer. Only qualified personnel approved by the Engineer shall be used for
inspection and quality control activities.
Inspection and quality control activities shall be adequate to ensure all surfaces are prepared and all coatings
applied to comply with this Specification and the Coating Manufacturer’s recommendations.
Inspection and quality control activities shall include but not be limited to:
• Surface preparation including surface profile amplitude measurement.
• Testing for soluble salts.
• Mixing of coatings.
• Application of coatings.
• Monitoring of ambient conditions.
• Appearance and DFT of applied cured coatings.
• Recording of batch numbers of materials used.
• Recording of results of inspections and monitoring.
• Daily log of activities.
All site records will be kept in legible hard copy format and shall be computerized daily and available for
review by the Engineer.
The CONTRACTOR shall permit coating VENDORS to inspect the work in progress, including surface
preparation, and to take samples of their products if required. The CONTRACTOR shall not comply with any
directions or requests given by the coating VENDOR’s representative unless and until confirmed in writing
by the Engineer.
The CONTRACTOR shall notify the Engineer of projected dates for start of surface preparation and coating.
Give the Engineer at least 3-day notice before coated members or components leave the works.
B. Bolt Testing
The CONTRACTOR shall arrange for the following tests to be carried out by an approved authority or firm:
• Slip factors for treated surfaces (if applicable).
• The tests specified shall be carried out by and at the expense of the CONTRACTOR who shall also supply
the necessary facilities for testing in their workshops. The Engineer may at any time request additional
tests.
C. Weld Testing
The CONTRACTOR will be responsible for visual inspection, non-destructive testing, and quality control of
all welding processes relevant to the work. CONTRACTOR shall submit to the Engineer’s records of visual
inspection, non-destructive testing, and quality control documentation. Inspection or testing conducted by
the Engineer shall not relieve the CONTRACTOR of full responsibility for the work.
All NDT procedures shall be submitted to the Engineer.
Operators carrying out testing and inspection shall hold a current certificate of competence to Level 2
according to BS EN ISO 9712 from a recognized authority.
• Welds shall be subject to 100% visual examination and 5% non-destructive testing carried out at
random for the Structural Steel required for the project unless noted otherwise on the Drawings.
• The tests specified shall be carried out by and at the expense of the CONTRACTOR who shall also
supply the necessary facilities for testing in their workshops. The Engineer may at any time request
additional tests; however, the cost of these additional tests only will be borne by the Employer.
• Copies of test reports shall be sent directly to the Engineer.
• The Engineer reserves the right to vary the extent of examination when, in their opinion, this
becomes necessary to ensure that the required level of acceptance is attained. Non- destructive
testing requirements shall be in accordance with the Standards presented in this Specification.
• In the event that, the supplied material or the assemblage does not meet the intended purpose or
has any manufacturing defect noticed in the material / equipment procured, the CONTRACTOR
shall be responsible at his own cost, for rectification of the defects by replacement or repair up to
the entire satisfaction of Engineer.
• All mechanical and non-destructive (radiographic, ultrasonic, and magnetic particle) test results
submitted with the qualification documents must be performed by qualified personnel. The
Engineer may elect to witness weld testing and every effort shall be made to accommodate the
Engineer’s representative if this is required.
Additional periodic testing may be required, if in the Engineer’s opinion, welding quality has declined. All
requirements specified for welder and weld procedures shall also be applicable to these tests.
D1. Magnetic Particle Inspection
Magnetic particle inspection (MPI) shall be carried out by the Contractor, as directed by the Engineer in
accordance with the procedures to the consent of the Engineer. These procedures shall be written in
accordance with ASME Section V, except as modified in the Employer’s Requirements, or to an alternative
standard proposed by the Contractor and approved by the Engineer. The Contractor shall submit procedures
to the Engineer for consent prior to their implementation.
MPI shall be conducted after acceptance of initial visual inspection and any weld profile grinding and prior
to and after any toe burr grinding.
The method for MPI shall be AC Yoke with articulated legs using white background paint and black ink. All
weld areas that are to be examined by MPI shall be sufficiently smooth to avoid false defect indications. MPI
shall be used to detect both longitudinal and transverse defects. The applied magnetic field strength and
sensitivity shall at all times meet the ASME V requirements.
Magnetic particle operators shall be qualified to a minimum standard of CSWIP 3.1 Tester (Magnetic
Particle) or to an alternative standard to the consent of the Engineer.
Acceptance levels shall be in accordance with Table 5.7.1 of PD 5500, or similar levels as agreed by the
Engineer. Spurious indications may be removed by grinding to a maximum depth of 1.0mm at weld toe
locations. Weld metal indications may be removed by grinding provided the weld profile requirements are
maintained. Light surface grinding may be carried out before or during MPI examination to provide a
satisfactory surface finish on which to carry out the test or to assist the operator in the interpretation of any
possible indication.
If surface indications cannot be removed by light dressing to a maximum depth of approximately 1.0 mm,
the Engineer shall be informed and shall witness any further grinding required to remove the indication. The
repair by welding of any location where grinding is carried out to a depth greater than 1.0 mm shall be at
the discretion of the Engineer and shall be carried out to an approved procedure. The operator shall produce
a test report for each weld joint arc strike examined in addition to a sketch showing the locations and lengths
of reject able flaws. Each magnetic particle inspection report shall detail as a minimum the information listed
below:
a) Joint identification number
b) Type of joint or area i.e., face penetration butt joint, ’T' butt joint, fillet weld, area of arc strike,
c) scar area etc.
d) Welder(s) and welding operator(s) identification(s)
e) Welding procedure(s) identification(s)
f) Operator identification and signature
g) Method of magnetisation and consumables (ink, powder, etc) used
h) Date and time of weld completion and MPI
i) Original weld or repair
j) Applied magnetic field strength
k) Heat treatment and sizes discovered and location
l) Conclusions; accept or reject with respect to the Employer’s Requirements
m) Flaw excavation profile (mimic)
All MPI reports shall be submitted to the Engineer.
D2. Ultrasonic Examination

Ultrasonic examination (UT) of welded joints shall be carried out by the Contractor, as directed by the
Engineer, in accordance with procedures to the consent of the Engineer. These procedures shall be in
accordance with ASME Section V except as modified by the Employer’s Requirements, or an alternative
standard to the approval of the Engineer. The Contractor's proposed UT procedures shall include a
procedure for the testing of welds at elevated temperatures, (i.e., up to the minimum preheat temperature)
and a procedure to enable the accurate sizing of embedded flaws.
Each weld shall be examined with sufficient probe angles to guarantee full coverage of the joint, with
scanning from both sides of the joint if geometry permits.
Prior to shear wave examination, a compression probe search shall be conducted to confirm that no
lamination type defects exist within the continuous members at T-butt weld locations, which will mask the
shear wave examination.
Prior to conducting ultrasonic examination, the operator shall ensure that the weld deposit and surrounding
areas are sufficiently smooth to avoid false or misleading defect indications. The maximum surface
correction factors shall be 6dB. If this correction factor is exceeded additional surface grinding shall be
performed prior to final ultrasonic examination. All flaw indications which exceed the 20% reference level
when examined with the dB increased gain shall be investigated and detailed in the operator's report.
Planar flaws are unacceptable regardless of length or amplitude and shall be weld repaired. When examining
for Chevron cracking any indication which equals or exceeds 20% of the reference curve shall be cause for
rejection.
Slag indications are acceptable if:
a) Defect length is less than that permitted by PD 5500, or similar approved standard, regardless of
DAC.
b) Defect length exceeds requirements of PD 5500 Table 5.7.1, or similar approved standard, but
response level is less than or equal to 50% DAC calibrated on the appropriate 2.4 mm or 3.2 mm
hole.
Slag indications are unacceptable if defect length exceeds requirements of BS5500 Table 5.7.1 and
response level is greater than 50% DAC calibrated on the appropriate 2.4mm or 3.2mm hole.
The standard on which the slag indication acceptability is to be finally determined is to be agreed and
confirmed prior to the commencement of any UT.
When positive flaw type interpretations cannot be ascertained in any instance the flaw shall be considered
planar and in need of repair.
All ultrasonic operators shall be qualified in accordance with the Certification Scheme for Weldment
Inspection Personnel (CSWIP) to the level of CSWIP 3.6 unless consent is otherwise given by the Engineer.
All supervisors shall be qualified to CSWIP 3.9.
During production examination the Contractor shall produce a test report for each weld joint or weld repair
examined in addition to a sketch of all flaw sizes and location and dB level for each flaw required.
Each ultrasonic examination report shall detail as a minimum (using joint diagrams to indicate scans) the
information listed below:
a) Joint identification number
b) Welder(s) and welding operator(s) identification(s)
c) Welding and ultrasonic procedure identification numbers
d) Operator identification and signature
e) Sketch showing location(s) face width, length and location of all indications exceeding the 20% DAC
reference curve and signal amplitude
f) Date and time of welding completion and NDE
g) Original weld or repair.
h) Heat treated condition or "as welded"
i) Plate thicknesses
j) Probe angles and frequencies.
k) Equipment identification serial numbers. The basic sensitivity.
l) The primary reference level sensitivity - basic plus transfer value.
m) State if "hot" or ambient temperature examination. Surface correction factor adopted during
examination and calibration.
n) Conclusions; accept or reject with respect to the Employer’s Requirements.
The Contractor shall make an initial assessment of defects against acceptance criteria and all ultrasonic
reports including recommendations shall be reviewed and approved by the Engineer.
3.4.2.3 Jetting
Jetting is not permitted.
3.5 Submittals
3.5.1 General
Prior to any work commencing, the CONTRACTOR shall forward method statements and risk assessments
detailing the procedures to be used together with an Inspection and Quality Plan to the Works CONTRACTOR
for acceptance.
The method statements, risk assessments, and Inspection Quality Plan shall include but not be limited to
the following:
• Coating system application procedure trials.
• Testing certification and traceability of coating materials.
• Health & Safety Data sheets for all materials used.
• Storage of Materials.
• Access arrangements and safety procedures.
• Surface cleaning.
• Steel surface preparation.
• Disposal of Waste.
• Coating material preparation.
• Coating application.
• Ambient conditions control.
• Inspection and testing.
• Restoration and repair of subsequent damage or defects.
• Recording and reporting of results.
• The CONTRACTOR/ VENDOR shall submit to Engineer the following:
o A dimensioned layout, general arrangement, and component drawings, documentation, and
specifications, as well as electrical diagrams installations, including all controls and control
equipment.
o All drawings and documents shall be subject to Engineer’s review before any work on the
equipment commences. Such drawings and documents shall be modified and re-submitted
if found necessary. The drawings shall include a materials specification of all the components
shown and also the weight of the individual components.
3.5.2 Drawings for Approval

A. General
Before commencing the relevant portion of the work, CONTRACTOR shall submit duplicate copies of
arrangement, assembly and detail Drawings for the approval of Engineer.
Drawings and calculations submitted for approval shall be in English and dimensioning throughout shall be
in the ISO Metric System. The information shall be clearly presented so that Engineer may check all details
for conformance with the Specification.
All Drawings and calculations submitted by CONTRACTOR including those of his suppliers shall be clearly
titled.
It must be understood that approval of Drawings and calculations, whilst made in good faith, does not carry
with its responsibility for subsequent alterations which Contractor may find necessary as the work proceeds,
nor shall it relieve Contractor of his responsibilities under the terms of the Contract.
The shop drawings shall contain all dimensional and geometric information. Materials shall not be ordered,
fabricated, or delivered to the construction site before the shop drawings have been approved.
Prior to review of the shop drawings by the Consultant, such shop drawings shall have been reviewed and
approved by the Contractor and shall be stamped to indicate this by the Contractor. Such approval by the
Contractor shall constitute the Contractor's representation that the Contractor has verified all quantities,
dimensions, specified performance criteria, installation requirements, materials, catalogue numbers and
similar data with respect thereto and has reviewed or coordinated each shop drawing with other shop
drawings and samples and with the requirements of the Work and the Contract Drawings and Specifications.
B. Shop Drawings
Shop drawings shall include layouts and details showing the type of steel for each member, sizes of
members, connections, cuts, copes, cope reinforcing, bolts, welds, and other pertinent data. Provisions for
the connection of any other work shall be indicated on the shop drawings.
All welds shall be indicated by standard welding symbols as defined by BS EN 1011. Shop drawings shall
show the size, length, and type of each weld.
Shop drawings shall be submitted in complete packages so that individual parts and the assembled unit may
be reviewed together.
The review of shop drawings by the Consultant shall not in any way relieve the Contractor from the
responsibility for the adequacy of the design of the connections and all required detailing, the responsibility
for the proper fitting of the Work in strict conformance with the Contractor requirements and from the
necessity of furnishing material and workmanship required by this Specification.
3.5.3 As-Built Drawings

On completion of the work, the CONTRACTOR shall provide as-made general arrangement and detailed
drawings. The Contractor’s designer/consultant shall certify that the as-built drawings are in line with the
approved design.
All final Drawings shall be certified as correct by CONTRACTOR and stamped “AS-BUILT”.
3.6 Shipping, Handling, Storage, and Installation

3.6.1 Identification and Marking
3.6.1.1 Materials Identification
Before shipment, all pieces shall be clearly marked with substantial tags, punching, or otherwise indicating
the piece number and such other information as is required for ready identification. The identification
marking shall not adversely affect the surface finish of the member, nor shall it detract from the final
appearance of the steelwork. Long members shall be marked at both ends and at approximately 6000 mm
intervals. Punch marks shall permit overcoating with paint without bleeding.
Loose items such as nuts, and bolts shall be sorted and tagged and securely bagged in waterproof containers.
Identification may be by size, grade and quantity or be referenced to a particular location of a structural
component and drawing.
All pieces shall be marked with identification marks shown on the marking plans and elevations.
When required, the Contractor shall suitably identify the steel for each building and structure in the project
by colour coding or some other method.
All steel members in each building and structure shall be marked by the Contractor prior to shipment as
follows:
• All steel members generally shall be marked with a prefix number indicating the drawing
on which the piece is detailed, followed by a letter designating the type of member, followed by
the specific part number, dash, and finally the floor elevation of the piece, (for example, SO148-
B10-1370 means the Beam 10 is detailed on detail sheet number S148 and is located in plan on
Elevation 1370).
• Columns shall be marked with the same plan designations as that shown on the design drawings.
Columns extending through several floors of a building should be marked by tiers, for example,
C13 (2) means column C13, second tier. The markings preferably should be made on the face of
the columns. Compass directions shall also be marked on the column flange faces for ease of
erection.
• Marking Plans and Elevations shall indicate the marking of beams and girders at one end of the
member as shown in plan, and the mark placed on the member by the Contractor shall be on the
corresponding end, in order to enable the erector to properly orientate the member for erection.
3.6.1.2 Method of Marking
Identification marks shall be applied to the members with the die stamp using minimum 12 mm high
lettering and placed in the same location on the member as shown on the erection drawing.
If a marking area of sufficient size is not available a corrosion resistant metal tag shall be securely affixed to
each individual piece by galvanized steel wire. The tag shall indicate the identification mark and 6mm high
lettering shall be stamped on the member.
After the final shop coat has been applied to the members, the identification mark shall be duplicated at the
same end of the member as the die stamp and shall be made with paint stick prior to shipment.
When required, colour coding shall be described herein or as shown on the design drawings.
3.6.2 Packaging
All structural steelwork components and accessories shall be assembled in manageable bundles or pallets.
All loose items including nuts, bolts, clips, and fasteners shall be securely bagged and tagged. Each type and
size of loose item shall be separately packaged and labelled within the loose items’ baggage.
The Contractor shall be responsible for the replacement of materials damaged or lost because of inadequate
packaging.
All bolts, washers nuts shall be packaged and delivered in rigid, weatherproof containers. Cardboard
containers are not acceptable.
3.6.3 Shipment / Handling

The Contractor shall ensure the structural steel elements are undamaged when delivered and shall be
handled and stored so as to prevent damage, such as bending or abrading end fittings, or damage to coating
of hardware.
Methods of handling shall ensure the steelwork is not damaged or marked by the lifting gear, impact with
the ground or in any other way. Steelwork shall not be dragged, dropped, or unnecessarily rolled, but shall
be lifted by crane of suitable capacity, operating with spreader beam if necessary. In the loading of members
for shipment, proper softeners, ‘soft’ slings, and dunnage shall be used to protect the finish paint.
The contractor shall send two (2) sets of Marking Plans and Elevations to the field with each respective steel
delivery.
Bolts, nuts, and washers shall be shipped in kegs or bags to the site in advance of respective steel deliveries.
Any single keg or bag shall contain one type, diameter and length of bolt and be marked by area.
Each shipment shall be accompanied by two sets of bolts take off sheets.
Grating and/or floor plate shall be shipped by area and elevation and be bundled, banded, tagged and,
where possible, shipped on pallets for lifting to erection elevation.
Handrails, grating and floor plate shall be shipped on trucks separate from the structural steel by area and
elevation and at the same time as the structural steel.
3.6.4 Storage
The Contractor shall be responsible for the unloading, storage, and safety of the steel parts after arrival at
the job site.
Steel shall be handled in such a manner as to prevent damage to the shop applied paint or galvanizing and
be free of mud, dirt, and other foreign substances. Proper softeners and 'soft' slings shall be used. Painted
steelwork shall not be stored with surfaces in contact but shall be separated by adequate spacers.
The steel parts shall be stored in the allocated spaces on timbers or blocking clear of the ground that has
been graded to properly drain.
Bolts, washers, and small parts shall be stored under cover in clean containers to prevent dirt and water
entering.
Rusted, corroded, bent or damages steel shall be rejected.
During storage, structural steel products shall be protected from exposure to damaging liquids, oils, greases
and extended exposure to sunlight.
3.6.5 Transport
Steelwork shall be kept well constrained and supported during transport by suitable timber packers, bearers,
or chocks. The steelwork shall be effectively tied down at each end, supported in the middle and prevented
from clashing during transport.
3.6.6 Rejection
In the event that, the supplied material does not meet the intended purpose, or has any manufacturing
defect noticed in the material / equipment procured, the Contractor shall be responsible at his own cost, for
rectification of the defects by replacement or repair up to the entire satisfaction of Engineer.
3.6.7 Installation / Erection

3.6.7.1 General
Members shall be prefabricated or pre-erected into sub-assemblies to facilitate field erection as directed.
Pre erection checks shall be carried out on all prefabricated members to ensure their dimensional accuracy.
Pre erection dimensional checks shall be carried out on all dimensions including bolt hole locations and
sizes.
Erection shall be in accordance with the drawings including requirements and tolerances specified in AISC
360-10.
The Contractor shall be responsible for maintaining the integrity of the structure in a safe and stable
condition during erection and shall ensure that no part is overstressed as a result of construction activities
Light drifting to draw parts together will be acceptable but drifting to enlarge holes will not be permitted.
During erection, the work shall be securely bolted or otherwise fastened, and if necessary, temporarily braced
to provide safety against erection stresses and conditions including those due to erection equipment and its
operation.
The procedures for the proposed erection sequence shall be submitted to the Engineer for review. Steelwork
shall not be fitted to concrete foundations until the concrete has attained sufficient strength to support the
loads from the structure. Normal concrete attains design strength 28 days after placement.
All structural steel shall be erected plumb, square and true to line and level and in precise positions.
Tolerances in elevation and alignment of steelwork shall not exceed 5.0 mm.
Temporary bracing and guys shall be used wherever necessary to provide for loads to which the structure
may be subjected, including those due to erection equipment and their operation. Temporary bracing and
guys shall be left in place as long as required for safeguarding all parts of the work.
As erection progresses the work shall be securely bolted as required to maintain the steel in correct position
while field bolting and welding is being carried out and as required to support all dead, wind and erection
loads. No final bolting or welding shall be done until the work has been properly aligned, plumbed, and
levelled.
3.6.7.2 Cutting and Fitting
The Contractor may perform a moderate amount of reaming, chipping and cutting to correct minor
misfits if approved by the Engineer. Drift pins shall be used only to bring members into position and not to
distort or enlarge holes.
Gas cutting shall be permitted on secondary structural steel only, and only following the Engineer’s approval
of the procedure before performing any gas cutting.
Major errors shall be reported to the Engineer. Contractor shall determine the corrective measures to be
taken for concurrence by the Engineer prior to the performance of such actions. All remedial and corrective
actions shall be at Contractor’s expense.
3.6.7.3 Tolerances
Dimensional properties, tolerances and rolling margins for hot rolled steel materials shall comply with the
following standards:
a) Structural steel, plates, and bars – BS EN 10029 or ASTM A572, Grade 50.
b) Universal beams, columns, rolled joists, channels and tees – BS 4: Part 1.
c) Rolled angles – BS EN 10056.
d) Structural hollow sections – BS EN 10210-2 or ASTM A500, Grade C.
e) Steel pipe – ASTM A53.
f) Bolts – Grade HFSG to BS 4395-1.
Dimensions, tolerances on dimensions shall be agreed at the time of the enquiry and order. Notwithstanding
these requirements, the tolerances to be achieved shall be such that the steelwork can be fabricated and
erected efficiently and satisfactorily. If in some cases the tolerances are more severe than the rolling
tolerances for dimensions of structural steel sections selection of stock may be necessary to achieve the
specified requirements.
3.6.7.3.1 Tolerances of Cast-in Items
All cast-in items (galvanized or stainless steel) cast into concrete shall not be permitted to be cast in contact
with the steel reinforcement bars or other steel cast-in items. All cast-in items shall be installed to a high
level of accuracy of ± 2 mm in the horizontal and vertical planes. All holding down bolts and box outs shall
be adequately supported from a template and accurately positioned to the satisfaction of the Engineer
before concrete is placed. All ducts shall be adequately restrained to resist movement.
3.6.7.4 Painting and Clean Up
Where damaged during transit, erection or field welds are made on galvanized members, the area shall be
hand abrasive cleaned and then coated with approved zinc rich paint. The surrounding galvanized area
affected by heat from welding shall also be similarly coated. Welding slag shall be completely removed prior
to coating.
Damage or welds to any paint finished steel shall be similarly repaired in accordance with this specification
and Vendor’s recommendations to the satisfaction of the Engineer.
The Contractor shall clean up from time to time as requested by the Engineer and on completion of the work
completely remove all waste steel, timbers, and rubbish to the satisfaction of the Engineer.
3.6.7.5 Fabrication Errors
The Contractor shall rectify on site any errors resulting from errors on the detail drawings or shop fabrication.
The Contractor shall be responsible for any errors on the detail drawings or shop fabrication. The Engineer
will notify the Contractor if an error is found, and the Contractor shall promptly rectify the error.
3.6.7.6 Grouting under Steelwork
All base plates to structural steelwork that are anchored to concrete foundations shall be grouted into place
by the Contractor. Prior to grouting, the Contractor shall obtain approval from the Engineer to proceed.
It is essential that top surfaces of all structures be horizontal in both directions and correctly aligned, unless
shown otherwise on the Drawings. Such line and level may be checked by the Engineer’s representative and
may be require realignment if incorrect. The Contractor shall carry out the grouting in accordance with the
Concrete Specification.
4 Pavement
4.1 General
The Specification describes the quality of materials and the standard of workmanship for all paving works to
be adopted on the project and shall be read in conjunction with all other relevant contract documents and
standards specified.
The General Specification shall comprise the United Kingdom, Highways England Manual of Contract
Documents and Specification for Highway Works (SHW) and the Particular Specification.
The Particular Specification Reference: SA1980PMD-JAC-70-ERE-CE-00001 follows the same numbering
system as the Specification for Highway Works. Where clauses have the same number in both SHW and the
Particular Specification, those in the Particular Specification shall supersede the former. Generally, Particular
clauses follow the last numbered clause in the relevant section of SHW. Where there is any conflict between
the Particular Specification and SHW, the former shall prevail.
This section covers the container terminal heavy duty pavement and the associated container handling
equipment which operate in the yard. The specifications for the quay wall, ground reclamation, ship to shore
crane rail supports and other marine facilities are covered in separate specifications.
4.2 Design Codes, Client Parameters and References

A list of the standards, codes, and industry guidance to be used in the design is as follows:
1) BS 6349-1-1: 2013: Maritime Works Part 1-1: General – Code of practice for planning and design for
operations
2) BS 6349-1-2: 2017: Maritime Works Part 1-2: General – Code of practice for assessment of actions
3) BS 6349-1-3: 2021: Maritime Works Part 1-3: General – Code of practice for geotechnical design
4) BS EN 206: 2013: Concrete. Specification, performance, production and conformity
5) Saudi Building Code 301
6) Concrete Society: 2008: Guide to the design of concrete structures in the Arabian Peninsula
7) CIRIA 577 and Concrete Society Special Publication CS 136. Guide to the construction of reinforced
concrete in the Arabian Peninsula
8) CIRIA C674: 2010: The use of concrete in maritime engineering
9) Interpave. The structural design of heavy-duty pavement for ports and other industries Edition 4
published 2007 amended 2008
10) PIANC Report No 165 – 2015. Design and maintenance of container terminal pavements
11) Britpave. Guidelines for the design of concrete hardstandings.
12) Technical Report No. 34. A guide to the design and construction of concrete industrial ground floors
13) Technical Report No. 66. External in-situ concrete paving
14) Phase 1 Employers Requirements
4.3 Employer’s Requirements

The Employer’s Requirements, where different from the requirements of SHW, are included within the
Particular Specification.
4.3.1 Standards
The materials and execution of the works shall comply with the latest editions of the relevant standards and
codes in the SHW.
4.3.2 Specification for Concrete
The Specification for concrete provides the minimum requirements for the provision and storage of
materials, mixing, transporting, placing, curing and testing of concrete, for new works concrete and should
be read in conjunction with this specification.
4.3.3 Gradients
The transverse slope of pavement, i.e. perpendicular to the quay line, shall generally be within the range of
1:80 to 1:110 upon initial installation.
4.3.4 Settlement Monitoring

The Contractor shall undertake monitoring of overall pavement settlement, by means of level surveys. The
Employer shall be given the opportunity to witness the surveys, and subsequent data handling and drawing
production, should he so desire. The results of each survey shall be presented to the Employer as AutoCAD
drawings (and a copy on disk). Drawings showing the initial installation levels shall be produced. Subsequent
survey drawings shall show the values of the actual levels taken, the value of the differential (if present)
between the survey levels and the initial installation levels, and settlement contours for the level differential
to indicate the degree and extent of settlement within the terminal.
Monitoring surveys shall commence from the date seven days prior to the issue of the Taking-Over
Certificate for each Section of the Works. Thereafter, the frequency of monitoring surveys shall be every
three months to the end of the Contract Period.
For each monitoring survey, the Site shall be surveyed on a repeatable, nominal 10m grid. Local variations
to this general grid spacing may be necessary in the areas subject to the more stringent settlement criteria
in order to fit the geometry of the areas.
The Contractor shall submit his proposed method for carrying out monitoring surveys, including the
proposed positions of monitoring points, for review by the Employer’s Representative. The method and
programme shall allow for working around and be subject to restrictions imposed by Port Operations.
Monitoring of differential settlement adjacent to structures and of surface rutting shall be carried out at the
same frequency as for overall settlement monitoring.
The maximum allowable for operational reasons before first maintenance is required after a minimum
period of one year from taking over the whole of the Works:
(a) Longitudinal or transverse slope of box: 1 in 60
(b) Out-of-plane of four corners of 20ft box: ± 15mm
(c) Differential settlement adjacent to structures/chambers: 5mm
(d) Surface rutting at any location: 10mm
(e) Differential settlement within pavement: 5mm
(f) Differential settlement between pavement types 10mm
(g) Differential settlement between new and existing pavement 10mm
Differential settlement shall be measured over any 3m length of pavement using a straight edge.
4.4 Materials and Durability

4.4.1 Concrete
The concrete mix requirements shall achieve the required design life in reinforced concrete when exposed
to the site environmental conditions. The concrete mix shall be designed with a very low permeability and/or
developed with admixtures to reduce water absorption, capillary rise, chloride ingress, and carbonation.
Refer to the concrete specification for the detailed requirements. The nominal cover to steel reinforcement
75mm and the minimum cover is 65mm assuming a steel fixing tolerance of +10/0 mm
The concrete elements will be designed using the nominal steel cover. The nominal cover is defined as the
minimum cover distance from the surface of the concrete to any steel reinforcement plus a tolerance. The
fixing tolerance to be considered in detailing the location of reinforcement is as follows:
1 Reinforced concrete – normal control levels: +15mm
2 Reinforced concrete – good control levels: +10mm
Crack widths will be calculated using the nominal steel cover.
All crack width calculations, design concrete crack width and reinforcement spacing will be limited to 0.3mm
for quasi permanent conditions in accordance with BS EN 1992. Early thermal cracking will be checked in
accordance with CIRIA C766 with a maximum crack width limited to 0.3mm.
4.4.2 Properties
The compressive strength Class of the concrete is C35/45 with an in-place flexural strength 5 MPa. The
required type of cement or combination should be CEM II/B-V, CEM III/A, and CEM III/B. The minimum
cement content should be 370 kg/m3 and maximum cement content 460 kg/m3. The maximum free
water/cement ratio should be 0.40 with a consistence Class S1 or S2 (to be confirmed by the Contractor).
The minimum cover to reinforcement should be 65 mm +10/-0 mm. Applicable exposure Classes XT3 (XS1)
shall apply.
4.5 Concrete Pavement Repair

4.5.1 General
The Contractor shall complete a detail visual inspection of the area of existing concrete pavement identified
on the drawings for repair. The Contractor shall determine the location and condition of each concrete bay
and should provide a schedule of required treatments together with a plan drawing identifying the location
of each bay and type treatment required. The Contractor should verify the construction of the existing
pavement and supporting foundation as per Volume 5 Site Data and visual inspections.
The Contractor shall verify the design drawings and provide the following information in shop drawings:
• Schedule of types of defects, crack widths and proposed treatments
• Plan drawing showing the location and type of treatment
• Depth of existing concrete pavement
• Depth and type of subbase beneath concrete pavement
• In-situ CBR or surface modulus of subgrade below the subbase
4.5.2 References
The Contractor shall refer to Appendix F Series 1000 Concrete Pavement for repair works.
Repair of Concrete Pavements
1079 Inspection and Testing of Existing Pavement
1080 Early Strength Concrete for Slab Replacement
1081 Bay Replacement
1082 Full Depth Repairs
1083 Thin Bonded Repairs
1084 Shallow Repairs – Early Strength Concrete
1085 Shallow Repairs – Polymeric Materials
1090 Crack Sealing
1091 Crack Stitching
1092 Longitudinal Diamond Grinding
1093 Fine Milling
4.5.3 Repair Strategy

The construction of the Terminal 1 existing pavement is 300 mm pavement quality concrete over crushed
rock limestone. The Contractor shall commission a structural survey to assess the strength and condition of
the existing pavement and its foundation.
If it is decided to proceed with repairs, the existing concrete will be repaired to reproduce its original capacity
as far as is practicable. Repairs shall be in accordance with Appendix F. The following types of repairs will be
required, but not limited to:
4.5.3.1 Full depth corner repair
A full depth corner repair is made with C35/45 concrete. The perimeter of the repair is saw cut and broken
out full depth. Care should be taken not to damage the remaining concrete. Holes are drilled in the
surrounding concrete and new dowel bars and tie-bars are bonded in place using a proprietary high strength
non-shrink cementitious material. Install new joint seals. See Figure 5-3. The type and functionality of the
existing bay joints should remain the same.
Figure 5-3. Plan and Section view of repair to corner break
Figure 5-4 Typical bay corner failure at Dammam T1
Perimeter of repair to bay corner

4.5.3.2 Partial Bay Replacement
This type of full depth repair is for defects which affect less than half of the slab.
A full depth repair is made with C35/45 concrete. The perimeter of the repair is saw cut and broken out full
depth. Care should be taken not to damage the remaining concrete. Holes are drilled in the surrounding
concrete and new dowel bars and tie-bars are bonded in place using a proprietary high strength non-shrink
cementitious material. Install new joint seals. See Figure 5-5. The type and functionality of the existing bay
joints should remain the same
Figure 5-5 Part Bay Replacement
4.5.3.3 Full Bay Replacement

This type of full depth repair is for bays which cannot be repaired.
A full depth repair is made with C35/45 concrete. The perimeter of the repair is saw cut and broken out full
depth. Care should be taken not to damage the remaining concrete. Holes are drilled in the surrounding
concrete and new dowel bars and tie-bars are bonded in place using a proprietary high strength non-shrink
cementitious material. Install new joint seal. See Figure 5-6. The type and functionality of the existing bay
joints should remain the same
Figure 5-6 Full Depth Bay Replacement
4.5.3.4 Joint Spall Thin Bonded Repair

Saw cut the perimeter of the repair to the required depth and carefully remove the damaged concrete at the
surface of the joint. Prepare the surfaces ready to receive a high strength low shrink flexible cementitious
repair material. install new joint seal. If during preparation of the repair the damage is found to extend full
depth of the bay a wider partial depth bay replacement is required. The minimum width of a full depth repair
should be 1.5m. The type and functionality of the existing bay joints should remain the same.
Figure 5-7 shallow thin bonded repair
Figure 5-8 Typical damaged to concrete bay joint at Dammam T1
4.5.3.5 Sealing of cracks

Narrow cracks up to 1.5 mm can be sealed with a bitumen sealant using a method shown in Figure 5-9
below. The crack should be cleaned and dried with a hot air lance and a bitumen seal applied to the
surface will fill the crack and seal the surface.
Wider mid bay cracks which are performing as movement joints should be repaired by forming a 10 mm
x 15 mm channel along the crack and filling with a 10 mm x 10 mm sealant.
Figure 5-9 Sealing narrow cracks
4.5.3.6 Replacing and sealing joints
Remove the remaining defective sealant, re-cut and seal joint with approved sealants.
5 TERMINAL LINE MARKING & SIGNAGE AND SAFETY BARRIERS
5.1 Work Scope
Comprehensive road markings and signage are required to allow the safe and satisfactory operation
of the Container Terminal, ancillary areas, and accesses thereto.
The Contractor shall provide clear, durable road markings to the Container Terminal to control the
movement of vehicles and equipment throughout the Terminal and to mark out container blocks
and ground slot locations and numbers. The Contractor shall mark out all car/ lorry parking and
trailer parking bays and bollard numbering on the quay face.
The Contractor shall provide barriers, road signs, traffic, and directional, to achieve a comprehensive
road system.
5.2 Materials and Structural Form

Marking materials shall be road marking paints with glass beads to BS EN 1871:2000, BS EN
1436:1998, BS EN 1423:1998, and BS EN 1424:1998 and shall be suitable for road surfaces as
follows:
(a) Chlorinated rubber for block paving and concrete surfaces

(b) Hot applied thermoplastic for asphalt surfaces
(c) Water-based acrylic or solvent-based acrylic resin road marking paint for block paving and
concrete surfaces. The properties of acrylic line marking paint shall be as follows:
Table 7—1 Requirements for the road marking
Description Required Test Limit Values

Method
Pigment ASTM D3723 45% to 55%
Non-volatile vehicle (% by FTMS 141 40% minimum
mass)
Lead, chromium, cadmium, 0%
barium
Volatile organic compounds 250g/litre maximum
Density ASTM D1475 1.44kg/litre minimum
Viscosity ASTM D562 75 – 90 Krebs units
Drying time no pick up ASTM D711 10 minutes
5.2.1 Chromaticity
The daytime visibility of the road-marking paint shall be defined by the luminance factor β. The luminance
factor β of the paint-marking system shall be greater than or equal to 0.30 for dry road markings (i.e. Class
B2) as determined in Annex A of BS EN1436:1998.
The colour shall be defined by x, y chromaticity coordinates of the CIE standard system in accordance with
BS EN 1436:1998 and shall lie within the regions defined by the corner points given in Table 6 and
illustrated in Figure 1 of BS EN 1436:1998. Measurements shall be made in accordance with annex C.
5.2.2 Road Signs
Standard reflectorised road signs shall be in accordance with the “Manual on Uniform Traffic Control
Devices (MUTCD)”, “Traffic Signs Manual”, the relevant part ofthe “Department of Transport Manual of
Contract Documents for Highway Works – Volume 1 - Specification for Highway Works” published by HMSO
and ‘The Traffic Signs Regulations and General Directions, 1994’. Road signs whether mounted on posts or
fixed to a structure shall be mounted at a height specified in the “MUTCD”. The proposed road sign layout
and details are indicated on the Drawings.
5.2.3 Safety barriers

Safety barriers shall be designed as reinforced concrete Jersey barriers. If required, the barriers are to be
embedded in the soil to increase the capacity to deflect vehicles after an impact. The safety barriers shall
not obstruct the drainage of stormwater.
Movable barriers shall include slots in the bottom to allow lifting by forklift truck. The weight of the
moveable barriers shall not exceed 2000 kg. The individual barriers shall include a mechanism to link the
individual barriers together.
5.3 Definition Dimensions and Layout

The layout and extent of the required road and container yard markings are shown on the Drawings. The
layout shown on the Drawings shall be developed by the Contractor for approval by the Engineer and
Employer and other relevant authorities.
5.4 Design Criteria

Road marking paint shall be suitable for use on surfaces at temperatures of up to 50°C and markings shall
comply with the details given on the Drawings.
Road signage shall be in compliance with the “Manual on Uniform Traffic Control Devices (MUTCD)”,
“Traffic Signs Manual”, the relevant part ofthe “Department of Transport Manual of Contract Documents
for Highway Works – Volume 1 - Specification for Highway Works” published by HMSO and ‘The Traffic
Signs Regulations and General Directions, 1994’
The design life of the lines and marking shall be 5 years with warranty of 2 years.
The Contractor shall submit for approval by the Engineer full technical details of the proposed layout and
materials for the marking system and signage.
5.5 Workmanship
5.5.1 General
The Contractor shall ensure consistent high quality workmanship is achieved. After an appropriate paint
has been selected and successful trials have taken place, a detailed method statement shall be submitted
to the Engineer.
Markings shall be applied strictly in accordance with the manufacturer’s instructions and these Employer’s
Requirements.
The user shall be aware of weather conditions, surface preparations, and the condition of equipment before
the application of water-based acrylic traffic paint.
Line marking, including in this context temporary line marking and removal, shall be completed to suit the
Sectional handover areas shown on the Drawings. To achieve these handovers, it will be necessary to liaise
with the Employer’s operational staff in order to complete line marking/ removal in existing areas of
pavement or in areas handed over in previous Sections or Phases. The Contractor shall agree mutually
convenient times for the line marking/ removal of such areas to ensure port operations are not disrupted.
Temporary lines and directional signs shall be marked at the ends of traffic lanes in Sections such that
traffic flow will be controlled in the same manner as in the completed Works.
5.5.2 Surface Preparation

Carriageway markings shall only be applied to surfaces that are clean and dry and clear of loose sand, oil
spillages, dirt, grease, laitance, curing compounds and the like that may reduce the bond between the paint
and the pavement.
The pavement surface to be painted shall be cleaned by mechanical brushing, by wet or dry abrasive
blasting, or by any other methods necessary to ensure adhesion of the paint to the surface and as
recommended by the paint manufacturer.
Adequate maturity of the surface to which paint is to be applied shall be assured.
If the pavement has become polished, a tack coat compatible with the marking material may be required.
The tack coat shall be applied in accordance with the manufacturer's instructions before marking.
An acid etching solution may be needed to counter leaching alkali and carbonate salts and to improve
adhesion to smooth, glassy aggregate particles/surfaces. Such surface preparation shall be subject to trials
to assess possible adverse reactions to the paint system(s) selected.
5.5.3 Application
Paint shall only be applied when the surface is completely dry or as recommended by the paint
manufacturer for water-based paint and has been prepared in accordance with these Employer’s
Requirements.
Paint shall be stored and applied strictly in accordance with the manufacturer's instructions. Minimum and
maximum temperatures of paint and surfaces to be painted shall be observed.
Markings shall be free from raggedness at their edges and be uniform and free from streaks, splattering,
or overspray.
Carriageway lane and edge lines shall be laid by an approved mechanical means, to a neat, accurate
alignment.
The painting of alphanumeric markings shall be accomplished with the use of full size stencils. On
completion of the work, the stencils shall be cleaned, repaired, and handed over to the Engineer at a
port workshop for storage.
The Contractor shall control traffic to protect fresh markings from damage. The traffic control shall cause
minimum interference to traffic and not affect port operations. Signs,barricades, flagmen, and control
devices shall be supplied by the Contractor. A system of spaced warning flags or blocks shall be used to
protect the fresh markings until dry. Markings defaced by traffic shall be repaired by the Contractor at his
expense.
5.5.4 Trials/Testing
Trials using the selected line marking systems shall be conducted in the presence of theEngineer and shall
determine:
a) the required surface preparation;
b) the optimum application conditions;
c) the thicknesses of the resulting applications;
d) the suitability of the proposed equipment and operators;
e) the accuracy of setting out methods.
The Contractor shall undertake paper spray tests every two hours during line marking to demonstrate the
specified coverage rates and paint thickness are being met. Manufacturer or supplier application rates shall
be adhered to closely. Normal thickness for water-based traffic paint is in the range of 350 – 400 microns.
Glass beads shall be applied at the rate of 6 to 8 pounds per gallon for road markings or as specified by
the manufacturer and approved by the Engineer.
5.5.5 Removal of Existing Markings

Where required existing markings shall be removed using either wet or dry abrasive blasting. Precautions
shall be taken to avoid damage to adjacent areas where the markings are to remain. Any such damage
shall be rectified by the Contractor at his own expense.
5.5.6 Tolerances
The minimum laid thickness of the markings shall be in accordance with BS EN 1436.
Edges of line markings shall not vary from the straight line more than 10 mm in 15 mand the
tolerance on the specified width of the laid line shall be +10% and –5%.
6 FENCING
6.1 General
High security anti-intruder fencing is required to enclose the perimeter of the Container Terminal and to
provide demarcation of traffic entrance areas as shown on the Drawings. Fencing is also required around
the stacks served by the automated RTGs. Sections of this fencing shall be removable to enable access for
maintenance and the delivery of future RTGs.
The Contractor shall provide high security anti-intruder fencing at locations and as shown on the
Drawings. Temporary high security fencing of an equivalent form to the permanent shall be provided as
necessary to surround completed areas to be taken over by the Employer, the Contractor’s works areas,
and areas where the existing terminal fence is removed to allow the Works to progress.
6.2 Materials and Structural Form

6.2.1 General
Temporary high security anti-intruder fencing (providing the same degree of security as the permanent
high security anti-intruder fencing) shall be an approved portable system.
Permanent fencing shall be of the following type, at the locations defined on the Drawings:
Fence Type 1 – High security anti-intruder fencing enclosing the perimeter of the Container Terminal
and providing demarcation of traffic entrance areas.
Fence Type 2 – Fencing around the perimeter of the container stacks served by the automated RTG.
The fencing is mounted on top of a vehicular barrier that runs adjacent to the tractor/trailer and
external truck loading lanes and shall be removable.
Fence Type 3 – Similar to Fence Type 2 but the fencing needs to be fixed.
The lengths and alignment of the fencing shall be as indicated on the Drawings subject to the avoidance
of existing services and by agreement with the Engineer before the commencement of fencing works.
6.2.2 Fence Type 1

6.2.2.1 Welded Mesh Fence
Welded mesh fencing shall comply in all respects with BS1722-10 2006 “Specification for Anti-Intruder
Fences in Chain Link and Welded Mesh” and shall be 2.4 m high from finished ground level. The welded
mesh shall be attached to the outward facing side of the fence posts. The vertical wires shall be fitted
outermost.
The fence posts shall be extended with galvanised steel cranked extension arms in the shape of a Y
supporting three strands of barbed wire on each crank (total six strands) to provide a fence height of 3.0
m (allowing for a maximum 5 mm gap below the bottom of the wire mesh). Three galvanised steel droppers
are to be provided at equal-distance centres between each pair of fence posts to retain the line and position
of the three strands of barbed wire. Concertina razor wire shall be placed in the middle of the Y cranked
arms.
6.2.2.2 Sill Treatment

Where the new fence line runs across a paved surface, be it asphalt, concrete block paving, or concrete, the
base of the fence panel shall be fixed to the ground with 4 mm diameter galvanised hairpin staples
threaded over the bottom line wire and mesh wire and grouted into the paving to a minimum depth of 150
mm with a general purpose non shrink cementitious grout. Where fencing is placed across ‘soft’ unpaved
ground, the weld mesh panels shall be buried 300mmm below ground level. The height of the welded
mesh shall be increased accordingly to provide a 3.0 m high fence.
6.2.2.3 Restricted Area Vehicular Gates

All new vehicular access gates shall comply in all respects with BS1722-10 for weld mesh fencing. All
vehicular access gates in weld mesh shall be constructed with steel gate posts comprising 180 x 180 mm
galvanised mild steel rectangular hollow section formed from a 6.3 mm thick plate. The exposed ends of
all posts shall be capped in a matching galvanised steel plate. Typical gate leaves shall be constructed in
all respectsin accordance with Figure C.4 of BS1722-10, including barbed wire vertical extension arms,
nonremovable hinges, internal drop bolts to both leaves, stop plates, and protected sliding bar locks. Mesh
panelling shall be in accordance with the weld mesh specification above.
Gate leaves for vehicular access shall be manufactured and installed in strict accordance with BS1722-10
Clause 11 and 12, with a hollow rectangular section, 50 x 50x 4 mm.
6.2.3 Fence Type 2

6.2.3.1 Chain Link Fence
Chain link fencing shall comply in all respects with BS1722:2006-10 “Specification for Anti-Intruder
Fences in Chain Link and Welded Mesh” and shall be 1.5 m high from finished ground level. The fence
posts shall be mounted on top of vehicular barriers. The fencing shall be easily removable with forklifts.
Emergency access gates 800 mm minimum wide shall be provided through the fencing at a maximum
spacing of 50 m.
6.2.3.2 Vehicular Barrier

Vehicular barriers shall generally comply with BS6579-8. The profile of the traffic face ofthe barrier shall
match one of the profiles given in BS6579-8. The non-traffic face can be non-profiled to optimise the
space available.
At the emergency access gates in the chain link, the fencing foothold shall be detailed in the barrier to
facilitate access over the barrier. The maximum spacing between footholds shall be 250 mm.
Termination units shall be provided at the ends of the barriers. The chain link fencing shall continue to the
end of the termination unit.
6.2.4 Fence Type 3

6.2.4.1 Chain Link Fence
Chain link fencing shall comply in all respects with BS1722:2006-10 “Specification for Anti-Intruder
Fences in Chain Link and Welded Mesh” and shall be 1.5 m high from finished ground level. The fence
posts shall be mounted on top of vehicular barriers. The fencing shall be fixed.
Emergency access gates 800 mm minimum wide shall be provided through the fencing at a maximum
spacing of 50 m.
6.2.4.2 Vehicular Barrier

Vehicular barriers shall generally comply with BS6579-8. The profile of the traffic face ofthe barrier shall
match one of the profiles given in BS6579-8. The non-traffic face can be non-profiled to optimise the
space available.
At the emergency access gates in the chain link, the fencing foothold shall be detailed in the barrier to
facilitate access over the barrier. The maximum spacing between footholds shall be 250 mm.
Termination units shall be provided at the ends of the barriers. The chain link fencing shall continue to the
end of the termination unit.
6.3 Definition Dimensions and Layout

The layout and extent of the required fencing are shown on the Drawings. The layout shown on the
Drawings shall be developed by the Contractor for approval by the Engineer and Employer and other
relevant authorities.
6.4 Design Criteria

The design shall be to BS1722-10 for welded mesh fencing and chain link fencing and BS6579-8 for the
vehicular barriers.
The Contractor shall prepare and submit for approval detailed working drawings. Fencing material orders
and upstand details shall not be finalised until working drawingshave been approved.
Concrete shall be designed in accordance with BS8110:1997. Concrete shall be in accordance with Volume
2 Part 1 of the Employer’s Requirements.
The Contractor shall submit for approval by the Engineer full technical details of the proposed layout and
materials for the temporary and permanent fencing system and the foundations.
6.5 Workmanship
Samples of fencing materials shall be submitted for approval by the Engineer.
Materials and installation layout shall be in accordance with BS1722-10 for welded meshfencing and chain
link fencing. Straining posts shall be provided at all ends and corners of the fence, at changes of direction,
and at intervals not exceeding 30 m on straight lengths of the fence.
Fencing shall be erected to the lines shown on the Drawings, to the approval of the Engineer. Fencing shall
be installed in accordance with BS1722-10 for welded mesh fencing and chain link fencing. The top of
the fence shall present a smooth line parallel to finished ground levels, with no discernible dips, humps, or
sudden changes in alignment.
Concrete construction shall be in accordance with Volume 2 Concrete Specifications.
7 SUSTAINABILITY PLAN AND ENVIRONMENTAL IMPACT OF
MATERIALS
7.1 SUSTAINABILITY PLAN

7.1.1 The Contractor shall submit its actionable and measurable sustainability plan for the Works
comprising the information on following, as a minimum.
7.1.1.1 Proposed source(s) of major reclamation materials considering transport distance (e.g. bulk
materials i.e murrum, sand rock etc., as relevant).
7.1.1.2 Approach on selection of materials to minimise CO2 footprint for permanent and temporary works.
7.1.1.3 Measures to minimise wastage of materials / energy (permanent and temporary works) and
measures for monitoring various emissions and carbon footprint throughout the Contract.
7.1.1.4 Methods to improve sustainability of the project including any steps over and above the
Specification, where relevant.
7.1.1.5 Marginal Abatement Cost Curve (MACC) showing the volume and cost of the opportunities to
reduce the emissions.
7.2 ENVIRONMENTAL IMPACT OF MATERIALS

7.2.1 The Contractor shall submit the information listed in the attached table for the Materials
proposed to be used in the Works. This information shall be used by the Employer to assess the
potential impact of the development on the environment due to the use of various construction
materials.
7.2.1.1 The Contractor shall provide details for all suppliers and manufacturers considered.
7.2.1.2 The Contractor shall re-submit the table any time there is a proposed change in Material supply.
7.2.1.3 The Contractor shall re-submit the information and confirm that it is up to date every six months
as a minimum.
APPENDIX 1
ENVIRONMENTAL IMPACT OF MATERIALS
Global Warming Eutrophicatio Resource Distance

Name of Potentials n(EP) in kg of consumption from
Materials Unit
Manufacturer (GWP)in kg of Phosphate - (ADP fossil) in production
CO2 - Equivalent Mega Joules facility to
Equivalent Site(km)
Supplier x xx x xx
Coarse Per kg x x
Aggregate material
Supplier x xx x xx
x x
Supplier x xx x xx
Per kg x x
Sand
Supplier material x xx x xx
x x
Supplier x xx x xx
Per kg
Rocks x x
material
Supplier x xx x xx
x x
Concrete Supplier xx xx xx xx
Per kg
material
Steel Supplier xx xx xx xx
Reinforcing Supplier xx xx xx xx
steel Per kg
material
And so on… Supplier xx xx xx xx
Note: Each manufacturer to be named for each Material. Additional rows to be added if relevant.
Civil and Yard Structures Specifications SA1980PMD-JAC-70-ERE-CE-00003 | P01

Appendix A. PERMITTED PAVEMENT OPTIONS
A.1 Permitted Pavement Options – Schedule 1
Drawing Ref. Area General Permitted
Requirements Pavement Types
Drawings: New full depth concrete pavement Schedule 2 PT1
SA1980PMD-JAC-10-00- New full depth light duty asphalt

Schedule 2 PT2
DWG-PA- 00001 to 00006 pavement
SA1980PMD-JAC-30-00- New full depth concrete block
DWG-PA- 00001,00002, Schedule 2 PT3
pavement
00003
Plane existing asphalt pavement to
SA1980PMD-JAC-50-00-
120 mm depth and construct a new Schedule 2 PT4
DWG-PA- 00001,00002,
120 mm asphalt inlay
00003
A.2 General Requirements – Schedule 2
Schedule 2: General Requirements
Grid for checking surface levels of pavement course Longitudinal dimension 10m
Transverse dimension 1.5m
Surface irregularity Category of Road A
Interval for measurement of longitudinal regularity Continuous
Interval for measurement of transverse regularity 10m
Whether surface macro-texture is required No
A.3 Permitted Construction Materials – Schedule 3

Schedule 3a: General Requirements for Construction Materials
Pavement Type PT 1. PT2. PT3.
JOINT REINFORCED CONCRETE LIGHT DUTY ASPHALT CONCRETE BLOCK PAVING
Pavement Layer Material Thickness Material Thickness Material Thickness

Ref. (mm) Ref. (mm) Ref. (mm)
Surface course SC1 380 SC2 50 SC3 100

Binder course BC1 120 LCS 30
Base BA1 270 BA2 570
Sub-base SB1 200 SB1 250 SB1 200
Total thickness 850 420 900

Schedule 3b: General Requirements for Construction Materials
Pavement Type PT 4.
ASPHALT INLAY REPAIR
Pavement Layer Material Thickness Material Thickness Material Thickness

Ref. (mm) Ref. (mm) Ref. (mm)
Surface course SC4 50

Binder course BC1 70
Base
Sub-base
Total thickness 120
A.4 General Requirements for Construction Materials – Schedule 4
Schedule 4: General Requirements for Construction Materials
Clause Requirement
801.2 / 801.3 Determine the limiting distance for deposition of unbound mixtures
801.7 Materials shall comply with sub-Clause 801.7
802.4 Unbound materials up to 225 mm compacted thickness can be spread in a single layer
901.6 Requirements for resistance to fragmentation (hardness) in accordance with the
requirements of sub- Clause 901.6
901.7 Requirements for resistance to freezing and thawing (durability) in accordance with the
requirements of sub-Clause 901.7
901.8 Requirements for cleanness in accordance with the requirements of sub-Clause 901.8
902.2 Requirements for reclaimed in accordance with the requirements of sub-clause 902.2
903.21 Longitudinal joints shall be positioned in accordance with the requirements of 903.21
903.22 Requirements for treating the faces of cold upstanding edges in accordance with the
requirements of 903.22
903.23 Requirements for assessment of compaction at joints in binder courses and bases in
accordance with the requirements of 903.23
903.24 Sealant shall be applied to the top surface of all base and binder course joints
903.25 Sealant shall be applied to any freestanding edge of the finished pavement
903.27 Requirements for PSV of temporary running surface in accordance with sub-Clause
903.27
925.2 A demonstration or approval trial is not required
1001.2 Requirements for concrete conformity shall be as described in sub-Clause 1001.2
1004.7 Testing requirements shall be in accordance with Appendices A and Appendix G
1028 Trial lengths are not required

Schedule 4: General Requirements for Construction Materials
1033.10 Butt welding of steel is not permitted
A.5 Requirements for Construction Materials – Schedule 5
Schedule 5 – Requirements for Construction Materials
Material Ref. Clause Description Requirement

SC1 1001 Pavement Quality Mixture designation: C35/45 Concrete
Concrete
Minimum in-place flexural strength 4.5 MPa.
Fine aggregate should be a hardstone or natural
Quaternary aggregate with a minimum declared
PSV 60. Limestone fine aggregate is not
permitted.
The contractor shall monitor compressive
strength. Set of 3-cubes shall be made and tested
for every 400 m2.
Install 1-layer of A292 steel mesh comprising
Longitudinal steel reinforcement: 8 mm bars

pitch 200 mm. Transverse steel reinforcement: 8
mm bars pitch 200 mm
Minimum cover to steel 65mm
Nominal cover to steel 75mm
Contraction joint
Dowel Bars: 32 mm x 600 mm long bars

complaint with clause 1011 at 300 mm centers
and spaced evenly and not within 150 mm of
parallel bay joint. Cover bar with 2-coats of
bituminous paint.
Expansion joint
Dowel bars: 32 mm x 600 mm long bars

complaint with clause 1011 at 300 centers coated
with 2-coats of bitumen paint and fitted with 100
mm long waterproof cap containing 35 mm
compressible material. Bars to be spaced evenly
and not within 150 mm of parallel bay joint.
Expansion joint filler board: complaint with

Clause 1015 and a sealing groove compliant
with Clause 1016

Joint seals shall comply with Clause 1017.
The pavement should be isolated from adjacent

structures
Isolation joints should consist of a joint filler
board complying with Clause 1015 and a sealing
groove complying with Clause 1016.
The finished surface of the concrete should have
a transverse brushed finish. The pavement should
be finished to the specified falls. Water standing
on the finished pavement surface is not
permitted.
SC2 912 AC10 Close Graded AC10 surface course 40/60

Asphalt Concrete Surface Coarse aggregate PSV: 60
Course
Coarse aggregate AAV: 12
Measurement of surface macrotexture is not
required
SC3 1107 Concrete Block Pavers Concrete block pavers 200 x 100 x 100
Compliant with BS EN 1338 for heavy duty use.
Construction shall be in accordance with the
guidance of BS 7533-3. Shall be laid in a 45
degree herringbone pattern with the direction of
traffic.
Polished Paver Value: 60
Joint sand shall comply with BS 7533-3 Table D.4
and BS EN 12620 Gf 85 0/1 (FP) fine aggregate.
SC4 941 SMA Thin Surface Course The Contractor is required to guarantee the
System installed system for a period of five years from the
date of opening to traffic.
The Contractor shall provide a SIPT Installation

Method Statement and shall demonstrate and
enable verification of the installation procedures
given in the SIPT method statement.
Coarse aggregate Declared PSV 60
Coarse aggregate Maximum AAV 14
Road/tyre Noise: No requirement
Resistance to permanent deformation: Class 2
Maximum Aggregate size: 14 mm
Design target layer thickness: 50 mm

Minimum design binder content shall be in
accordance with Table 9/10
Water sensitivity category ITSR min80
Design void content shall be Vmin 2 to Vmax 5%
Surface macrotexture depth measurement is

required and shall comply with sub-clause 23
Retained surface macrotexture shall comply with

sub-clause 24 after opening to traffic
Surface macrotexture performance guarantee is
required.
Table 9/15: Installed performance characteristics
shall apply
Bond Coat: shall be applied and shall be in
accordance with the installation method
statement. A calibrated mechanised system shall
be used.
The torque bond strength between a surfacing
system and its substrate shall be ≥400 kPa,
measured in accordance with Clause 951
LCS 1107 Laying Course Sand Sand shall comply with BS 7533-3 Table D.3 and
BS EN 12620 Gf 85 0/4 (MP) fine aggregate with
fines content Category I passing 0.063 mm 1.0.
BS EN 12620 fine content category f1.0.
Laying course shall be constructed in accordance
with the guidance in BS 7533-3.
BC1 906 AC20 Asphalt Concrete AC20 Binder course 40/60
Binder Course
BA1 1030 Lower Strength Concrete Designation: C12/15 Concrete (Unreinforced)

Subbase Density shall be monitored in accordance with
clause 1003.
Compressive strength shall be monitored in
accordance with Clause 1004
SB1 803 Type 1 Unbound Mixtures Minimum in-service CBR 80%
Mixtures containing crushed gravel coarse
aggregates are not permitted

A.5.1 Schedule 5A – Specification for Pavement Quality Concrete
Concrete Mixture Requirements
Concrete Reference Pavement Quality Concrete
Application Reinforced
Specification approach Designed
Compressive strength Class of Concrete C35/45
28-day Minimum Flexural strength (N/mm2)
5.0
beam
Minimum Cover to Reinforcement (mm) 55
Nominal Cover to reinforcement (mm) (1) 65
Applicable Exposure Classes BS 6349-1-4
XT3 (XS1)
(Excluding DC-class)
DC Class (BRE SD1) NA
Minimum Cement Content (kg/m3) 370
Max Free Water-Cement Ratio 0.40
Required Group or Type of Cement or
CEM II/B-V CEM III/A CEM III/B
Combination
Average chloride migration coefficient (m2/s)
(5) 8.0 6.0 4.0
Max Aggregate Size 20 mm

Chloride Content Class Cl 0,10
Consistence Class (2) S1 and S2
Clay lumps and friable particles:
› Maximum 1% in fine aggregate
Required Source/Special Type of Aggregate › Maximum 0.5% in coarse aggregate
Resistance to fragmentation of coarse aggregate:
› Los Angeles coefficient ≤30 (LA30
Maximum Cement Content (kg/m3) 460
Sampling and testing (4) 3
Each shift or 25m , whichever is most frequent
Other requirements NA
Notes:
(1) Fixing tolerances given assume ‘normal’ control for in situ and all concrete cast against
formwork (i.e. not directly against the soil)
• In situ - Good control =10mm
(2) Contractor to confirm consistence class
(3) Lower placing temperatures may be required for early age crack control (CIRIA C766)
(4) the sampling and testing frequency may be lowered after 500m3 subject to the approval from
the Contractors Designer to “Each shift or 50m3, whichever is most frequent)
(5) The average chloride migration coefficient shall be determined at 28 maturity days in
accordance with the procedure described in Section 3.2.1 of the specification.

Appendix B. BOND COATS, TACK COATS AND OTHER BITUMINOUS
SPRAYS (SHEETS 1, 2 AND BINDER DATA SHEET)
B.1 Sheet 1: Information to be provided by the Compiler
i. All areas of carriageway resurfacing requiring application of a bond or tack coat are shown on relevant
drawing no.
ii. Site specific limitations [Note: any access restrictions, timing constraints etc. should be specified in Volume
1 Prime Contract Document.
iii. Bond Coat
a) A bond coat to BS EN 14023 shall be applied to all surface and horizontal edges of existing bituminous
pavements prior to the application of overlaying layers in accordance with the requirements of BS EN
594987.
b) The bond coat shall be applied at a rate of 0.35 kg per square metre of residual binder
c) A Polymer modified bond coat to BS EN 14023 shall be used with all Thin Surface Course Systems as
an integral part of the system.
iv. The vertical faces of access chamber covers, gully tops, kerbs, channels and similar projections against
which the asphalt is to abut shall be cleaned and painted with a thin uniform coating of hot applied 40/60
or 70/100 paving grade bitumen
v. All surfaces to be overlaid shall be swept clean with a mechanical road sweeper prior to the application of
the bond coat to remove all dust, detritus and standing water that would otherwise reduce the effectiveness
of the bond coat.
vi. Street furniture, iron work and any dropped kerbs shall be masked using self-adhesive masking material
before application starts and removed prior to completion of work

B.2 Sheet 2: Information to be provided by the Contractor
The Contractor shall provide the following information with his tender, or prior to the commencement of the
work;
i. The product or products he proposes to use together with their data sheets, product identification data,
cohesivity data as specified. [920.2, 920.3, 920.4, 920.5]
ii. For each product, a copy of the BS EN ISO 9001 certificate showing the name of the manufacturer, the
name of the certification body and the reference number and date of the certificate.
iii. The spraying equipment proposed and a test certificate. [920.7, 920.9]
iv. The source or sources of blinding material proposed. [920.12]
v. Contingency plans in the event of any breakdown.
vi. (The results of any other tests or other data the Contractor considers would assist the Overseeing
Organisation in assessing the technical merit of the treatment such as;
vii. Tackiness test and/or trafficability time and methods of test.
viii. Breaking time test results for different weather conditions and substrates.
ix. Test results for bond to newly laid concrete [e.g. from a BBA/HAPAS certificate if available]. The data
supplied should not be more than 6 months old.

Binder Data Sheet – Appendix B Bond Coats, Tack Coats and Other Bituminous Sprays
Manufacturer of Binder: Product Name:
Binder Type: Batch No.:
Binder Grade (highlight as required)

Conventional Intermediate Premium Super-premium Non-tack Other
Source
Binder Recovered Binder Recovered Binder after
Ageing Test
Test
Recovered in accordance Aged in accordance with
with Clause 923 clause 923
Penetration at 25ºC 0,1 mm (100g and 5 secs)
Penetration at 5ºC 0,1 mm (200g and 60 secs)
Vialit pendulum cohesion see Clause 957 The Contractor shall attach The Contractor shall
maximum peak value J/cm2 a Report and graphical attach a Report and
output to this schedule as graphical output to this
specified in Clause 957 schedule as specified in
Clause 957
Product identification test. The provision of data The Contractor shall attach The Contractor shall
for identification and ageing is optional for a Report and graphical attach a Report and
unmodified bituminous emulsions to BS 434 and output to this schedule as graphical output to this
for bitumen to BS EN 12591 and cutback bitumen specified in Clause 956 schedule as specified in
to BS 3690. Complex shear (stiffness) modulus Clause 956
(G*) and phase angle (δ) data. See Clause 956.
Other properties the Contractor considers useful:

Minimum Binder Content
Binder temperature range for spray application
Emulsion Properties and Viscosity
Break time
Breaking Agent type
Weather limits – information from binder
manufacturer: road or air temperatures; humidity;
wind chill adjustment; tolerance of surface
dampness; etc.
Temperature max:
Temperature Min:
Other:

Appendix C. SERIES 700 ROAD PAVEMENTS – GENERAL

SERIES 700 ROAD PAVEMENTS – GENERAL
Contents
Clause
700 General
701 Pavement Construction
702 Horizontal Alignments, Surface Levels and Surface Regularity of Pavement Courses
703 to 705 Not used
706 Excavation, Trimming and Reinstatement of Existing Surfaces
707 - 708 Not used
709 Cold-milling (Planing) of Bituminous Bound Flexible Pavement
710 Testing for Constituent Materials in Recycled Aggregate and

Recycled Concrete Aggregate
1
SERIES 700 ROAD PAVEMENTS – GENERAL
General
Dammam Port intends to complete substantial structural repairs to the container terminal
pavement. The Works will involve the full depth removal of the existing pavement and replacing
with a heavy duty pavement.
It will be necessary to determine the strength of the pavement subgrade once the existing
pavement is removed.
Function
The paving and surfacing will staify the employers requirements and will be designed and
constructed for container stacking, reach stacker operation and truck traffic.
The servicable life of the new pavement should be 30 years. The pavement will require regular
monitoring and maintenance during the design period.
Paved Areas
The calculated volume of traffic and loading of the pavement is based on information provided
by SGP. Loaded reach stackers have access to all areas of the container termnial.
Materials and Structural Form

Where possible materials recovered from the existing road pavements should be processed, re-
purposed and incorporated into the new pavement. This may take the form of aggregates
incorporated into new material design mixtures. The specification for the material and
construction of the road pavements is performance based.
Subgrade
The subgrade will comprise of existing fill material. It has been assumed that a California Bearing
Ratio (CBR) 10% will be achieved for the pavement subgrade (engineered sand fill). If a lower
CBR is achieved the paving design will be reviewed to ensure adequate base and subbase depth
and strength are provided.
Subbase Layer
The subbase layer will provide a working platform for the pavement equipment and will
comprise a unbound crushed rock or crushed concrete aggregate.
Base Layer
The base layer will comprise C12/15 Concrete base and should be a plant mixed material. A
curing coat of bituminous emulsion spray should be applied to the surface of the base layer
immediately after finishing.
Surface Layer
The surface layer will comprise Joint Reinforced Concrete of minimum mean compressive
strength C35/45 and minimum in-place flexural strength 4.5MPa.
2
Interface with existing pavement
Where the new pavement abuts existing paving, each layer of the existing paving will be
exposed to form an interface joint. The interface joint will be designed and constructed to meet
the structural requirements of both new and existing pavements. In general, the new pavement
will be isolated from the existing pavement.
Construction Joints
Longitudinal and transverse bay joints should be positioned outside known wheel paths.
Material Specifications
Paving material should comply with the structural requirements in the Interpave Design Guide
for Heavy duty Industrial Pavements and the material performance requirements and the
construction requirements in the Specification.
Although each Series in the specification is particularly relevant to the subject matter in its title it
must be read in conjunction with the requirements in all other Series included in the particular
specification for the works to be undertaken. Where there is conflict the Particular specification
takes precedence.
701 Pavement Construction

1. Road pavements shall be constructed from one of the permitted options described in
contract specific Appendix A and in compliance with this Series and the appropriate clauses
of Series 800, 900 and 1000
2. The Contractor shall, in his choice of permitted materials for subbases and bases, have
regard to the nature of those materials and of the subgrade or any capping and the need to
protect them from deterioration due to the ingress of water, the adverse effects of weather
and the use of constructional plant. The Contractor shall programme the laying and
compaction of the subbase and the subsequent pavement courses and take such other steps
as may be considered necessary, to afford protection to the base, subbase and subgrade.
702 Horizontal Alignments, Surface Levels and Surface Regularity of

Pavement Courses Horizontal Alignments
1. Horizontal alignments shall be determined from one edge of the pavement The edge of the
pavement as constructed and all other parallel alignments shall be correct within a
tolerance of 15 mm therefrom, except for kerbs and channel blocks which shall be laid with
a smooth alignment within a tolerance of ±10 mm.
Surface Levels of Pavement Courses

2. The design levels of pavement courses shall be calculated from the vertical profile,
crossfalls and the pavement course thicknesses described in contract specific Appendix A.
The level of any point on the constructed surface of the pavement courses shall be the
design level subject to the appropriate tolerances stated in Table 7/1.
3
TABLE 7/1: Tolerances in Surface Levels of Pavement Courses
* Where a surface water channel is laid before the adjacent road pavement layer the top of that
layer, measured from the top of the adjacent edge of the surface water channel, shall be to the
tolerances given in Table 7/1.
3. Notwithstanding the tolerances permitted in surface levels of pavement courses, the

cumulative tolerance shall not result in a reduction in thickness of the pavement, excluding
the subbase, by more than 10 mm from the specified thickness nor a reduction in the
thickness of the concrete surface course by more than 10 mm from that specified.
4. For checking compliance with sub-Clause 2 of this Clause, measurements of the surface
levels of all courses will be taken on a grid of points located as described in contract specific
Appendix A. In any length of pavement, compliance shall be deemed to be met for all
surfaces, other than the final road surface, when not more than one of ten consecutive
measurements taken longitudinally or one in any transverse line, exceeds the tolerances
permitted in Table 7/1, provided that this one measurement shall not exceed by more than
5 mm the tolerance for the course concerned. For the final road surface the tolerance given
in Table 7/1 shall apply to any point on that surface.
Surface Regularity
5. The longitudinal regularity of the surfaces of surface courses, binder courses and concrete
slabs shall be such that the number of surface irregularities is within the relevant limits
stated in Table 7/2. An irregularity is a variation of not less than 4 mm or not less 7 mm of
the profile of the road surface as measured by the rolling straight-edge set at 7 mm, or
equivalent apparatus capable of measuring irregularities within the same magnitudes over a
3 m length. No irregularity exceeding 10 mm shall be permitted.
TABLE 7/2: Maximum Permitted Number of Surface Irregularities

Pavement Layer Maximum number of 7mm Maximum number of 7mm
irregularities over any 150m irregularities over any 75m
length length
Surface Course 4 2
Binder Course 8 3
6. Prior to checking any final road surface or top surface of base in pavements for regularity or
macrotexture depth, it shall be cleaned of loose or extraneous materials. These operations
4
shall be carried out without damaging the surface of the pavement, as soon as possible and
within 3 days of construction of the pavement.
7. Compliance with Table 7/2 shall be checked by the rolling straight-edge along known wheel
paths and the center of a traffic lane or any line or lines parallel to the edge of pavement on
sections of 150 m at regular intervals, whether or not it is constructed in shorter lengths.
Sections shorter than 150 m forming part of a longer pavement shall be assessed using the
number of irregularities for a 150 m length pro-rata to the nearest whole number. Where
the total length of pavement is less than 150 m, the measurements shall be taken on 75 m
lengths.
8. Pavements shall be measured transversely for irregularities at 20 intervals, by a 3 m long

straight-edge placed at right angles to the centre line of the road. The maximum allowable
difference between the pavement surface and the straight-edge shall be 3mm.
9. A straight-edge 3 metres long, shall be used to check longitudinal surface regularity in the
following cases:
(i) for lengths of less than 75 m of surface course and binder course;
(ii) where use of the rolling straight-edge or equivalent apparatus is impracticable;
The maximum allowable difference between the surface and the underside of the straight-edge,
when placed parallel with, or at right angles to, the centre line of the road shall be:
for pavement surfaces 3 mm
for binder courses 6 mm
Rectification
10. Where any pavement area does not comply with the specification for regularity, surface
tolerance, thickness, macrotexture depth, material properties or compaction, the full extent
of the area which does not comply with the specification shall be made good and the surface
of the pavement course shall be rectified in the manner described below:
(i) Unbound and hydraulically bound materials
The top 75 mm shall be scarified, reshaped with material added or removed as necessary,
and recompacted. The area treated shall be not less than 20 m long and 2 m wide. For
hydraulically bound materials, all rectification shall be completed within 48 hours of the
binder being added to the material.
(ii) Cement bound subbases and bases
The method of correction will depend on the period which has elapsed between
detection of the error and the time of mixing of the material. If this is less than 2 hours,
the surface shall be scarified to a depth of not less than 50 mm, surplus material
removed or freshly mixed material added as necessary, and re-compacted in accordance
5
with the specification. If the period is 2 hours or more the full depth of the layer shall be
removed from the pavement and replaced with material in accordance with the
specification. In either case the area treated shall be at least 15 m long and the full width
of the paving laid in one operation.
(iii) Bituminous bases
With asphalt bases, the full depth of the top layer as laid shall be removed and be
replaced with fresh material laid and compacted in accordance with the specification. Any
area so treated shall be at least 15 m long and the full width of the paving laid in one
operation. Alternatively for low areas in bituminous bases, the Contractor may make up
the level with additional binder course material in the subsequent layer.
(iv) Asphalt Surface courses and binder courses
These shall have the full depth of the course removed and replaced with fresh material
laid and compacted in accordance with the specification.
The area rectified shall be the full width of the paving laid in one operation, and at least
15 m long.
Where the number of surface irregularities exceeds the limits in Table 7/2, the area to be
rectified shall be 150 m or 75 m long as appropriate and the full width of the lanes
affected, or such lesser length as necessary to make the number of surface irregularities
conform with the limits and shall be the full width of the lanes affected.
Checking of the surface course for compliance with this Clause shall be carried out as
soon as possible after completion of the surfacing and remedial works completed before
the road is opened to traffic.
Areas to be removed shall be delineated both longitudinally and transversely by saw

cutting prior to the material being removed. Joints shall be formed either by coating the
exposed sawn face with hot bitumen or heating by a suitable heater. The heater shall
raise the temperature of the full depth of the course immediately before laying the new
material to a figure within the range of minimum rolling temperature and maximum
temperature at any stage specified for the material and for a width of not less than 75
mm.
(v) Concrete Slabs
Concrete slabs shall be rectified by planing, grinding or bump cutting. Large depressions,
which cannot be dealt with in this way, shall be rectified by cutting out the surface and
replacing by a thin bonded surface repair complying with Clause 1032. Retexturing of
hardened concrete shall be carried out by sawing grooves in accordance with the
specification. Texturing of replaced surfaces shall be by brushing in accordance with the
specification. Where the slab cannot be rectified as above, the full depth of slab shall be
removed and replaced with a slab constructed in compliance with Clause 1033 to the
6
extent required to obtain compliance with the specification. Remedial works involving the
placing of fresh concrete shall be completed in sufficient time for the concrete strength
to have developed as required in Clause 1048, before that section of pavement is opened
to traffic.
703 to 705 Not used
706 Excavation, Trimming and Reinstatement of Existing Surfaces
General
1. The Contractor shall not excavate pits, trenches or other openings in paved areas which have
been constructed as part of the permanent works in order to construct other parts of the
works, including Statutory Undertakers and other service works, except with the prior
approval of the Overseeing Organisation.
2. Where excavation and trimming of existing paved areas and areas not constructed as part of
the permanent works are required, they shall be carried out and reinstated in compliance
with this Clause and with any additional requirements described in contract. Excavations shall
be carried out to the dimensions described, or, if not so described, to the minimum
dimensions, subject to sub-Clause 3 of this Clause, necessary to carry out the work.
Excavations
3. Excavations in existing pavements and other paved areas, except those described in sub-
Clause 4 of this Clause, including surfacing, base and subbase, shall be cut to neat lines to
dimensions at least 75 mm greater on each side than the dimensions of any further
excavation below formation level. Excavations in capping shall be taken at least 75 mm
outside the dimensions of any excavation below. Road surfacing of bituminous material shall
be cut back by sawing or planing to a further 75 mm on each side. Planing shall be carried
out in accordance with Clause 709. Concrete surfacing and concrete bases, except CBM, shall
be cut back by sawing by at least 300 mm on each side to the level of any reinforcement in
reinforced slabs and to the full depth of the slab in unreinforced slabs.
If excavations are required to inspect the condition of lower layers, each layer shall be
excavated separately and cleaned of debris to permit inspection.
Junctions between New Pavement Construction and Existing Pavement or Other Paved Areas
4. Where new pavement construction abuts an existing bituminous pavement which has to be
reduced in level or overlaid to match alignment and levels, the existing surface shall be
trimmed by the minimum amount of cold-milling (planing) to a depth which will allow the
specified thickness of new construction to be laid, the edge being trimmed and treated in
compliance with this Clause.
Compressed Air
5. When compressed air is used to clean dust, dirt and debris from prepared faces of existing
concrete or bituminous pavements which are otherwise ready for reinstatement, only oil-free
compressed air shall be used and this shall be at a pressure of not less than 0.5 N/mm2.
7
707, 708 Not used
709 Cold-milling (Planing) of Bituminous Bound Flexible Pavement

1. Where cold-milling of bituminous bound flexible pavement is required, the area of
carriageway to be milled shall be removed by a suitable milling machine to the requirements
specified in the contract. The process shall be carried out so as not to produce excessive
quantities of dust, which shall be minimised by damping with water sprays.
2. The cut edges shall be left neat, vertical and in straight lines. The Contractor shall brush and
sweep the milled surface by mechanical means to produce a clean and regular running
surface with a groove depth not greater than 10 mm, and with a uniform texture.
3. Carriageways shall be milled to the tolerance of ± 6 mm. If the tolerances in this Clause are
exceeded, the full extent of the area which does not comply shall be rectified by further
milling or by regulating with materials in accordance with Clause 907.
4. Existing ironwork shall not be disturbed by the milling action. Where necessary, surfacing in
the vicinity of ironwork and in small or irregular areas shall be cut out by pneumatic tools or
other suitable methods and removed.
5. Where milling is carried out on areas open to traffic, temporary ramping to ensure the safe
passage of vehicles.
6. If the milled surface profile varies by more than 10 mm, when measured transversely or
longitudinally by a 3 metre straight-edge, adjustments or replacements shall be made to the
cutting teeth on the milling drum before work continues. Any discontinuity between adjacent
milling passes exceeding 10 mm, when measured transversely by a 3 metre straight-edge,
shall be rectified by further milling or regulating before placing bituminous material.
7. Where milling is required over extensive areas, the Contractor shall programme the work to
allow removal of full lane widths unless this is impracticable. The Contractor shall notify his
proposed programme of milling to the Overseeing Organisation prior to commencement of
the work.
8. Immediately after milling, surplus materials shall be removed by a machine of suitable and
efficient design and the milled surface swept to remove all dust and loose debris.
9. The material removed from the carriageway shall be removed from site, unless otherwise
described in the contract. No stockpiling shall be allowed on site unless the material is to be
used in the works.
10. Roads which are closed to traffic to permit milling shall be resurfaced after milling prior to
reopening the road to traffic unless otherwise agreed by the Overseeing Organisation.
11. 48 hours prior to cold-milling the Contractor shall carry out a sweep of the area(s) to locate
any buried metalwork within the layer to be cold-milled. The sweep shall be carried out with
electronic detection equipment suitable for the purpose. The surface shall be clearly marked
above all objects to show their detected extent. The objects shall be referenced and their
location and depth reported to the Overseeing Organisation within 6 hours of discovery.
Surfacing in the vicinity of such objects shall be excavated using pneumatic tools or other
suitable methods.
8
710 Testing for Constituent Materials in Recycled Aggregate and Recycled
Concrete Aggregate
Scope
1. This Clause specifies the basic procedure and test methods for the examination of recycled
aggregate and recycled concrete aggregate for the purpose of identifying and quantifying
constituent materials.
Quality Control Procedure

2. The quality control procedure shall be in accordance with the ‘Quality Protocol for the
production of aggregates from inert waste’ and the ‘Producers’ compliance checklist’. The
results of all quality control checks carried out by the Contractor shall be compiled in
accordance with the procedure set down in the above document and with those in this
Clause. These shall be delivered promptly to the Overseeing Organisation on request.
Test Method
3. The constituents of a sample of recycled aggregate shall be classified by hand-sorting the
coarse aggregate particles in accordance with EN 933-11. The test shall be carried out by a
suitably trained laboratory technician who has demonstrated competence in classifying the
constituent classes in accordance with the test method.
9
Appendix D. SERIES 800 ROAD PAVEMENTS — UNBOUND, CEMENT
AND OTHER HYDRAULICALLY BOUND MIXTURES

SERIES 800 ROAD PAVEMENTS — UNBOUND, CEMENT AND OTHER
HYDRAULICALLY BOUND MIXTURES
Contents
Clause Title
801 General Requirements for Unbound Mixtures
802 Transport, Laying, Compaction and Trafficking of Unbound Mixtures
803 Type 1 Unbound Mixtures
804 – 806 Not used
807 Type 4 (asphalt arisings) Unbound Mixtures
808 & 881 Not Used
882 Determination of the Construction Subgrade Surface Modulus
883 Demonstration Area for Performance Foundation Designs
884 Permanent Works Performance Assessment for Performance Foundations
885 Top of Foundation Performance Assessment
886 Wheelpath Deformation Measurement
Page 1 of 15
SERIES 800. ROAD PAVEMENTS – UNBOUND, CEMENT AND OTHER
HYDRAULICALLY BOUND MIXTURES
801 General Requirements for Unbound Mixtures
Unbound Mixtures for Subbase 1

1. This Series is part of the Specification. Whilst this Series is particularly relevant to the subject
matter in its title it shall be read in conjunction with all other Series relevant to the Specification
for the Particular works to be undertaken.
2. Unbound mixtures shall be made and constructed to conform to EN 13285, the requirement
categories in Table 8/1 and Clauses 802 to 807.
TABLE 8/1: Mixture and Grading Requirement Categories for Unbound Mixtures
3. The permitted alternatives for each part of the permanent works shall be as described in contract
specific Appendix A.
4. The properties of aggregates used in unbound mixtures shall comply with the selected
requirements of EN 13242 listed in Table 8/2.
Page 2 of 15
Table 8/2: Requirements for Aggregates Used in Unbound Mixtures
5. Where recycled coarse aggregate or recycled concrete aggregate is used in unbound mixtures
complying with Clauses 802 to 807 as appropriate, it shall have been tested in accordance with
Clause 710.
6. Recycled coarse aggregate and recycled concrete aggregate used in unbound mixtures in
accordance with Clauses 803, 804 and 807 shall also comply with the requirements of Table
8/3.
Page 3 of 15
TABLE 8/3 Requirements for Recycled Coarse Aggregate and Recycled Concrete Aggregate
Used in Type 1, Type 2 and Type 4 Unbound Mixtures
7. The unbound mixture shall satisfy the minimum surface modulus requirement of contract
specific Appendix A when tested in accordance with Procedure A in Clause 885.
8. The mixture shall be tested at the density and moisture content likely to develop in equilibrium
field conditions which will be taken as being the density relating to the uniform air voids content
of 5% and the value of optimum water content declared when tested as required by EN 13285
Limitations to Use
Water-soluble sulphate
9. Unbound mixtures placed within 500 mm, or any other distances described in contract specific
Appendix A, of concrete, cement bound materials, other cementitious mixtures or stabilised
capping forming part of the permanent works shall conform to requirements A and B below:
A. Mixtures shall conform to the following two criteria:
(i) Water-soluble sulfate (WS) content determined in accordance with EN 1744-1 clause 10
not to exceed 1500 mg of sulfate (as SO4) per litre;
(ii) Total sulfur (TS) content determined in accordance with EN 1744-1 clause 11 expressed
as (S) not to exceed 1% for aggregates other than air cooled blast furnace slag or2% for air
cooled blast furnace slag.
B. Mixtures shall conform to at least one of the following two options:
(i) When described in accordance with EN 932-3 and EN 13242 Annex A, limestone, chalk,
dolomite, blast furnace slag, steel slag or crushed concrete are predominant; or
(ii) The sulfide content of the mixture determined in accordance with EN 1744-1 clause 13 is
less than 0.5% (as SO4).
10. When determining WS, TS or sulfide content, at least five samples of each material shall be
tested. The mean of the highest two values to be used for comparison with the limiting values.
This also applies if six to nine results are available. If ten or more results are available, the mean
of the highest 20% of the results to be used for comparison with the limiting values. The pH of
the mixture shall be reported.
Page 4 of 15
11. Unbound mixtures placed within 500mm, or any other distances described in contract specific
Appendix A, of metallic structural elements forming part of the permanent works shall conform
to requirements C and D below.
C. Mixtures shall conform to the following two criteria:
(i) Water-soluble sulfate (WS) content determined in accordance with EN 1744-1 clause
10 to not exceed 300 mg of sulfate (as SO4) per litre;
(ii) Total sulfur (TS) content determined in accordance with EN 1744-1 clause 11
expressed as (S) to not exceed 1% for aggregates other than air cooled blast furnace
slag or 2% for air cooled blast furnace slag.
D. Mixtures shall conform to at least one of the following two options:
(i) When described in accordance with EN 932-3 and EN 13242 Annex A, limestone,
chalk, dolomite, blast furnace slag, steel slag or crushed concrete are predominant;
or
(ii) The sulfide content of the mixture determined in accordance with EN 1744-1 clause
13 is less than 0.06% (as SO4).
12. When determining WS, TS or sulfide content, at least five samples of each material shall be
tested. The mean of the highest two values to be used for comparison with the limiting values.
This also applies if six to nine results are available. If ten or more results are available, the mean
of the highest 20% of the results to be used for comparison with the limiting values. The pH of
the mixture to be reported.
13. The requirements in (i) and (ii) above shall not apply to metallic items protected by concrete and
ancillary metallic items such as the tops of chambers and gullies.
Frost Heave
14. Subject to the tolerances given in Table 7/1 and unless otherwise stated in contract specific
Appendix A, material shall not be frost susceptible if it is used within 450 mm of the designed
final surface of a road or paved central reserve, or 350 mm if the Mean Annual Frost Index
(MAFI) of the site is less than 50.
15. Material shall be classified as non-frost-susceptible if the mean heave is 15 mm or less, when
tested in accordance with BS 812-124. Comparator specimens will be used.
Aluminium Particles
16. Mixtures containing manufactured aggregates, other than air-cooled blast furnace slag and steel
slag, covered with less than 150 mm asphalt shall meet the requirements of Table 8/4.
TABLE 8/4 Requirements for mixtures containing manufactured aggregates
17. The following test procedure shall be followed.

(i) Obtain test portion in accordance with EN 932-1 1997, with a minimum mass of 10 kg.
(ii) Pass the test portion over a 14 mm test sieve conforming to EN 933-2 1999, discard
particles passing the 14 mm sieve.
Page 5 of 15
(iii) Spread particles retained on the 14 mm sieve onto a clean flat surface
(iv) Separate by hand any aluminium particles and agglomerated particles that contain a
portion of aluminium.
(a) Discard non-aluminium particles and agglomerated particles that do not contain a
portion of aluminium.
(b) Place any aluminium particles in a tray.
(v) Separate the aluminium fraction from any agglomerated particles.
(a) Add any non-separated agglomerated particles to the tray.
(b) Discard any resulting non-aluminium fraction.
(c) Re-pass any resulting aluminium fraction over the 14 mm sieve and discard particles
passing the 14 mm sieve.
(d) Add any resulting aluminium fraction retained on the 14 mm sieve to the tray.
(vi) The particles in the tray are classified as aluminium particles retained on 14 mm sieve.
18. The test report shall include the following information:
(i) reference to this Clause;
(ii) name and location of the sample source;
(iii) date of sampling;
(iv) mass of test portion (kg);
(v) date of test;
(vi) number of aluminium particles retained on 14 mm sieve;
(vii) description of any retained particles.
802 Transport, Laying, Compaction and Trafficking of Unbound Mixtures
Transporting
1. Unbound mixtures shall be protected from drying out and segregation both during transit to the
point where it is to be laid and whilst awaiting tipping.
Laying
2. Unbound mixtures in a frozen condition shall not be incorporated in the works but may be used,
if acceptable, when thawed.
3. Unbound mixtures shall not be laid on any surface which is frozen or covered with ice.
4. All unbound mixtures shall be placed and spread evenly.
Page 6 of 15
5. Spreading shall be undertaken either concurrently with placing or without delay.
6. Unbound mixtures shall be spread using a paving machine or a suitable spreader box and
operated with a mechanism which levels off the material to an even depth.
7. Except where otherwise stated in contract specific Appendix A, material up to 225 mm
compacted thickness shall be spread in one layer so that after compaction the total thickness is
as specified.
8. Material of compacted thickness greater than 225 mm shall be laid in two or more layers and the
minimum compacted thickness of any such layer to be 110 mm.
9. Where the layers of unbound mixtures are of unequal thickness, the lowest layer shall be the
thickest layer.
Compaction
10. Compaction shall be completed after the mixture has been spread and in accordance with the
requirements for the individual mixtures.
11. Full compaction shall be obtained over the full area including in the vicinity of both longitudinal
and transverse joints.
12. Compaction of unbound mixtures shall be carried out by a method specified in Table 8/5, unless
it is demonstrated at site trials that a state of compaction achieved by an alternative method is
equivalent to or better than that using the specified method.
13. The surface of any layer of material shall on completion of compaction and immediately before
overlaying, be well closed, free from movement under construction plant and from ridges, cracks,
loose material, potholes, ruts or other defects.
14. All loose, segregated or otherwise defective areas shall be removed to the full thickness of the
layer, and new material laid and compacted.
15. For the purposes of Table 8/5 the following shall apply:
(i) The number of passes is the number of times that each point on the surface of the layer
being compacted is traversed by the item of compaction plant in its operating mode (or
struck, in the case of power rammers).
(ii) The compaction plant in Table 8/5 is categorised in terms of static mass. The mass per
metre width of roll is the total mass on the roll divided by the total roll width. Where a
smooth-wheeled roller has more than one axle, the category of the machine is determined
on the basis of the axle giving the highest value of mass per metre width.
(iii) For pneumatic-tyred rollers the mass per wheel is the total mass of the roller divided by
the number of wheels. In assessing the number of passes of pneumatic-tyred rollers the
effective width is the sum of the widths of the individual wheel tracks together with the sum
of the spacings between the wheel tracks provided that each spacing does not exceed 230
mm. Where the spacings exceed 230 mm the effective width is the sum of the widths of the
individual wheel tracks only.
(iv) Vibratory rollers are self-propelled or towed smooth-wheeled rollers having means of
applying mechanical vibration to one or more rolls:
Page 7 of 15
(a) The requirements for vibratory rollers are based on the use of the lowest gear on a
self propelled machine with mechanical transmission and a speed of 1.5-2.5 km/h
for a towed machine or a self-propelled machine with hydrostatic transmission. If
higher gears or speeds are used an increased number of passes need to be provided
in proportion to the increase in speed of travel.
(b) Where the mechanical vibration is applied to two rolls in tandem, the minimum
number of passes is half the number given in Table 8/5 for the appropriate mass
per metre width of one vibrating roll but if one roll differs in mass per metre width
from the other, the number of passes to be calculated as for the roll with the smaller
value. Alternatively the minimum number of passes may be determined by treating
the machine as having a single vibrating roll with a mass per metre width equal to
that of the roll with the higher value.
(c) Vibratory rollers operating without vibration are to be classified as smooth-wheeled
rollers.
(d) Vibratory rollers are to be operated with their vibratory mechanism operating at the
frequency of vibration recommended by the manufacturer. All such rollers to be
equipped, or provided with devices indicating the frequency at which the
mechanism is operating and the speed of travel. Both devices to be capable of being
safely read by an inspector alongside the machine.
(v) Vibrating-plate compactors are machines having a base-plate to which is attached a

source of vibration consisting of one or two eccentrically-weighted shafts:
(a) The mass per square metre of base-plate of a vibrating-plate compactor is

calculated by dividing the total mass of the machine in its working condition by its
area in contact with compacted material.
(b) Vibrating-plate compactors re to be operated at the frequency of vibration

recommended by the manufacturer. They will normally be operated at travelling
speeds of less than 1 km/h but if higher speeds are necessary, the number of passes
are to be increased in proportion to the increase in speed of travel.
(vi) Vibro-tampers are machines in which an engine driven reciprocating mechanism acts on a
spring system, through which oscillations are set up in a base-plate.
(vii) Power rammers are machines which are actuated by explosions in an internal combustion
cylinder; each explosion being controlled manually by the operator. One pass of a power
rammer is considered to have been made when the compacting shoe has made one
strike on the area in question.
(viii) Combinations of different types of plant or different categories of the same plant will be
permitted; in which case the number of passes for each is to be such proportion of the
appropriate number in Table 8/5 as will together produce the same total compactive
effort as any one operated singly.
Page 8 of 15
TABLE 8/5: Compaction Requirements for Unbound Mixtures
Use of Surfaces by Construction Plant and Other Traffic

16. Construction plant and other traffic used on pavements under construction shall be suitable in
relation to the material, condition and thickness of the courses it traverses so that damage is not
caused to the subgrade or the pavement courses already constructed.
17. The wheels or tracks of plant moving over the various pavement courses shall be kept free from
deleterious materials.
18. Where it is proposed to use the unbound mixture layers for construction plant these layers shall
be improved to accommodate the method of construction and the type of plant and vehicles
which are to be used, in order to avoid damage to the laid layer(s), any capping and the
subgrade.
19. Any permanent thickening shall be across the whole width of the pavement.
20. Temporary thickening shall not impede drainage of any layer or the subgrade.
Page 9 of 15
Trafficking Trial
21. When required by contract specific Appendix A, a Trafficking Trial shall be undertaken
incorporating the unbound mixture proposed for use in the permanent works.
22. A trial area shall be constructed, trafficked and assessed in accordance with the procedure
described in sub-Clauses 25 to 29 of this Clause.
23. The mean vertical deformation after 1000 equivalent standard axles shall be less than 30 mm
when measured in accordance with the procedure stated in sub-Clause 31 to 33 of this Clause.
24. Proposals for trafficking trials shall be submitted to the Overseeing Organisation for review and
acceptance five days in advance of construction.
Trial Procedure
25. The trial area shall be located on a formation prepared in accordance with the specification. The
trial area may be located so that it can be incorporated within the permanent works if the
resistance to wheel track rutting is demonstrated to comply with sub-Clause 19 of this Clause.
26. The trial area shall be at least 60 m long, and of sufficient width that when trafficked, the wheel
paths of the test vehicle are at least 1 m from either edge of the top of the unbound mixture
layer.
27. The unbound mixture layer shall be compacted to the thickness specified in contract specific
Appendix A.
28. The formation shall extend for a further 1 m either side of the unbound mixture layer.
29. A sufficient run off/run on area shall be constructed at each end of the trial area of the same
width, and compacted to the same level, as the trial area, to ensure correct tracking by the test
vehicle and minimise dynamic effects of the vehicle bouncing on its springs. Suitable guidance is
to be given to assist the driver in maintaining the same track in each pass and to achieve
channelled trafficking. Examples of suitable guides would be a string or painted line.
Mixtures
30. The unbound mixture used in the trial shall be transported, laid and compacted using the
equipment proposed for use in the works.
31. Maximum vertical deformation shall be measured in both wheel tracks using optical or laser
levels at pre-determined monitoring points on five transverse lines spaced equally along the
length of the trial bay.
32. The transverse lines at the ends of the trial area shall be at least 5 m from the run off/run on
areas.
33. The average deformation of the two wheel tracks after 1000 standard axles shall be recorded.
Reporting and Acceptance of Trafficking Trial Area
34. A report on the Trafficking Trial, stating how the use of the unbound mixture was validated shall
be provided.
35. The main construction of the permanent works shall not start until the Trafficking Trial area has
been accepted by the Overseeing Organisation.
Page 10 of 15
803 Type 1 Unbound Mixtures
1. Type 1 unbound mixture shall be made from crushed rock, crushed slag, crushed concrete,
recycled aggregates, manufactured aggregates, or well burnt non-plastic shale and may contain
up to 10% by mass of natural sand that passes the 4 mm test sieve. Where permitted by contract
specific Appendix A, crushed gravel complying with sub-Clause 803.7 may be used
2. The mixture shall meet the requirements of EN 13285 and Table 8/1. The grading requirements
for the mixture are summarised in Tables 8/6a or 8/6b. Table 8/6b shall only be used for trench
reinstatements and narrow widenings less than 1 m.
Table 8/6a. Summary Grading Requirements for Type 1 and Type 4 Unbound Mixtures
Table 8/b. Summary Grading Requirements for Type 1 F Unbound Mixtures (0/20)
Page 11 of 15
3. The properties of aggregates used in the mixture shall be in accordance with EN 13242 and the
requirements of Table 8/2.
4. The size fraction of the unbound mixture passing the 0.425 mm size test sieve shall be non-
plastic as defined by BS 1377-2 and tested in compliance therewith.
5. Mixtures containing recycled coarse aggregate, or recycled concrete aggregate, shall meet the
requirements of sub-Clause 801.5 and 801.6.
6. The mixture shall be transported, laid and compacted without drying out or segregation.
7. All mixtures shall meet the minimum surface modulus requirement in sub-Clause 801.7.
804, 805 and 806 not used
807 Type 4 (asphalt arisings) Unbound Mixtures

1. Type 4 unbound mixture shall be made from recycled aggregates containing asphalt arisings,
and may contain crushed rock, crushed slag, manufactured aggregates, crushed concrete or well
burnt non-plastic shale and up to 10% by mass of natural sand that passes the 4 mm size test
sieve.
2. Asphalt arisings shall be either asphalt road planings or granulated asphalt, but excluding
materials contaminated with tar or tar-bitumen binders. Asphalt planings are defined as
materials derived from the asphalt layers of the pavement using a mobile machine fitted with
milling cutters. Granulated asphalt is defined as asphalt bound material recycled from roads
under reconstruction or surplus asphalt material destined for bound pavement layers, but
unused, which has been granulated.
3. Type 4 unbound mixture shall have an asphalt (Class Ra) content greater than 50% when tested
in accordance with Clause 710.
4. The recovered bitumen content of the asphalt shall be not more than 10% when tested in
accordance with EN 12697-1.
5. Type 4 unbound mixture shall comply with EN 13285 and the requirements of Table 8/1. The
grading requirements for the mixture are summarised in 8/6a.
6. The properties of aggregates used in t hr mixture shall be in accordance with EN 13242 and the
requirements of Table 8/2.
7. The size fraction of the unbound mixture passing the 0.425 mm size test sieve shall be non-
plastic as defined by BS 1377-2 and tested in compliance therewith.
8. Where the mixture contains recycled coarse aggregate or recycled concrete aggregate, it shall
comply with sub-Clause 801.5 and 801.6.
9. The mixture shall be transported, laid and compacted without drying out or segregation, at a
moisture content within the range 1% above to 2% below the declared value of optimum water
content when tested as required by EN 13285. The moisture content to be determined by oven
drying at a reduced temperature setting of 45ºC to 50ºC.
10. Where required by contract specific Appendix A, Type 4 unbound mixtures shall be assessed
using a trafficking trial complying with sub-Clause 802.21.
808 and 881 Not Used
Page 12 of 15
882 Determination of the Construction Subgrade Surface Modulus
Scope
1. The test methods described in this Clause shall be used for the determination of the subgrade
surface modulus of the foundation prior to the commencement of construction of the overlying
layers.
Procedure
2. The construction subgrade surface modulus shall be determined in accordance with this Clause
at intervals suitable for the type of subgrade material and its condition, with a maximum spacing
of 60 m along each lane of prepared subgrade and staggered to the mid-point between adjacent
lanes, see Figure 8/1.
FIGURE 8/1: Subgrade Surface Modulus Test Locations
3. At least 10 tests shall be carried out for each prepared foundation area.
4. The measurement of the construction subgrade surface modulus shall be taken at formation
level or at sub-formation level if capping is part of the foundation design.
5. The test site shall be free from standing water, ice and snow.
6. Where the construction subgrade surface modulus is found to be less than the design subgrade
modulus, the area shall either be improved or the foundation redesigned in accordance with CD
225 (DMRB).
Construction Subgrade Surface Modulus Measurement
7. The subgrade surface modulus shall be determined using one of the following devices:
(i) Dynamic Cone Penetrometer (DCP);
(ii) Falling Weight Deflectometer (FWD); or
(iii) Lightweight Deflectometer (LWD).
Page 13 of 15
Dynamic Cone Penetrometer (DCP) Testing
8. Dynamic Cone Penetrometer (DCP) testing shall be undertaken following the procedure outlined
within CS 229 (DMRB).
9. Result expressed as mm/blow shall be converted to a California Bearing Ratio (CBR) value,
expressed as a percentage, using the following relationship:
EQUATION 8/1: (03/20) DCP (mm/blow) to CBR Relationship
Log10 (CBR) = 2.48 – 1.057 * Log10 (mm/blow)
10. The CBR value obtained in sub-Clauses 883.6 to 883.8 shall then be converted to surface
modulus (E) using the following equation:
EQUATION 8/2: CBR to Subgrade Surface Modulus Equation
E = 17.6(CBR)0.64 MPa
Falling Weight Deflectometer (FWD) Testing
11. FWD testing shall be undertaken using a calibrated FWD in accordance with BS 1924-2
Lightweight Deflectometer Testing (LWD)
12. LWD testing shall be undertaken using a calibrated LWD in accordance with BS 1924-2
13. In accordance with BS 1924-2, a LWD device shall only be used with a site-specific correlation
versus a FWD or if it has an annual correlation certificate.
14. Testing shall either be undertaken to:
(i) Procedure A – the standard target stress as per BS 1924-2; or
(ii) Procedure B – a range of target stresses centred around 100 KPa to determine stress
dependency.
886 Wheelpath Deformation Measurement
Scope
1. This procedure shall be used at the top of a pavement foundation to measure and provide
limitations to deformation in the foundation under construction trafficking.
Procedure
2. Apparatus required:
(i) Straight edge with a minimum length of 2 m;
(ii) Two identical blocks; and
(iii) Ruler.
3. The straight edge shall be placed transverse to the rut and raised clear from the rut by two
identical blocks. The blocks shall be placed on undisturbed material outside the wheel path. The
Page 14 of 15
amount of deformation shall be the difference of the foundation (A) and the height of the blocks
(B), see Figure 8/2.
FIGURE 8/2: (03/20) Wheelpath Deformation
4. Ruts that develop under construction traffic, measured in accordance with this Clause, shall
nowhere exceed the following limits:
(i) All bound surfaces – 10 mm;
(i) < 250 mm design thickness of granular material – 30 mm; and
(ii) ≥ 250 mm design thickness of granular material – 40 mm.
Page 15 of 15
Appendix E. SERIES 900 ROAD PAVEMENTS – BITUMINOUS BOUND
MATERIALS

SERIES 900 ROAD PAVEMENTS – BITUMINOUS BOUND MATERIALS
Contents
Clause
900 General
901 Bituminous Mixtures
902 Reclaimed Asphalt
903 Placing and Compaction of Bituminous Mixtures
904-906 not used
907 Regulating Course
908 Warm Mix Asphalt
909 -919 not used
912 Close Graded Asphalt Concrete Surface Course
920 Bond Coats, Tack Coats and Other Bituminous Sprays
921-924 not used
925 Testing of Bituminous Mixtures
926 & 928 Not Used
929 Dense Base and Binder Course Asphalt Concrete Design Mixtures
930 to 940 Not Used
941 SMA Surface Course Systems
942 - 944 not used
945 Weather Conditions for Laying of Bituminous Mixtures
946 – 950 not used
951 Torque Bond Test
952 & 953 Not Used
954 Method for Laboratory Determination of Interface Properties
Using the Modified Leutner Shear Test
955 Ageing Profile Test Using a Modified Rolling Thin
Film Oven Test (MRTFOT)
956 & 957 Not Used
958 Modified Binder Storage
Page 1 of 42
ROAD PAVEMENTS – BITUMINOUS BOUND MATERIALS
900 General
Although each Series in the Particular specification is particularly relevant to the subject matter in its
title it must be read in conjunction with the requirements in all other Series included in the
specification for the works to be undertaken.
901 Bituminous Pavement Mixtures
General
1. This Clause gives general requirements for production of bituminous mixtures, as well as the
properties of the aggregates and bitumen used in plant-produced mixtures. These requirements
shall apply to all plant produced bituminous mixtures unless otherwise specified in contract
specific Appendix A or where other requirements are given in specific Clauses in this Series.
2. Asphalt mix formulations produced and supplied in accordance with EN 13108 shall be CE
marked.
3. The Contractor shall submit the Declaration of Performance which demonstrates that the asphalt
mix formulation provides the performance required by the specification.
Aggregates for Bituminous Mixtures

4. Natural, recycled unbound and manufactured (artificial) aggregates shall be clean, hard and
durable and comply with EN 13043 and be CE marked and have a declared performance which
demonstrates that the aggregate meets the requirements of the specification.
5. Where recycled coarse aggregate or recycled concrete aggregate is used in bituminous mixtures,
it shall have been tested in accordance with Clause 710.
6. The content of other materials (Class X) including wood, plastic and metal shall not exceed 1% by
mass.
7. Reclaimed asphalt shall comply with Clause 902.
8. The use of aggregate derived as a by-product during the extraction of china clay is permitted. It
shall comply with the requirements of this Clause, EN 13043 and the examples of the relevant
annex of BSI PD 6691.
Crushed Slate Aggregate
9. The use of crushed slate aggregate is only permitted in base and binder course layers. It shall not
be used in surface layers.
10. Crushed slate aggregate shall comply with the requirements of this Clause, EN 13043 and the
examples of the relevant annex of BSI PD 6691.
Page 2 of 42
11. The flakiness category of crushed slate aggregate shall be approved by the Overseeing
Organisation.
12. Mixtures of crushed slate aggregate with coarse aggregate of a different geological type shall not
be permitted.
Resistance to Fragmentation (Hardness)
13. When tested in accordance with clause 4.2.2 of EN 13043 and unless otherwise stated in contract
specific Appendix A the resistance to fragmentation of the coarse aggregates for bituminous
mixtures shall meet the following criteria:
a. ≤ LA30 for natural aggregates and ≤ LA50 for blast furnace slag; or
b. for aggregates greater than LA30 but less than LA35, where evidence can be presented to
the Overseeing Organisation of previous satisfactory use of the source in asphalt.
Resistance to Freezing and Thawing (Durability)

14. When required in contract specific Appendix G, the resistance of the coarse aggregate to freezing
and thawing shall be declared.
15. The freezing and thawing (soundness) category, as defined in EN 13043 clause 4.2.9.2, shall be
MS25 unless otherwise specified in contract specific Appendix A.
16. The water absorption value of the coarse aggregate shall be determined in accordance with EN
13043 clause 4.2.9.1.
17. If the water absorption value of the coarse aggregate is greater than WA242, the soundness test
shall be carried out on the material delivered to site. The requirements for water absorption do
not apply to blast furnace slag aggregate.
Cleanliness
18. Unless otherwise specified in contract specific Appendix A, the proportion of coarse and fine
aggregates for bituminous mixtures passing the 0.063 mm test sieve (fines content) shall not
exceed the limits stated in BSI PD 6691 Annex B, Annex C and Annex D, when tested in
accordance with the washing and sieving method of EN 933-1.
Resistance to Polishing and Surface Abrasion

19. When specified in the appropriate Clause or contract specific Appendix A, the aggregate shall
conform to the required declared PSV category in accordance with EN 13043 clause 4.2.3 and
BSI PD 6682-2 clause 4.3.2.
Page 3 of 42
20. The resistance to surface abrasion of coarse aggregate used in surface courses in accordance with
EN 13043 clause 4.2.3 shall conform to category AAV10 unless otherwise specified in the
appropriate Clause or in contract specific Appendix A.
Chemical Requirements
Dicalcium Silicate Disintegration

21. Air-cooled blast furnace slag aggregates shall be free from iron dicalcium silicate disintegration as
defined in EN 13043:2002, clause 4.3.4.1.
Iron Disintegration
22. Air-cooled blast furnace slag aggregates shall be free from iron disintegration as defined in EN
13043:2002, clause 4.3.4.2.
Volume Stability
23. The volume stability category of steel slag aggregates as defined in EN 13043, clause 4.3.4.3
shall not exceed V10.
Bitumen
24. Paving grade bitumen shall comply with EN 12591.
25. Polymer modified bitumen shall comply with EN 14023.
Asphalt Durability – Base and Binder Course
26. The water sensitivity of base and binder course mixtures designed in accordance with Clause 929
and to be used on trunk roads including motorways shall be determined by testing in accordance
with Method A of EN 12697-12.
27. The minimum Indirect Tensile Strength Ratio (ITSR) shall be ITSRmin70.
28. Mixtures that include 2% hydrated lime filler are deemed to result in mixtures which satisfy water
sensitivity requirements and testing is not required. Hydrated lime filler shall be Ca(OH)2 in the
form of hydrated lime, type CL 90-S.
902 Reclaimed Asphalt

1. The requirements of this clause apply to all bituminous mixtures containing reclaimed asphalt.
2. Reclaimed asphalt may be used in the production of bituminous binder course, regulating course
and base. Unless otherwise specified in contract specific Appendix A, the use of reclaimed asphalt
shall be in accordance with:
(i) BSI PD 6691, B.2.4.4 for Asphalt Concrete mixtures
(ii) BSI PD 6691, D.2.2.3 for Stone Mastic Asphalt mixtures
Page 4 of 42
Other recycled materials shall only be used in bituminous mixtures with the approval of the
Overseeing Organisation. The mixed material shall comply with the requirements of all the
relevant Clauses in this Series.
Reclaimed Feedstock
3. All reclaimed material shall be pre-treated before use such that it is homogeneously mixed, and
the maximum particle size does not exceed 32 mm.
Properties of Binder
4. The fresh bitumen added to the mixture shall not be more than two grades softer than the
nominal grade for the mixture given in Table 12 of BSI PD. Checks on the penetration of the
binder recovered from the reclaimed asphalt, together with a calculation of the properties of the
combined binder, shall be carried out in accordance with the relevant parts of EN 13108. When
more than 10% of reclaimed asphalt is incorporated in a mixture, tests on binder recovered from
the mixture shall be carried out following the example in BSI PD 6691 13.3.6.2. The results shall
be within the limits set out in BSI PD 6691 13.3.6.2.
Mixed materials containing more than 25% reclaimed asphalt

5. When more than 25% of reclaimed asphalt is incorporated in a designed base or binder course
mixture, cores taken to assess compliance with Clause 929.12 or Clause 930.14 shall also be
tested for stiffness in accordance with EN 12697-26 (ITSM method 20°C). The frequency of
testing shall be agreed with the Overseeing Organisation prior to the commencement of works
and shall comply with the requirements of contract specific Appendices 1/5 and 1/6.
6. The stiffness of the mixture shall comply with the appropriate category from Table 9/1.
TABLE 9/1: Stiffness Categories for Designed Base and Binder Course Mixtures Incorporating Greater
than 25% Reclaimed Asphalt
Nominal binder grade of mixture Stiffness category (Smin)
10/20 5500
15/25 5500
30/45 2800
40/60 1800
903 Placing and Compaction of Bituminous Mixtures
General
1. This Clause gives general requirements for the placing and compaction of bituminous mixtures,
which are complementary and additional to the requirements of BS 594987. These requirements
and the requirements of BS 594987 apply to all bituminous mixtures, unless otherwise specified
in the other Clauses in this Series or in contract specific Appendix A.
Page 5 of 42
2. Bituminous pavements shall be laid by organisations operating a quality management system
registered to and operating in compliance with EN ISO 9001 and constructed using the materials
specified in contract specific Appendix A.
3. There shall be full interlayer bonding between bituminous layers. This may be achieved by
keeping the surface of the bituminous layers clean and uncontaminated, and by excluding
moisture.
4. Unless agreed with the Overseeing Organisation, the only traffic permitted to run on the surface of
bituminous material to be overlaid shall be that engaged in laying and compacting the next
course or, where a binder course is to be blinded or surface dressed, that is engaged on such
surface treatment.
5. If full interlayer bonding cannot be achieved due to surfaces becoming contaminated, the
surfaces shall be made good by cleaning and, if this proves impracticable, by rectification in
compliance with Clause 702.
6. Prior to placing bituminous material on any new or existing bound substrate, a bond coat or shall
be applied in accordance with Clauses 920 or 941, as appropriate.
7. Before work commences, the Contractor shall submit a method statement to the Overseeing
Organisation that includes:
a. laying and compaction procedures for each layer – including paving speed and
paved width; size, type and number of rollers; number of roller passes; and laying
and compaction temperatures.
b. the joint formation procedures for each layer – including the location of
longitudinal and transverse joints; and the method(s) of treating upstanding
edges.
Transporting
8. Bituminous mixtures shall be transported in accordance with the requirements of BS 594987 and
shall remain covered whilst awaiting tipping.
Laying
9. Bituminous mixtures shall be laid in accordance with the requirements of BS 594987 and sub-
Clauses 10 to 19 of this Clause.
10. Surfacings specified under Clause 941 shall also be laid in accordance with the additional
requirements of that Clause.
11. Wherever practicable, bituminous mixtures shall be spread, levelled and tamped by a self-
propelled paving machine.
Page 6 of 42
12. Where the rate of delivery of material to the paver is intermittent for any reason, and the
temperature of the material falls below that recommended by the manufacturer for laying, the
cold material shall be removed, and a perpendicular joint formed in accordance with Clause
903.35 before laying recommences.
13. Hand placing of bituminous mixtures shall be restricted to the following circumstances:
a. for laying regulating courses of irregular shape and varying thickness.

b. in confined spaces where it is impracticable for a paver to operate.
c. for footways.
d. at the approaches to expansion joints at bridges, viaducts or other structures; and
e. for laying mastic asphalt.
14. Hand-raking of surface course material or the addition of such material by hand-spreading to the
paved area, for adjustment of level, shall be restricted to the following circumstances:
a. at the edges of the layers of material and at gullies, manholes and other ironwork; and
b. at the approaches to expansion joints at bridges, viaducts or other structures.
15. The method of laying shall be such that the finished mat is free from dragging, tearing and
segregation of the material.
16. When laying mixtures from more than one source, the mixtures shall have equivalent laying and
compaction characteristics so that surface evenness is not compromised.
17. When paving adjacent to an expansion joint of a structure, the joint or joint cavity shall be kept
clear of material.
18. When laying binder course or surface course, the paver shall be taken out of use whilst laying the
remainder of the pavement up to the joint and the corresponding area beyond it.
19. When paving directly onto bridge deck waterproofing systems, any special requirements which
apply to that system shall be complied with.
Compaction
20. The compaction of bituminous mixtures shall be in accordance with 594987 and the
requirements for specific mixtures in:
a. Clause 929 for dense base and binder course asphalt concrete (design mixtures);
b. Clause 930 for EME2 mixtures; and
c. Clause 941 for thin surface course systems.
21. Except where otherwise specified, rollers shall comply with the general requirements of BS
594987
Page 7 of 42
22. The minimum mass of deadweight smooth wheeled rollers shall be 8 tonnes.
23. Multi-wheeled pneumatic tyred rollers and vibratory rollers shall only be used if they are capable
of achieving at least the standard of compaction of an 8-tonnes deadweight roller.
24. Where compaction is to be determined in accordance with Clauses 929 and 930, the
requirements to prove the performance of rollers do not apply. In such cases, the Contractor is
permitted use any plant to achieve the specified level of compaction and shall carry out
compaction at temperatures above the minimum specified rolling temperature.
25. Vibratory rollers shall not be used in vibrating mode on bridge decks.
Joints
26. For new, widened and realigned pavement construction, all longitudinal joints in all layers shall be
situated outside wheel track zones.
27. Where an existing road pavement is resurfaced, joints in the surface course shall coincide with
either the lane edge, the lane marking, or the middle of a traffic lane, whichever is appropriate.
28. Joints shall not coincide with the wheel path
29. Stepping of all joints shall be offset by 300mm from parallel joints in the layer beneath.
30. Where indicated on the drawings, or in contract specific Appendix A, that the requirements of
300mm steps and prohibition of joints in wheel track zones cannot be met, for example due to
new lane configuration, the joints shall be offset as close as practicable to 300mm but not less
than 150mm and only if the layer above is less than 150mm thick.
31. Unless otherwise specified in contract specific Appendix A, the faces of all cold upstanding edges,
including previously laid asphalt, against which bituminous mixtures are to be laid to form joints
shall be treated with one of the following:
a. hot bituminous binder with a penetration value of not less than 40/60;
b. hot elastomeric polymer-modified bituminous binder complying with EN 14023 with a
penetration Class 4; and
c. cold applied thixotropic bituminous compound of similar bitumen or polymer-modified
bitumen grade;
d. or
e. polymer-modified adhesive bitumen strip with a minimum thickness of 2mm.
32. This operation shall be done so that the binder adheres to both the cold and the warm upstanding
edges when the asphalt is placed.
Page 8 of 42
33. Unless otherwise specified in contract specific Appendix A, joints in binder courses and bases shall
be compacted such that the air voids content measured from core pairs whose centres are not
more than 100mm from the final joint is not greater than 2% above the maximum permitted limit
for core pairs in the body of the mat.
34. The air voids content shall be calculated in accordance with EN 12697-8 using the relevant bulk
and maximum densities defined in Appendix B of EN 13108-20 for the relevant mixture type.
35. Within 24 hours of the joint being formed, a sealant shall be applied to the top surface of all base
and binder course joints such that there is not less than 0.50 kg/m2 of residual bitumen 75mm
either side of the joint, unless otherwise specified in contract specific Appendix A.
36. The sealant, which may contain mineral filler to EN 13043, shall be one of the following:
a. (hot elastomeric polymer-modified bituminous binder complying with EN14023 with a
penetration Class 4;
b. bitumen emulsion with a cohesion by pendulum of Class 4 or above in accordance with EN
13808.
c. or
d. slurry surfacing complying with Clause 918.
Regulating Course
37. Regulating course material shall be produced and laid in accordance with the requirements of
Clause 907.
Use of Surfaces by Traffic

38. Where a new bituminous layer other than the surface course is to be opened to highway traffic as
a temporary running surface it shall contain a coarse aggregate of category of not less than
PSV60, unless otherwise specified in contract specific Appendix A.
39. Construction plant and traffic shall not be permitted to damage the subgrade or the pavement
courses already constructed.
40. Temporary running surfaces used by construction traffic shall be kept free of deleterious
materials.
907 Regulating Course

1. Regulating courses, which may consist of one or more layers of a bituminous material, shall have
their finished surfaces laid to achieve the appropriate tolerances for horizontal alignments,
surface levels and surface regularity for pavement layers, in accordance with Clause 702.
2. Unless otherwise specified in contract specific Appendix A, stone mastic asphalt complying with
Clause 937, or base or binder course asphalt concrete complying with Clause 929 shall be used
for regulating courses immediately below surface courses. Bituminous mixtures for regulating
courses shall meet the requirements for the appropriate material, as specified above.
Page 9 of 42
3. Where the total depth of a regulating course exceeds 150 mm then the course shall be laid so
that each regulating layer has a compacted thickness of between 75 mm and 150 mm.
908 Warm Mix Asphalt (WMA)
WMA General
1. WMAs shall be installed in accordance with the producer’s instructions.
WMA Permitted Mixtures

2. Mixtures produced as Warm Mix Asphalts shall fulfil the requirements given in:
(i) Clause 929 for Dense Base and Binder Course Asphalt Concrete (Design Mixtures);
(ii) Clause 937 for Stone Mastic Asphalt (SMA) Binder Course and Regulating Course;
(iii) Clause 941 for SMA Surface Course Systems; and
(iv) Clause 901 and Clause 903 and contract specific Appendix A.
3. Warm mixtures conforming to Clause 941 shall have Product Acceptance Scheme certification
for their installation in compliance with sub-Clause 104.16 and Clause 941 to demonstrate their
performance.
4. For the purposes of traceability, the mixture designation shall include a reference to the use of
warm mix technologies e.g AC20 bin HDM 40/60 "W".
WMA Production Temperatures

5. The maximum production temperatures, when measured in accordance with EN 12697-13, shall
be in accordance with Table 9/1A and the material's Declaration of Performance and not
compromise the efficacy of the binder, additives or process.
Table 9/1A. Maximum production temperatures for WMAs incorporating paving grade binders, hard
paving grade binders or Polymer Modified Binders
Water Sensitivity
6. Unless otherwise stated in contract specific Appendix A, the water sensitivity expressed as an
Indirect Tensile Strength Ratio or Compression strength ratio shall be in accordance with Table
9/1B and contract specific Appendix A and be declared on the Declaration of Performance.
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7. Designated WMA mixtures in Table 9/1B which include 2% hydrated lime filler aggregate are
deemed to result in mixtures which satisfy water sensitivity requirements and testing is not
required. Hydrated lime filler shall be Ca(OH)2 in the form of hydrated lime, type CL 90-S.
Table 9/1B Minimum Water Sensitivity Values for Warm Mix Asphalts
8. Mixtures produced as WMA shall comply with the requirements in Clause 903, contract specific
Appendix A, Table 9/1C and the producer's recommendations and not compromise the efficacy
of the WMA binder, additives or process.
Table 9/1C (07/21) Minimum Rolling Temperatures for WMAs Incorporating Paving Grade Binders,
Hard Paving Grade Binders or Polymer Modified Binders
9. The carbon footprint analysis shall be conducted in accordance with TRL PPR 575 – Protocol for
the calculation of whole life cycle greenhouse gas emissions generated by asphalt, covering Steps
1 to 5 of the asphalt life cycle, from ‘raw material acquisition’ to ‘road component production’.
10. The carbon footprint shall be stated in kgCO2e per tonne of the warm mixture and broken down
into totals for Steps 1-3, Step 4 and Step 5.
Page 11 of 42
912 Close Grade Asphalt Concrete Surface Course
1. Close graded asphalt concrete (formerly macadam) surface course recipe mixes shall be asphalt
concrete conforming to BS EN 13108-1, the example of BSI PD 6691 Annex B and requirements
specified in contract specific Appendix A. The mixture designation shall be AC10 Close Graded
Surface Course 40/60.
Coarse Aggregate
2. To ensure adequate resistance to polishing and abrasion, the coarse aggregate shall have a
minimum declared PSV and a maximum AAV, as specified in contract specific Appendix A
920 Bond Coats, Tack Coats and Other Bituminous Sprays

1. Bond coats and tack coats used in conjunction with bituminous mixtures, other than those
covered by Clause 941, shall be in accordance with this Clause and the requirements specified in
contract specific Appendix A and Appendix B.
Bond Coats
2. Bond coats for bituminous mixtures shall be cationic polymer modified bitumen emulsions
complying with EN 13808 or polymer modified bitumen complying with EN 14023 with a
minimum peak cohesion value of 1.0 J/cm2 when tested in accordance with EN 13588. They
shall be CE marked and the Contractor shall submit the declaration of performance to the
Overseeing Organisation prior to their application. The declaration of performance shall
demonstrate that the bond coat meets the requirements of the specification.
Tack Coats
3. Tack coats for bituminous mixtures shall be unmodified bitumen emulsion complying with EN
13808. They shall be CE marked and the Contractor shall submit the declaration of performance
to the Overseeing Organisation prior to their application. The declaration of performance shall
demonstrate that the tack coat meets the requirements of the specification.
Bituminous Sprays
4. Bituminous sprays used to facilitate sealing and curing shall consist of either bitumen emulsion
complying with EN 13808 or paving grade bitumen complying with EN 12591. They shall be CE
marked and the Contractor shall submit the declaration of performance to the Overseeing
Organisation prior to their application. The declaration of performance shall demonstrate that the
spray meets the requirements of the specification.
Product Information
5. For bond coats, tack coats and bituminous sprays the Contractor shall provide the information
specified in contract specific Appendix B and supply a copy to the Overseeing Organisation prior
to the application of the product.
Preparation
6. The Contractor shall comply with any limitations on area availability and timing or other
constraints for the work as specified in contract specific Appendix 1/13. Before spraying is
commenced, the surface shall be free of all loose material and standing water and shall comply
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with any requirements specified in contract specific Appendix B. When specified in contract
specific Appendix B, street furniture, ironwork and drop-kerbs shall be masked using self-adhesive
masking material before application starts and removed on completion of the works.
Application
7. Application shall be by metered mechanical spraying equipment, spray tanker or spraying device
integral with the paving machine. The spraying equipment used shall not cause permanent
deformation in the surface. For small or inaccessible areas, application may be by hand held
sprayer with the agreement of the Overseeing Organisation.
8. The target rates of spread of bond coats or tack coats below bituminous mixtures shall be in
accordance with BS 594987, clause 5.5.
Accuracy of Application
9. Spray application shall be uniform. Before spraying begins, the Contractor shall provide the
Overseeing Organisation with a test certificate showing the results for rate of spread and accuracy
of spread. These tests shall be carried out in accordance with EN 12272-1 by an appropriate
organisation, accredited in accordance with sub-Clause 105.4 for those tests. The certificate shall
demonstrate that the spraying device has been tested, using the product to be used in the
contract, not more than six weeks before commencement of the work. The tolerance on the
specified rate of spread shall not exceed ±20% and the coefficient of variation of the transverse
distribution shall not exceed 15%. During the works the Contractor shall repeat the tests for rate
of spread and accuracy of application at the frequency specified in contract specific Appendix 1/5.
The results shall be reported verbally to the Overseeing Organisation within 24 hours of carrying
out a test and in writing within 7 days. Where application is by hand held sprayer, the rate of
spread shall be measured by calculating the volume applied per square metre and evenness shall
be visually assessed.
Joints
10. There shall be no bare strips or areas having less than the minimum permitted rate of spread.
Transverse joints shall have an overlap not wider than 300 mm. Longitudinal joints shall have an
overlap to ensure that the minimum permitted rate of spread is achieved across the joint. For
quartering (using part of the spraybar) the longitudinal joint overlap width may be extended to a
maximum of 300 mm. Paver integral sprayers shall provide a wet edge to ensure spray overlap
under adjacent overlays such that the minimum permitted rate of spread is achieved across the
longitudinal joint. Where the longitudinal spray overlap causes the effective rate of spread to be
increased by more than 50% of the specified rate, then the width of overlap shall not be greater
than 100 mm and shall be outside the location of the wheel tracks for the lane.
Overlaying Concrete Surfaces

11. The Contractor shall submit evidence of the suitability of the bond or tack coats he intends to use
when overlaying concrete surfaces to the Overseeing Organisation prior to the commencement of
the work.
Page 13 of 42
Blinding Material for Bituminous Sprays
12. When specified in contract specific Appendix B, blinding material shall consist of hard clean
crushed fine aggregate or slag fine aggregate or sand containing not more than 15% by mass
retained on a 6.3 mm sieve. It shall be distributed over the sprayed area and left. Blinding used on
cementitious materials shall be light in colour to minimise solar gain. All loose material on a
sprayed surface including non-adhered blinding material shall be removed prior to the
application of an overlay.
Chipping to Prevent Binder Pickup

13. When chippings are used to prevent tack or bond coat pickup on vehicle tyres, they shall consist
of hard, clean aggregate 2/4 mm or 2/6 mm Gc 85/35. The rate of application of aggregate shall
be the minimum necessary and shall be distributed by metered mechanical means. Bond coat
shall be visible after aggregate application to ensure bond is still achieved between the pavement
layers.
925 Testing of Bituminous Mixtures

1. The contract compliance sampling and testing of bituminous mixtures shall comply with EN
12697, except where otherwise specified in this Series.
2. Additional testing shall be carried out as specified in contract specific Appendix A and Appendix G
926 to 928 Not Used
929 Dense Base and Binder Course Asphalt Concrete (Design Mixtures)
1. Designed dense base and binder course asphalt concrete (formerly macadams), including HDM
and HMB, shall be asphalt concrete conforming to BS EN 13108-1, the example of BSI PD 6691
Annex B for the selected mixture, and requirements specified in contract specific Appendix A. The
mixture designation shall be one of the following:
(i) AC 32 HDM base 40/60 des.
(ii) AC 32 dense base 40/60 des.
(iii) AC 20 HDM bin 40/60 des.
(iv) AC 32 HDM bin 40/60 des.
(v) AC 20 dense bin 40/60 des.
(vi) AC 32 dense bin 40/60 des.
2. The volumetric properties of mixtures shall follow the example in BSI PD 6691, clause B.3.2 for
designed base mixtures and BSI PD 6691, clause B.3.3 for designed binder course mixtures.
3. When specified in contract specific Appendix A, the volumetric properties of the mixture shall be
monitored by determining the void content of cores compacted to refusal. Core pairs and samples
of loose mix shall be taken every 500 lane metres and tested in accordance with BS 594987,
clauses C.2.1, C.2.2, C.3, C.4.1 and C.4.2. If the mean air void content at refusal of any three
Page 14 of 42
consecutive pairs of cores falls below 0.5%, the mixture target composition shall be reviewed and
the type test revalidated in accordance with BS 594987, Annex C.
Deformation Resistance
4. The resistance to permanent deformation of the mixture shall be in accordance with the
appropriate class selected from Table D.2 of PD 6691, as specified in contract specific Appendix
A.
5. When specified in contract specific Appendix A, the resistance to permanent deformation of

material laid in the permanent works shall be monitored by testing in accordance with clauses D
3.1, 3.2 and 3.3 of BS 594987 Annex D. Six cores shall be taken from the first kilometre length of
material from each mixing plant and thereafter one further core from each subsequent lane
kilometre. Results shall be assessed on successive rolling means of sets of six consecutive results
and shall be deemed to conform if the mean is no greater than the specified value and individual
values not more than 50% greater than the specified value.
Stiffness
6. Stiffness of the mixture shall be assessed in accordance with BS 594987, Annex E. Mixtures with
40/60 grade binder shall conform to category Smin 1800 as defined in BS EN 13108-1, clause
5.4.2. Mixtures with 30/45 grade binder shall conform to category Smin 2800 as defined in BS
EN 13108-1, clause 5.4.2.
Compaction Control for the Permanent Works

7. Compaction shall be controlled and monitored in accordance with the general requirements of BS
594987 9.5.1 and the specific requirements of this Clause.
8. Compaction shall be continuously assessed using an indirect density gauge in accordance with BS
594987 9.4.2 with readings taken at 20 m intervals in alternate wheel-tracks. Gauge readings
shall also be taken at each core location specified in sub-Clauses 12 and 14. Each gauge shall be
individually calibrated on each mixture from each mixing plant and the calibrations shall be
continually checked and updated based on correlations between gauge readings and core
densities at the same locations.
9. For each location, the in situ void content shall be determined in accordance with BS EN 12697-8
using the bulk density from the gauge reading and a maximum density taken from the mixture
type testing data and updated with values from testing in accordance with sub-Clause 12.
10. The average in situ void content calculated from any six consecutive indirect gauge readings shall
not exceed 7%.
11. In the event of a failure to meet the requirements in sub-Clause 10, cores shall be taken at each
location and void contents determined as described in sub-Clause 12 and the evaluation of the
extent of any non-conformity shall be based on these. If it is necessary to remove and replace any
material to restore conformity this shall be in lengths not less than 15 m unless otherwise agreed
by the Overseeing Organisation.
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12. For the material from each mixing plant, a pair of cores shall be taken from every 1,000 linear
metres laid and the void content shall be determined in accordance with BS 594987, clause
9.5.1.3.
13. The average in situ air voids for each core pair shall not exceed 7%.
14. For the material from each mixing plant a pair of cores shall be taken every 250 linear metres laid,
centred 100 mm from the final joint position at any unsupported edge and the air void shall be
determined in accordance with BS 594987, clause 9.5.1.3.
15. The average in situ void content for each of these pairs shall not exceed 9%.
16. In the event of non-conformity with sub-Clauses 13 or 15 then density readings with indirect
gauges and, if necessary, further cores shall be taken to establish the extent. If it is necessary to
remove and replace any material to restore conformity, this shall be in lengths not less than 15 m
unless otherwise agreed by the Overseeing Organisation.
17. Each core extracted shall be examined for evidence of excessive voids below the depth to which
the indirect density gauge penetrates. If excessive voids are observed, further cores shall be taken
to determine its extent.
18. Two copies of the final indirect density test results obtained and their correlation with in-situ air
void contents shall be passed to the Overseeing Organisation within 72 hours.
Warm Mix Asphalt (WMA)

19. Mixtures to be produced as WMAs shall comply with Clause 908
930 to 940 Not Used
941 SMA Thin Surface Course Systems
General
1. Thin surface course systems shall be provided and installed in accordance with the requirements
stated in this Clause and those given in contract specific Appendix A.
2. Thin surface course systems specified under this Clause shall be between 20mm and 50mm
thick.
Overall Performance Requirements

3. The Contractor shall guarantee the installed thin surface course for a period of 5 years from the
date of opening to traffic. For the period of the guarantee the thin surface course shall meet the
performance requirements stated in this Clause and contract specific Appendix A. The thin
surface course shall not have the following defects for the 5 year period: deformation, fretting,
ravelling, stripping, aggregate loss or cracking. The guarantee shall exclude defects arising from
accidental damage or damage caused by settlement, subsidence or failure of the underlying
carriageway on which the surfacing material has been laid.
Page 16 of 42
4. For the period of 2 years the surface texture shall be within the limits stated in this Clause and
contract specific Appendix A.
5. The Contractor shall demonstrate that the 'as installed' enhanced thin surface course system can
meet the requirements of the specification. This shall be demonstrated by the system meeting
the stated material requirements and by paving undergone a System Installation Performance
Trial (SIPT) to cover the aspects of the installation not covered by the material's declaration of
performance. The SIPT shall comply with the requirements of sub-Clauses 27 to 48 of this
Clause.
Material Requirements
6. The enhanced thin surface course mixture shall comply with EN 13108-1, EN 13108-2 or EN
13108-5. It shall be CE marked and the Contractor shall submit the declaration of performance
for the material to the Overseeing Organisation. The declaration of performance shall
demonstrate that the material meets the requirements of the specification.
7. The coarse aggregate shall be crushed rock or steel slag complying with Clause 901 and EN
13043. The Contractor shall submit the declaration of performance for the aggregate to the
Overseeing Organisation. The declaration of performance shall demonstrate that the aggregate
meets the requirements of the specification. The resistance to polishing and abrasion, PSV and
AAV, shall be as specified in contract specific Appendix A.
8. The aggregate resistance to fragmentation and flakiness Index shall be as follows:
1) Resistance to fragmentation: Los Angeles Coefficient (LA) - not greater than LA30;
2) Flakiness Index (FI) - not greater than FI20.
9. The maximum aggregate size shall be 14mm
10. The minimum target design binder contents shall be in accordance with Table 9/10 and contract
TABLE 9/10 Minimum Design Binder Content
11. The resistance to permanent deformation shall be as specified in contract specific Appendix A.
The resistance to permanent deformation of mixtures conforming to EN 13108-1 and EN
13108-5 shall be in accordance with the appropriate class selected from Table B.4 or D.2
respectively of BSI PD 6691.
Page 17 of 42
12. The water sensitivity shall be as specified in contract specific Appendix A. The water sensitivity of
mixtures conforming with EN 13108-1, EN 13108-2 [Ref 10.N] or EN 13108-5 shall conform to,
at least, category ITSRmin80, determined in accordance with EN 12697‑12.
13 The design void content shall be Vmin 2 to Vmax 5% with the exception of 6 mm nominal size
aggregate which shall be Vmin 2 to Vmax 7%. The bulk density shall be determined in
accordance with EN 12697-6 Procedure B in a saturated surface dry condition, maximum density
to EN 12697-5 using Procedure A in water and maximum density calculated to EN 12697-8.
14. Contract compliance testing of the mixture shall be carried out as required in contract specific
Appendix G.
15. Specimens for testing shall be compacted from loose bituminous mixture in accordance with the
following methods:
1) Laboratory roller compactor (EN 12697-33) shall be used for manufacturing asphalt slabs at
the target design voids, and cores to be taken from these slabs for permanent deformation
testing;
2) Impact compactor (EN 12697-30) at compaction energy of 2 x 50 blows shall be used for
manufacturing specimens for water sensitivity testing and air void content determination.
Installation Requirements: General

16. The Contractor shall provide an Installation Method Statement to the Overseeing Organisation. It
shall include the SIPT method statement as described in sub-Clause 32 of this Clause, all
installation instructions relevant to the system being used, details as specified in this Clause and
details to meet the requirements of Clause 903.
17. The design thickness of the enhanced thin surface course system shall be as specified in the
contract specific Appendix A. The permitted minimum deign thickness is 40mm and maximum
permitted design thickness is 50mm. The installed layer thickness must not be less than the
permitted minimum thickness, nor greater than the permitted maximum thickness, stated in the
Installation Method Statement.
18. Where required in the Installation Method Statement or in contract specific Appendix A, to
achieve final pavement levels and/or thicknesses the existing substrate surface shall be
strengthened or regulated in accordance with Clause 907.
19. Where the existing substrate surface is regulated in accordance with Clause 907, evidence that
the deformation resistance of the regulating material will meet the specification shall be
submitted by the Contractor to the Overseeing Organisation. Where the combined thickness of
the regulating material and the thin surface course is more than 20 mm, evidence of the
deformation resistance of the combined layers shall be provided.
20. Surface preparation including the removal of road markings, cleaning and drying, resetting of
ironwork shall be in accordance with BS 594987 and the Installation Method Statement.
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Method Statement.
21. Where required in the Installation Method Statement a bond coat or tack coat shall be applied. It
shall be in accordance with the Installation Method Statement. Unless otherwise stated in the
Installation Method Statement is shall also comply with Clause 920 and BS 594987. A calibrated
mechanised method of application shall be used unless otherwise agreed with the Overseeing
Organisation.
22. Transportation of the thin surface course material shall be in accordance with the System
Installation Method Statement and Clause 903.
Installation Requirements: Surface Macrotexture – Un-trafficked

23. The surface macrotexture depth of the thin surface course system shall be measured in
accordance with EN 13036-1. Unless otherwise stated in contract specific Appendix A the
average macrotexture per 500m section of the installed surfacing shall be within the range
0.8mm to 1.3mm. The minimum average for a set of 10 measurements shall be 0.7mm.
Installation Requirements: Macrotexture - Trafficked

24. For a period of two years from the date of opening to traffic the average macrotexture, measured
using the volumetric patch technique in accordance with EN 13036-1, will be maintained above
the levels given in contract specific Appendix A. The measurements shall be in the most heavily
trafficked lane at 10 m intervals along the centre of the most heavily worn wheel- track. The
average retained surface macrotexture per 500m section shall be 0.8mm
Installation Requirements: Torque Bond

25. The bond strength between a thin surfacing system and its substrate shall be ≥ 400 kPa,
measured in accordance with Clause 951.
Installation Requirements: Noise

26. No requirement
System Installation Performance Trial (SIPT) Requirements

27. The thin surface course used in the SIPT shall meet the performance requirements of the thin
surface course to be supplied under the contract. This shall be demonstrated by the assessments
and testing undertaken for the SIPT.
28. The installed thin surface course system shall be assessed, tested and certified by a Certification
Body using one or more trial areas of surfacing. The Contractor shall submit details of the SIPT
for the systems to be used in the contract as required in sub-Clause 32 to the Overseeing
Organisation for acceptance.
29. The area of surfacing for the SIPT shall be a minimum of 50 m in length and 3.5 m in width. The
design target layer thickness shall be 40-50 mm.
30. A SIPT method statement shall be prepared. The SIPT shall demonstrate, and enable verification
of, the installation procedures given in the SIPT method statement. This will include the correct
application rates of the bond (or tack) coat, application method of bond coat, paving speed of
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mixed material, joint formation, laying temperatures, methods of verification to be used on site,
maintenance and repair techniques, aftercare, and frequency of testing and acceptable variations
within the specified limits.
31. A SIPT inspection protocol shall be prepared. It shall demonstrate qualitatively and quantitatively
the applicability of the SIPT for the system in order to satisfy the performance requirements.
32. The SIPT method statement, SIPT inspection protocols, all inspection and testing results and the
SIPT certification shall be submitted to the Overseeing Organisation along with the Installation
Method Statement.
33. The SIPT shall include the following to be undertaken by the Certification Body:
1) Verification that the system installation trial has been undertaken in accordance with the SIPT
method statement and the stated protocols;
2) Assessment of the visual condition of the completed system at the times stated in sub-Clause
35;
3) Assessment of the data from the site performance tests detailed in sub-Clause 35.
34. The assessments shall be undertaken by an assessment team that includes a lead assessor with
experience in pavement inspections and a minimum of two additional suitably experienced
persons to comprise an inspection panel for the visual condition of the SIPT installation and
interim inspections.
35. The installed performance characteristics of the trial area shall meet the criteria stated in Table
9/15 at the times and intervals stated.
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TABLE 9/15 Installed Performance Characteristics
No requirement
36. Defects identified during the visual inspections shall be recorded. The assessment of defects shall
be summarised as a Performance Band as listed in Table 9/16.
TABLE 9/16 Site Installation Performance Trial Visual Inspection Requirement
37. The torque bond strength between the thin surface course and its substrate shall be established
in accordance with Clause 951. This shall be established between 28 and 56 days after the SIPT
is installed.
38. The void content of the mixture for the SIPT shall be design Vmax, as specified in Sub-Clause 13,
from the average of 6 cores.
943-942 not used
Page 21 of 42
945 Weather Conditions for Laying of Hot Bituminous Mixtures
1. The Contractor shall take account of the weather conditions when planning his working methods.
The Contractor’s working methods shall comply with all weather-related requirements. When
laying is to be undertaken during winter the contractor shall work to a Quality Plan that allows for
the specific issues raised by day and/or night time working.
Surface Course Systems

2. The weather conditions for laying thin surface course systems shall comply with those identified
as being acceptable in the Installation Method Statement as required in Clause 941.
946 – 950 not used
951 Torque Bond Test

1. The bond strength between a thin surfacing system and its substrate, which may be bituminous
or cementitious, shall be established between 28 and 56 days after the SIPT is installed by
measuring the peak shearing torque at a known temperature.
2. Six evenly spaced, 100±5 mm diameter cores shall be cut to a depth of 20 mm below the thin
surfacing layer to be tested, along a diagonal line across the lane width from a 100 m length of
the installation. The surface to be tested must be clean and dry.
3. A metal plate of mild steel having a diameter of 95±5 mm and a thickness of 14±2 mm,
incorporating a fitting to enable it to be coupled to a torque meter shall be secured to the surface
of the core using a suitable bonding agent, taking care to ensure that the plate is parallel to the
surface.
4. When the bonding agent has developed sufficient strength, (ie. failure should not occur within
the adhesive) a torque meter, fitted with a fiducial reading gauge, calibrated over a range of 0-
350 Nm with a scale readable to at least 10 Nm, shall be fitted to the metal plate, using adapters
and extension rods as appropriate.
5. Torque shall be applied to the core at a steady rate so that the torque wrench sweeps an angle of
90° within 30±15 seconds. Care must be taken to ensure that the torque is applied parallel to the
core surface within ± 10°. Torque is applied to the plate until failure of the bond occurs or a
torque of 300 Nm is exceeded.
6. The value of torque at failure shall be recorded in Newton metres (M). The bond interface
temperature shall be measured and recorded immediately after failure, using a thermometer
readable to a temperature of 0.1ºC and accurate to 0.5ºC.
7. The core diameter shall be measured and recorded at two locations approximately 90° apart
using callipers and the mean value, D, recorded to an accuracy of 1 mm.
8. The bond strength is calculated for each specimen using the following formula:
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where: τ: inter-layer bond strength in kiloPascals (kPa),
M: peak value of applied shearing torque in Newton metres (Nm),
D: diameter of core in millimetres (mm)
9. The arithmetic mean of the inter-layer bond strength, τ, for the six specimens shall be calculated
and shall be greater than or equal to 400 kPa.
10. The test report shall include the name of organisation carrying out the test, description of
materials (system and substrate), date of test, peak torque at failure (Nm), inter-layer bond
strength (kPa), (individual and mean values), time to failure (seconds), diameter of core (mm),
depth of Bond interface (mm), temperature of the bond interface at test (ºC), identification of site
or scheme, core location, age of the installation/specimen at the time of test, nature of the bond
interface, mode of failure.
952 & 953 Not used
954 Method for Laboratory Determination of Interface Properties Using the

Modified Leutner Shear Test
Scope
1 This Clause specifies a laboratory test method to assess the bonding between adjacent asphalt
pavement layers using cylindrical samples. It is also appropriate for asphalt applied to concrete.
Terms and Definitions

2 For the purposes of this Clause the terms and definitions given in 6100 shall apply, together with
the following:
(i) Peak Shear Stress: The maximum value of shear stress, determined as the maximum force
divided by the initial cross-sectional area of a specimen when tested as described in this Clause.
(ii) Displacement at Peak Shear Stress: The displacement at the maximum value of shear stress of
a specimen when tested as described in this Clause.
(iii) Shear Stiffness Modulus: The peak shear stress divided by the displacement at the peak shear
stress of a specimen when tested as described in this Clause.
Principle of Test
3. Cylindrical test specimens of nominal 150 mm diameter shall be subjected to direct shear
loading at 20°C using the modified Leutner shear test. The maximum shear stress (in MPa) at the
interface between layers shall be determined.
Test Apparatus and Materials

4. The following test apparatus and materials shall be used:
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(i) Shear test apparatus, as shown in Figure 9/2, composed of a base body (A) on which are
fixed the sample support (B) and the lower shear ring (D). The upper shear ring (C) is
attached to the upper body (E), which is movable along the guiding bars (F). The gap
between shear rings (C and D) is 5 mm.
(ii) Loading frame capable of achieving a constant vertical displacement rate of 50.0 ± 2 mm
per minute and a maximum load of at least 50kN.
(iii) Data logging system to record load and displacement during the test.
(iv) Metal extension, as shown in Figure 9/3.
(v) Stiff adhesive, such as epoxy resin, with sufficient strength to avoid failure within the
adhesive or at the adhesive/asphalt material interface.
Sample Preparation
5. Test specimens shall be cores of 150 ± 2 mm diameter; the minimum thickness of the layers
above and below the interface to be tested shall be 15 mm and 60 mm respectively. Specimens
shall be cored from an in-service pavement or from a slab manufactured using a laboratory roller
compactor in accordance with EN 12697-35 and EN 12697-33. If the thickness of the layer
above the interface is between 15 and 30 mm, a metal extension shall be glued on top of the
layer above the interface.
Procedure
6. The diameter and thickness of the specimen shall be determined to the nearest mm.
7. The specimen shall be placed into a suitable temperature-controlled conditioning environment

at 20 ± 0.5°C for a minimum of 5 hours.
8. The appropriate shear rings, to form a loose fit around the specimen (for example, 151 mm
diameter shear rings for a 150 mm diameter specimen), shall be selected and attached to the
Leutner test frame.
9. The specimen shall be placed into the test apparatus and the interface aligned, (Figure 9/2 (G)),
between the upper and lower shear rings (Figure 9/2 (C and D)). If a metal extension is used, the
specimen shall be placed into the test apparatus so that the direction of the grooves is
perpendicular to the direction of the applied shear load.
10. Tighten the sample support using a suitable spanner.
11. The test apparatus shall be placed into the loading frame and adjusted until the upper shear ring
(Figure 9/2 (C)) nearly touches the specimen.
12. Start the data logging system (to record load and displacement) and commence shear loading.
The loading rate shall be 50.0 ± 2 mm per minute.
13. Record the load (F) to the nearest 0.1 kN and the displacement (δ) to the nearest 0.1 mm.
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14. Stop the shear loading when the test frame reaches its limit of 7 mm displacement. The length of
time between removal of the specimen from the temperature-controlled conditioning
environment and completion of testing shall not exceed 15 minutes.
15. After the test has been completed, the apparatus shall be dismantled, and the specimen
removed.
16. Both sections of the specimen shall be observed (especially the interface) for any visual cracks
and unusual appearance (i.e. crushed aggregates on edges). Record any comments as necessary.
Calculation and Expression of Results

17. Calculate the shear stress as follows:
Where: τ = shear stress in (MPa)
F = load (in kN)
r = initial radius of specimen (in mm)
18. Produce a shear stress versus shear displacement graph (an example is shown in Figure 9/4)
using the recorded data.
19. Determine the following parameters from the graph:
(i) τ max = peak shear stress, MPa, expressed to the nearest 0.1
(ii) δ max = displacement at peak shear stress, mm, expressed to the nearest 0.1
(iii) k = shear stiffness modulus = τ max/ δ max, MPa/mm, expressed to the nearest 0.1
Test Report
20. The test report shall contain not less than the following information:
(i) A reference to this test method and test conditions.
(ii) Material descriptions for both layers.
(iii) Type and amount of tack (bond) coat (if known).
(iv) For each specimen tested, report:
– specimen diameter, expressed to the nearest mm
– layer thicknesses, expressed to the nearest mm
– maximum load (F), expressed to the nearest 0.1 kN
– peak shear stress (τ max), expressed to the nearest 0.1 MPa
– displacement at peak shear stress(δ max), expressed to the nearest 0.1 mm
– shear stiffness modulus (k), expressed to the nearest 0.1 MPa/mm
– any cracks or other damage.
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(v) The test temperature, expressed to the nearest 0.5°C
(vi) The use (or otherwise) of a metal extension.
FIGURE 9/2: Schematic Diagram of the Modified Leutner Shear Test apparatus
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FIGURE 9/3: Schematic Drawing of the Metal Extension
FIGURE 9/4: (05/18) Example of Shear Stress vs Displacement Data Plot
955 Ageing Profile Test Using a Modified Rolling Thin Film Oven Test (MRTFOT)
Scope
1. This Clause specifies the procedure for obtaining samples of ‘Aged Binder’ after various stages of
conditioning. In this way, a plot of binder properties providing an ‘Ageing Profile’ may be
accomplished in a short time using the Modified Rolling Thin Film Oven Test (MRTFOT) to
simulate ageing in road materials over many years in service.
MRTFOT utilises the Rolling Thin Film Oven (ASTM 2872) specified in EN 12607-1.
The method is suitable for generating small quantities of binder for rheological testing
The ‘Ageing Profile’ is generated by determining the rheological properties of complex shear
(stiffness) modulus
G* and phase angle δ of samples taken from the oven at intervals throughout the test period,
typically one day.
Other properties such as durability of cohesion may also be assessed.
Three protocols are used depending on the type of binder and its use:
(i) a method to simulate ageing of polymer modified binder or paving grade bitumen used in the
manufacture of asphalt;
(ii) a method to remove the water phase and volatile flux from polymer modified bituminous
emulsions and simulate ageing and;
(iii) a method to test the potential for preservatives to reduce the ageing rate of bitumen.
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The ‘Ageing Profile’ in terms of rheological characteristics provides ‘Product Identification’ and
this is essential to ensure consistency and to enable proprietary binders to be identified.
Warning
2. The use of this test method can involve hazardous materials, operations and equipment. This
Clause does not purport to address all of the safety problems associated with the use of the test
method. It is the responsibility of the user of these test methods to establish appropriate safety
and health practices and determine the applicability of regulatory limitations prior to use.
Asphalt Binders
3. Binders used to manufacture hot mixed asphalt (asphalt binders) are first subjected to a ‘Short-
term Ageing Test’ to simulate the effects of manufacture, transport and laying. In this respect, the
test described in this Clause has been shown to be equivalent to EN 12607-1. The binder is
continually stirred by rotating stainless steel screws in sample cans to obtain a homogeneous
sample; the procedure also benefits from a faster oxidation rate (rapid ageing), because of the
increased exposure to the jetted air stream and, therefore, a shorter test duration.
The binder samples are then aged at a lower temperature and samples removed at intervals and
tested to obtain an ‘Ageing Profile’. This is particularly useful for asphalt, because different air
void contents and binder contents in a road pavement result in different ageing rates.
The ‘Long-term Aged’ binder sample, where the characteristics are equivalent to those obtained
after 65 hours using the Pressure Ageing Vessel PAV85 Test, is obtained after 7 hours; therefore,
the test may be carried out in one day. PAV85 is detailed in EN 14769.
Binders used for manufacturing ‘Warm Asphalt’ are mixed at much lower temperatures than for
hot mixed asphalt and they do not need the same high temperature protocol for ‘Short-term
Ageing’; this part of the procedure is therefore amended for these binders. All the ageing is done
at the lower temperature.
Bituminous Emulsion Binders

4 Bitumen and polymer modified bituminous emulsions are first subjected to a ‘Rapid Recovery
Test’ which removes any water phase and volatile oils to produce a ‘Recovered Binder’. The
‘Recovered Binder’ has similar properties to that produced from other evaporative tests but is
achieved over a shorter period and the use of nitrogen, replacing air, reduces risks associated
with volatile oils in the oven. The ‘Recovered Binder’ in rheological terms is equivalent to that
recovered using EN 13074-1.
The ‘Ageing Profile’ is provided by continuing the ageing of the ‘Recovered Binder’ in the MRTFO
at a higher temperature, replacing the nitrogen gas with air and removing samples after specified
periods for testing. A ‘Stabilised Binder’, equivalent in rheological terms to that produced using
EN 13074-2, may be obtained from the ‘Ageing Profile’ Plot for a particular emulsion. Fluxed and
vegetal fluxed binders where volatile oils are thought to be present may also be tested using this
protocol.
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Preservatives
5. 40/60 penetration grade bitumen, used as a control, is subjected to ‘Short-term Ageing’ in the
MRTFOT followed by an extended period at a lower temperature to simulate the ageing of the
bitumen in a road pavement. This aged bitumen control is then cooled to ambient and treated
with the preservative. Most of the volatile oils are then removed by conditioning the samples in
the MRTFOT using a nitrogen blanket. The aged bitumen, treated by preservative, is then
subjected to further ageing with the MRTFOT. The properties of the aged bitumen, after action of
the preservative, are assessed by an ‘Ageing Profile’ using rheology and compared with the
‘Ageing Profile’ of the control bitumen.
Definitions
6. For the purposes of the procedures specified in this Clause the following definitions apply:
(i) Laboratory Sample: sample of bituminous binder intended for laboratory tests. It may be a
spot sample, a composite sample or a part thereof (a divided sample) as described in EN 58.
(ii) Test Sample: sample of bituminous binder produced by treatment or subdivision of a

laboratory sample for individual test (EN 58).
(iii) Recovered Binder: material remaining after removal of water or flux from a polymer
modified or unmodified bituminous emulsion or fluxed binder in the presence of nitrogen,
equivalent to the recovered binder using EN 13074-1.
(iv) Aged Binder: material remaining after the Ageing protocol.
(v) Short-term Aged Binder: material obtained during the MRTFOT which is equivalent to that
provided by EN 12607-1(RTFOT)
(vi) Long-term Aged Binder: material obtained during the MRTFOT which is equivalent to that
provided by EN 14769
(vii) Ageing Profile: graphical plot of performance-related results from samples tested during the
ageing protocol of this method. Performance-related testing is carried out using a Dynamic
Shear Rheometer (DSR), providing G* and phase angle data at a determined temperature
and frequency.
Test Apparatus (common to all protocols)

7. The following test apparatus shall be used:
(i) RTFOT apparatus to EN 12607-1.
(ii) Eight identifiable sample cans with threaded screw top lids (or other fixing system)
manufactured from aluminium and coated on all internal surfaces with polytetrafluoroethylene
(PTFE) with internal dimensions and aperture diameter (L2) as shown below:
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The taper in the throat (from L2 aperture to lid top) is 45 ± 5°
FIGURE 9/5: Sample Can and Lid (both with threads)

(iii) Eight screws manufactured from high quality stainless steel (surgical quality) complying with EN
10088-3, designation 1.4404 to a ‘fine machined finish’. All screws shall have dimensions:
diameter 12.2 ± 0.2mm, length 120 ± 0.5mm and have between 18 and 19 turns with a pitch
of 6 ± 0.2mm. The depth of cut shall be 2 ± 0.2mm with a semi-circular profile – see Figure
9/6. At one end, the screw shall have an unthreaded shank 10 ±0.5mm long and 7.5 ± 0.5mm
diameter, ending in a 45° cone, truncated to give a flat end at the apex 1.5 to 2.0mm diameter.
The minimum weight of a screw shall be 70g. The direction of screw shall be such that the
binder sample is drawn to the closed end of the sample can bottle when the can containing the
screw is rotated in the carousel. If the RTFO carousel rotates anticlockwise, viewed from the
front, screws with a right-hand thread are required and if the carousel rotates clockwise, screws
with a left-hand thread are required.
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Dimension a = 1.5mm to 2mm
FIGURE 9/6: Screw with Right-handed Thread (for anti-clockwise rotating carousel)
(iv) A spatula for removing the binder from the sample cans (a flat blade with a square end has
been found suitable).
(v) A balance accurate to 0.05g.
(vi) A timer capable of timing 100 minutes, accurate to 1 second in five minutes and, for the
MRTFOT, a timer capable of timing 25 hours to the same accuracy.
(vii) Nitrogen gas supply (for Rapid Recovery Test and preservative test).
(viii) Air supply, clean dry air (for MRTFOT).
(ix) An oven to pre-heat the sample cans and the binder to the required temperature.
Principle of the Ageing Profile Test for Polymer Modified and Unmodified Bituminous Binders for
Asphalts
8. A thin film of binder is rotated in aluminium sample cans with screw top lids, both coated
internally with PTFE (replacing glass bottles), using the Rolling Thin Film Oven Test (RTFOT)
apparatus, as described in EN 12607-1. Special screws are used to disturb the binder and
maintain a homogenous material during ‘Ageing’. Air is jetted over the film of binder for a much
longer period than in the conventional test and a lower temperature used in order to simulate the
‘ageing’ of the binder in the road after application. The screws accelerate the process, and are
necessary to maintain a homogeneous sample, especially when testing polymer modified
binders, which tend to form a skin and may phase separate in static ageing tests. The initial
conditioning test is to simulate the changes to the properties of the binder caused by the high
temperatures during manufacture, transport and laying, termed ‘Short-term Ageing’.
Further ageing is carried out at a reduced temperature and samples removed after set periods
and tested, so that an ‘Ageing Profile’ may be plotted.
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Test Procedure for Determining the Ageing Profile of Hot Mixed Polymer Modified and
Unmodified Bituminous Binders for Asphalts
9. Obtain a sample in accordance with EN 58. Stir the sample thoroughly to ensure it is completely
homogenized. If sub-samples are taken these shall have a minimum volume of 250ml. Ensure
that the RTFO is level so that the horizontal axes of the sample cans when in position in the
carousel are level. Pre-heat the oven to 163 ± 1°C, 1h is generally sufficient. For binders used to
manufacture warm mixed asphalts, substitute 135°C for 163°C throughout the test procedure.
Insert a stainless steel screw into each of the sample cans with the tapered end of the screw
towards the aperture of the container and record the mass of each assembly to 0.1g. Heat the
sample cans and the stainless steel screws to 163 ± 1°C for 90 ± 10 min.
Heat the sample to 170 ± 3°C. Thoroughly stir the sample to ensure homogeneity immediately
prior to decanting into the sample cans.
Pour 19.0 ± 0.5g of the sample into a preheated sample can and record the mass with lid.
Immediately after weighing, roll the sample cans to ensure distribution of the binder on the walls
of the can.
Mount the sample can in the carousel of the RTFO. Repeat for the remaining sample cans. Close
the door of the RTFO between mounting each sample can in the carousel. The period between
weighing the first sample can with binder and mounting of all the sample cans and the start of
the rotation of the carousel shall not exceed 20 minutes.
When the carousel is fully loaded, rotate the carriage assembly at a speed of 15.0 ± 0.2min-1.
Start the flow of air at a set rate of 4000 ± 200ml/min. Start the timer. Maintain the samples in
the oven and the air flowing for 45 ± 1min from the time the test temperature reaches 163 ±
1°C.
If the test temperature of 163°C is not reached within the first 15 minutes, discontinue the test.
After 45 ± 1min, sample cans (minimum 2) may be removed for testing and to determine mass
loss, if required.
This is the Short-term Aged binder, equivalent to RTFOT, EN 12607-1.
To continue the Ageing Profile test, maintain the temperature at 163°C for a further 15 minutes,
with the carousel rotating in the air flow, then reduce the temperature of the oven to 135 ± 1°C.
Note the time the RTFO takes to reach 135°C. Once the temperature has been achieved, continue
to rotate the samples in the air supply and remove sample cans to obtain samples of aged binder
as required for testing after three periods:
2h ± 10min; termed Aged2 Binder
6h ± 10min; termed Aged6 Binder: this is the Long-term Aged Binder, equivalent to PAV85.
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Other periods may be used either for convenience or to allow other degrees of ageing to be
investigated.
TABLE 9/31 Summary of Sampling Times
For binders used to manufacture ‘Warm Asphalt’, ‘Short Term Ageing’ at 163°C is not required,
therefore, replace 163ºC by 135ºC in Table 9/31 and report in addition Aged1 result (ageing at
135°C after a cumulative time of 1h ± 5min).
Handling of the Aged Binder

10. If the binder is to be tested immediately, remove a sample can from the carousel, extract the
screw using a small spatula and set the screw aside for cleaning. Place the sample can(s) in an
oven preheated to the softening point of the binder plus 100°C (if known), or 170°C if the
properties of the binder are unknown, for 20 ± 5min.
Place the containers on their sides in an oven. This allows the binder to drain to one side of the
container, which is more easily removed with the spatula.
At the end of 20 ± 5min, remove the sample can from the oven, unscrew the lid and, using the
spatula, scrape the aged binder from the sample can and prepare the test samples in accordance
with the relevant test method. Warming the spatula to the same temperature as the binder
facilitates removal of the binder.
If the aged binder from more than one sample can is needed to produce a test sample, combine
the aged binder from the sample cans and re-heat. Re-heating for testing shall be in accordance
with EN 12594, ensuring that aged binder is heated for no longer than is absolutely necessary.
The binder shall be thoroughly homogenized by stirring after heating and before being used for
testing, while taking care not to entrain any air.
If the binder is not to be tested immediately, remove a sample can from the RTFO, extract the
screw using a small spatula and set the screw aside for cleaning. Unscrew the lid and, using the
spatula, scrape the aged binder from the sample can and place on a silicon sheet. The binder
shall be sealed and stored at between 0°C to 5°C. The sample shall be re-heated in accordance
with EN 12594 and homogenised immediately before testing.
If the aged samples are to be transferred to another laboratory for testing, they shall not be
subjected to temperatures greater than ambient after ageing and before testing, and the delay
before testing shall not exceed 120 hours.
The thermal history of the sample shall be recorded.
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Principle of the Ageing Profile Test for Polymer Modified or Unmodified Bituminous Emulsions or
Fluxed Binders
11. A thin film of binder is rotated in aluminium sample cans with screw top lids, both coated
internally with PTFE (replacing glass bottles), using the RTFOT apparatus, as described in EN
12607-1, to evaporate water from bituminous emulsions and/or the light solvent or highly
volatile fraction from fluxed or other binders. Special screws are used to disturb the binder and
maintain a homogenous material during breaking and/or curing. Nitrogen gas instead of air is
jetted over the film of bituminous binder at a lower temperature in order to minimize ageing
effects and simulate the condition of the binder soon after application. The first part of the
process is carried out with the RTFO set at 85°C to prevent frothing of the binder. The
temperature is then increased to 135°C to drive off any remaining water and/or solvent to
provide the ‘Recovered Binder’, which is equivalent to the recovered binder obtained from EN
13074‑1. The ‘Ageing Profile’ is provided by continuing the ageing of the binder in the RTFO at
135°C, replacing the nitrogen gas with air and removing samples after specified periods for
testing.
Test Procedure for Recovery and Ageing of Bituminous Emulsion and Fluxed Binders
12. Obtain a sample in accordance with EN 58. Stir the sample thoroughly to ensure it is completely
homogenized. The temperature of the binder sample shall not be less than 70% of the normal
application temperature in degrees Celsius and shall be recorded (for example, high binder
content surface dressing emulsion may require a minimum of 60°C, or a polymer modified fluxed
binder, 130°C). The sample history if known shall be recorded; this is important, as some ageing
may have occurred. If sub-samples are taken these shall have a minimum volume of 250ml.
Ensure that the oven is level so that the horizontal axes of the sample cans, when in position in
the carriage, are level. Pre-heat the oven to 85 ± 1°C, 1h is generally sufficient.
Insert a stainless steel screw into each of the sample cans with the tapered end of the screw
towards the aperture of the container and record the mass of each assembly to 0.1g. Heat the
sample cans, lids and the stainless steel screws to 85 ± 1°C for 90 ± 10min.
Heat the sample to the application temperature of the binder, or, if this is not known, to 60 ± 3°C.
Thoroughly stir the sample to ensure homogeneity immediately prior to decanting into the
sample cans, taking care to minimise loss of water content and/or any volatile oil. Some cut-back
binders and other binders such as primers having low flash points are not suitable for this test. If
there is any doubt concerning the volatile nature of the sample for test, a suitable flash point test
must be carried out before proceeding with the ‘Ageing Profile test’ or heating to 60°C.
Pour 19.0 ± 0.5g of the sample into a preheated sample can and record the mass. Immediately
after weighing, roll the containers to ensure distribution of the binder round the bottle.
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Start the flow of nitrogen at a set rate of 4000 ± 200ml/min. Start the timer. Maintain the
samples in the oven and the nitrogen flowing for 75 ± 1min from the time the test temperature
reaches 85°C. At this stage there may still be residual water in emulsion binders, especially those
with high polymer contents.
If the test temperature of 85°C is not reached within the first 10 minutes, discontinue the test.
Increase the temperature of the oven to 135 ± 1°C. Note the time the RTFO takes to reach 135°C.
Once the temperature has been achieved, continue to rotate the carousel for a further 30 ± 1min
at 135°C. At the end of the 30 minutes, turn off the nitrogen. If required, sample cans may be
removed, and the samples may be used for testing or determination of mass loss. This is the
‘Recovered Binder’ and is equivalent to that obtained using EN 13074-1.
The Ageing Profile can be determined by maintaining the RTFO at 135°C and switching to an air
supply set at 4000 ± 200ml/min.
Rotate the samples in the air supply and remove sample cans to obtain samples of aged binder
as required for testing after three periods:
5h ± 10min; termed Aged5 Binder, and
22h ± 10min, termed Aged22 Binder
Other periods may be used either for convenience or to allow different degrees of ageing to be
investigated. Longterm Ageing equivalent to PAV85 has been found to occur at 22 hours. It takes
longer to achieve than with asphalt binder, because there is no short-term ageing at 163°C. The
PAV85 ageing period is not thought to be relevant for emulsion binders used in most road
applications. If samples at 22 hours are not required to simulate PAV85, a combined sample
from three sample cans may be useful at 3 and 5 hours, or another aged sample from two cans,
say at 4 hours, may be obtained for test to enhance the ‘Ageing Profile’
TABLE 9/32 Summary of Sampling Times
Handling of the Recovered Binder

13 If the binder is to be tested immediately, remove a sample can from the carousel, extract the
screw using a small spatula and set the screw aside for cleaning. Immediately transfer the sample
can (s) to an oven and heat until at the required test temperature. Place the containers on their
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sides in an oven. This allows the binder to drain to one side of the container, which is more easily
removed with the spatula.
Unscrew the lid of the sample can and, using the spatula, scrape the recovered binder from the
sample can and place in the test apparatus. Warming the spatula to 135°C facilitates removal of
the binder.
If the recovered binder from more than one sample can is needed to produce a test sample,
combine the recovered binder from the sample cans and re-heat. Re-heating for testing shall be
in accordance with EN 12594, ensuring that recovered binder is heated for no longer than is
aolutely necessary. The recovered binder shall be thoroughly homogenized by stirring after
heating and before being used for testing, while taking care not to entrain any air.
If the recovered binder is not to be tested immediately, remove a sample can from the RTFO,
extract the screw using a small spatula and set the screw aside for cleaning. Unscrew the lid and,
using the spatula, scrape the recovered binder from the sample can and place on a silicon sheet.
The binder shall be sealed and stored at between 0°C to 5°C. The sample shall be re-heated in
accordance with EN 12594 and homogenised immediately before testing.
If the recovered samples are to be transferred to another laboratory for testing, they shall not be
subjected to temperatures greater than ambient after recovery and before testing, and the delay
Handling of the Aged Binder

14. If the binder is to be tested immediately, remove a sample can from the carousel, extract the
screw using a small spatula and set the screw aside for cleaning. Place the sample can (s) in an
oven preheated to the softening point of the binder plus 100°C (if known), or 170°C if the
properties of the binder are unknown, for 20 ± 5min. Place the sample cans on their sides in an
oven. This allows the binder to drain to one side of the sample can, which is more easily removed
with the spatula.
At the end of 20 ± 5min, remove the sample can from the oven, unscrew the lid and, using the
spatula, scrape the aged binder from the sample can and prepare the test samples in accordance
If the aged binder from more than one sample can is needed to produce a test sample, combine
the aged binder from the containers and re-heat. Re-heating for testing shall be in accordance
If the binder is not to be tested immediately, remove a sample can from the RTFO, extract the
screw using a small spatula, and set the screw aside for cleaning. Unscrew the lid and, using the
Page 36 of 42
spatula, scrape the aged binder from the sample can and place on a silicon sheet. The binder
shall be sealed and stored at between 0°C to 5°C. The sample shall be re-heated in accordance
with EN 12594 and homogenised immediately before testing.
Principle of Assessing the Action of Preservatives using the MRTFOT

15. A thin film of 40/60 penetration grade binder is rotated in aluminium sample cans, coated
internally with PTFE (replacing glass bottles), using the Rolling Thin Film Oven Test (RTFOT)
apparatus, as described in EN 12607-1. Special screws are used to disturb the binder and
maintain a homogenous material during conditioning. The bitumen is subjected to ‘Short-term
Ageing’ followed by an extended period in the RTFO to simulate the ageing of the bitumen in a
road pavement. The properties of the ‘Long-term Aged’ bitumen may be determined at this
stage. The aged bitumen control in the remaining samples is then cooled to ambient, treated
with the preservative and left for 24 hours. Most of the remaining highly volatile oils are
subsequently removed by conditioning the samples in the RTFO using a nitrogen blanket. The
aged bitumen, treated by preservative, is then subjected to further ageing with the Modified
RTFO. The properties of the aged bitumen, after action of the preservative, are assessed by an
‘Ageing Profile’ test, using rheology values of complex shear (stiffness) modulus G* and phase
angle δ, in accordance with EN 14770. Cohesion durability may also be determined.
Test Procedure for Determining the ‘Ageing Profile’ of Aged Paving Grade Bitumen as a Control
Treated with a Preservative
16 Obtain a sample of 40/60 paving grade binder in accordance with EN 58. Stir the sample
thoroughly to ensure it is completely homogenized. If sub-samples are taken these shall have a
minimum volume of 250ml.
Ensure that the RTFO is level so that the horizontal axes of the sample cans when in position in
the carousel are level. Pre-heat the oven to 163 ± 1°C, 1h is generally sufficient.
Insert a weighed stainless steel screw into each of the sample cans with the tapered end of the
screw towards the aperture of the can lid; record the mass of each assembly to 0.1g. Heat the
sample cans, lids and the stainless steel screws to 163 ± 1°C for 90 ± 10min.
Heat the sample to the maximum storage temperature of the binder. Thoroughly stir the sample
to ensure homogeneity immediately prior to decanting into the sample cans.
Pour 19.0 ± 0.5g of the sample into a preheated sample can and record the mass. Immediately
after weighing, roll the sample can on the bench to ensure distribution of the binder round the
walls of the can.
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Start the flow of air at a set rate of 4000 ± 200ml/min. Start the timer. Maintain the samples in
the oven and the air flowing for 45 ± 1min from the time the test temperature reaches 163°C.
If the test temperature of 163°C is not reached within the first 10minutes, discontinue the test.
After 45± 1min at 163 ± 1°C, sample cans (minimum 2) shall be removed for testing and to
determine mass loss. This is the ‘Short-term Aged Binder’.
Reduce the temperature of the oven to 135 ± 1°C. Note the time the RTFO takes to reach 135°C.
Once this temperature has been achieved, continue to rotate the samples in the air supply for
240 ± 10min. At the end of this period, remove the sample cans from the RTFO and determine
their mass loss.
Remove the screws and weigh to determine the mass of binder retained on each identified screw.
A quantity of binder shall be removed from each sample can, which shall be:
8 ± 1g, less the mass of binder retained on the particular screw removed.
It may be necessary to warm the sample cans to facilitate the removal of the screws and binder.
After removing the binder, lay the sample cans on their sides and allow them to cool to ambient
temperature.
Add 10 ± 0.5g of preservative to each sample container and swill the preservative around the
sample container for approximately 15 seconds. Determine the mass of each sample can.
The sample cans with the binder and preservative are stored on their sides, with the pooled
binder at the bottom, in a ventilated fume cupboard at ambient temperature for 24 hours. This
process allows any very low flashpoint volatile oil to safely evaporate and consequently reduce
the amount of hydrocarbon solvent within the sample can.
Pre-heat the oven to 50 ± 1°C and transfer the sample cans from the fume cupboard to the RTFO
carousel. Start the carousel and jet nitrogen at 4000 ± 200ml/min over the sample cans for 120
± 10min.
Identify and weigh eight clean screws and heat the screws to 135°C.
After 2 hours, the RTFO temperature is raised from 50°C to 135°C and air jetted at 4000 ±
200ml/min substituted for the nitrogen supply. Note the time when the oven achieves 135°C.
When the RTFO has reached 135°C, stop the carousel and add a preheated screw to each sample
can, with the tapered end of the screw towards the aperture/lid of the sample can (and noting
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which screw is added to which sample can). Restart the carousel and continue the conditioning of
the samples at 135°C in air jetted at 4000 ± 200ml/min for 120 ± 10 min.
Remove the sample cans from the RTFO to obtain samples of aged binder as required for testing
and determine the mass of each sample can.
The control bitumen may be substituted with a binder recovered from a road or from a laboratory
aged sample, in which case the ‘Short-term Ageing’ and subsequent ageing protocol are not
carried out, because the binder will already have been aged and heated. In this case, the
recovered binder sample is heated in accordance with EN 12594 and 11 ± 0.5g added to heated
cans (135°C) which are then rolled to achieve a film around the walls.
After this, they are cooled, 10 ± 0.5g preservative added and the preservative treated samples
subjected to the same Ageing Profile protocol as described above.
Handling of the Preservative Treated Aged Bitumen

17 If the binder is to be tested immediately, remove a container from the carousel, extract the screw
using a small spatula and set the screw aside for cleaning. Place the sample can (s) in an oven
preheated to 140°C for 20 ± 5min. Place the containers on their sides in the oven. This allows the
binder to drain to one side of the container, which is more easily removed with the spatula.
At the end of 20 ± 5min, remove the container from the oven, unscrew the lid and, using the
spatula, scrape the aged binder from the container and prepare the test samples in accordance
If the aged binder from more than one container is needed to produce a test sample, combine
the aged binder from the containers and re-heat. Re-heating for testing shall be in accordance
If the binder is not to be tested immediately, remove a container from the RTFO, extract the
screw using a small spatula and set the screw aside for cleaning. Unscrew the lid and, using the
spatula, scrape the aged binder from the container and place on a silicone sheet. The binder shall
be sealed and stored at between 0°C to 5°C. The sample shall be re-heated in accordance with
EN 12594 and homogenised immediately before testing.
before testing shall not exceed 120 hours. The thermal history of the sample shall be recorded.
Report
Sample description (e.g. type, age/condition and source).

18. The Ageing Profile test procedure adopted for the work.
Page 39 of 42
The change in mass of the sample from each stage of the recovery and /or ageing protocol shall
be plotted to develop an Ageing Profile for mass change.
Similarly, results of tests (for example G* using EN 14770), carried out after each stage of
recovery and /or ageing protocol, shall be plotted to develop an Ageing Profile for that property.
These results shall include:
• A plot of G* (0.4Hz) over a range of temperatures between 0°C and 60°C
• A plot of phase angle (0.4Hz) over a range of temperatures between 0°C and 60°C
• G* and phase angle at 0.4Hz and 25°C
• Temperature (0.4Hz) where the phase angle is 45 degrees (Viscous Elastic Transition (VET)
temperature)
• G* (0.4Hz) at the VET temperature where phase angle is 45 degrees
For Clause 930 hard grade binder samples and other samples where they are considered to have
a softening point above 60°C the temperature range shall be increased to 80°C.
The thermal history of the samples, if they are not tested immediately, shall be reported.
956 & 957 (05/18) Not used
958 Modified Binder Storage Stability Test
Scope
1. This test determines the susceptibility of a pre-blended modified binder to separation or
instability during prolonged storage at high temperature.
Summary of Method
2. A sample of modified binder shall be contained in a closed vessel of specific dimensions and
shall be maintained at 160 ± 2°C for 7 days ± 2 hours. A binder sample shall then be taken from
the top and bottom thirds of the vessel and both samples shall be tested for compliance with the
binder specification.
Apparatus
3. The apparatus shall consist of:
(i) Cylinder, made of heat resistant glass, 190 ± 30 mm long and 65 ± 5 mm internal diameter
having a removable lid, flush fitting to exclude air when the cylinder is filled with binder, and
provided with three drain valves, one at the base, the other two spaced equally down the side
of the cylinder, to allow the sample to be divided into three equal portions as in sub-Clause 4
(vii) of the procedure.
Page 40 of 42
Alternatively, a thin-wall sheet metal tube or similar vessel such as a 500 ml beverage can, of
similar dimensions to the glass cylinder, and having a similarly removable lid, fitted either with or
without drain-valves.
(ii) Oven, electrically heated, fan assisted, and capable of maintaining a temperature of 160 ±
2 °C, having interior dimensions not less than 330 mm from the top of the heating element
to the top of the chamber and not less than 305 mm in width and depth.
(iii) Tube holder, made of metal, that will hold either the glass cylinder or sheet metal can, in a
vertical position, such that the base of the cylinder or can is not in direct contact with the
oven floor.
(iv) Apparatus for determining the penetration and softening point of bitumen in accordance
with EN 1426 and EN 1427.
(v) Transfer dishes (3), made of metal, each of a capacity sufficient to hold at least one-third of
the test sample.
Test Procedure
4. The procedure shall be as follows:
(i) The bulk sample of modified binder shall be obtained by sampling in accordance with EN
58.
(ii) Place the bulk sample of modified binder and the glass cylinder (or metal tube or
equivalent vessel) in the preheated oven at 160 ± 2°C for a period not exceeding 3.75 ±
0.25 hours.
(iii) Remove the bulk sample from the oven and thoroughly mix by stirring to ensure obtaining
a representative test sample.
(iv) Remove the glass cylinder (or metal tube or equivalent vessel) from the oven and
completely fill with the modified binder test sample to allow no air space when the lid is
fitted.
(v) Support the filled cylinder in a vertical position in the holder and transfer to the oven
which shall be controlled at a temperature of 160 ± 2°C and allow to stand undisturbed for
a period of 168 ± 2 hours.
(vi) If a vessel having drain-valves has been used for the test proceed using Method A below,
otherwise proceed using Method B.
(vii) Method A
(a) Remove the glass cylinder (or alternative approved vessel) from the oven, keeping the
cylinder vertical.
Page 41 of 42
(b) Open the uppermost drain-valve and run off the top third portion of the test sample
into a transfer dish for testing.
(c) Open the middle drain-valve and run off the middle third portion of the test sample
into a suitable container and discard.
(d) Open the lower drain-valve and run off the bottom third portion of the test sample
into a transfer dish for testing.
(viii) Method B
(a) Remove the tube or vessel containing the test sample from the oven and allow it to cool at
room temperature for 2 ± 0.25 hours whilst maintaining the vessel vertical in the holder.
(b) When the vessel of modified binder has cooled to ambient temperature, remove it from
the tube holder and make two cuts through the vessel and the sample at positions one-
third and two-thirds of the length from, and parallel, to the base.
(c) Retain the top and bottom thirds of the test sample for further testing and discard the
middle third. (ix) Determine the penetrations and softening points of the top and bottom
thirds of the test sample, in accordance with EN 1426 and EN 1427.
Reporting
5. For both the top and bottom thirds of the test sample the following shall be reported:
(i) The penetration, to EN 1426.
(ii) The softening point, to EN 1427.
(iii) Whether Method A or Method B was used.
(iv) The location and date of obtaining the bulk sample, and the dates of test
Page 42 of 42
Appendix F. SERIES 1000 CONCRETE PAVEMENTS

Series 100 GENERAL REQUIREMENTS
Goods, Materials, Sampling and Testing Goods and Materials

1. The Contractor shall provide the Overseeing Organisation with details of the suppliers from
whom he proposes to purchase the goods and materials necessary for the execution of the
works prior to their inclusion in the works. Unless otherwise detailed in contract specific
Appendix 1/5 the Contractor shall keep and maintain supply records of all works, goods and
materials incorporated into the works. These shall include:
(i) supplier’s details, including name/company name and address;

(ii) date of supply to site;
(iii) manufacturer’s information and safety information;
(iv) details of where the goods are incorporated into the works.
These details shall be provided to the Overseeing Organisation by the Contractor upon request
and at completion of the works.
Sampling and Testing

2. The testing scheduled in contract specific Appendix 1/5, including sampling and provision of
the associated samples, shall be undertaken by the Contractor. The Contractor shall carry out
each of the tests required in contract specific Appendix 1/5 within an elapsed time from the
taking of the respective samples which shall be reasonable in all the circumstances unless
otherwise prescribed by the Overseeing Organisation. The Contractor shall supply to the
Overseeing Organisation, within 24 hours of the completion of each test, a copy of the results.
The following operations are not included in contract specific Appendix 1/5:
(i) checking, inspecting, examining, measuring (except in connection with testing);

(ii) trials and demonstrations;
(iii) routine testing carried out by manufacturers and suppliers in compliance with a
specified standard or specification;
(iv) testing of plant.
3. Where required in contract specific Appendix 1/5 test certificates and/or product certification
complying with the provisions of the relevant standard or specification where applicable and
certifying that the goods or materials meet the specified requirements, shall be supplied to the
Overseeing Organisation by the Contractor at least four weeks prior to the incorporation of the
goods or materials in the works. Where goods or materials are required to be CE marked or
where the Contractor proposes to use CE marked goods or materials the Contractor shall
supply the Overseeing Organisation with the CE marking information including any relevant
instructions and safety information at least four weeks prior to the incorporation of the goods
or materials in the works. This information shall be in English.
4 Where required in contract specific Appendix 1/5 tests and associated sampling shall be
undertaken by testing laboratories accredited in accordance with EN ISO/IEC 17025. The
accreditation shall be by a European accreditation organisation which is party to a multi-lateral
agreement (MLA) with any other equivalent International Accreditation Forum MLA signatory
with a scope that includes EN ISO/IEC 17025.
5 Where goods or materials are accepted on the basis of an equivalent standard, quality
management scheme, product certification scheme or product acceptance scheme as provided
for in Clause 104, testing and sampling as specified in or applicable to such an equivalent
standard quality management scheme, product certification scheme or product acceptance
scheme is accepted and shall be substituted for those specified in contract specific Appendices
1/5 and 1/6 respectively.
6 Where testing is undertaken by a supplier or manufacturer in accordance with the Contract,

other than for products which are CE marked, the Contractor shall ensure that each supplier
and manufacturer will admit the Overseeing Organisation’s representative to his premises
during normal working hours for the purposes of inspecting, selecting the samples and
witnessing the testing.
8 Where testing or in use operation of works, goods or materials which are CE marked identifies
failure of the CE marked works, goods or materials, the Contractor shall make formal
notification of the failure to the relevant Trading Standards office. The Contractor shall copy
such correspondence to the Overseeing Organisation.
SPECIFICATION APPENDIX 1/5 – COMPLIANCE TESTING
Appropriate contract compliance testing should be scheduled for all relevant works, goods or
materials on site and as installed including those falling under the Construction Products
Regulation
CLAUSE REQUIREMENTS TEST FREQUENCY TEST COMMENTS

OF TESTING CERTIFICATE
Series Tests on exposed LWD / CBR 3 test per 500m2 Required
600 formations
Series
700
710 Constituent Quality control 1 per 200 Required
materials in tonnes or per
recycled aggregate location if less
and recycled than 200 tonnes
concrete aggregate
Series Unbound crushed aggregate mixtures for Subbase
800
801 General Water-soluble 1 per 400 Site [Acceptance
802 requirements for sulphate (WS) content tonnes or per testing can be
unbound mixtures (N) location if less scheduled for
803 for use adjacent to than 400 tonnes materials not
807 cement bound
falling under the
materials, concrete
pavements, Construction
structures or Products
products Regulation
(CPR)]
[Appropriate
contract
compliance
testing should
be scheduled for
all products
including those
falling under
CPR]
Oxidisable sulphides 1 per 400 Site
(OS) content and total tonnes or per
potential sulphate location if less
(TPS) content (N) than 400 tonnes
General Frost heave (N) 1 per source Supplier
requirements for
unbound mixtures 1 per 200
beneath the Grading’s and fines tonnes or per
Site
surface of a road content location if less
pavement. than 200 tonnes
1 per 200
tonnes or per
Plastic index (N) Site
location if less
than 200 tonnes
Resistance to 1 per source Supplier

fragmentation (N) then 6 monthly
Resistance to wear – 1 per source Supplier

micro-Deval test then 6 monthly
Resistance to freezing
and thawing
1 per source Supplier
(magnesium sulphate
soundness) (N)

Water absorption
then monthly
Volume stability of 1 per source Supplier

blast furnace slags then 6 monthly
Volume stability of Supplier

1 per source
steel (BOF and EAF)
then 6 monthly
slags
CBR (N) Supplier
(samples conditioned 1 per source
by soaking for 96 then monthly
hours prior to test)

OMC/mc (N)
then monthly

Density (N)
then monthly
1 per source Supplier/Site

Water absorption
then monthly
Series 800. Cement and other Hydraulically Bound mixture

810 General Binder content For Audit Test Required
821 Requirements for Purpose Only
Cement and other
822 Hydraulically Required Required
Coefficient of linear
823 Bound mixtures expansion
830
Tests for control and Required Required
831 checking of HBM
832 Tests specified in
834 Table 8/16
835 Immediate Bearing Required Required
Index Category Test
BS EN 13286-47
Compressive strength Required Required
BS EN 13286-41 (N)
Modulus of elasticity Required Required
BS EN 13286-43 (N)
Surface modulus Required Required
Specified in Clause
884 (N)
Deformation Required Required
resistance specified in
Clause 886
840 Hydraulically Audit test Required
Stabilised Solis Binder content
purposes only
Performance Required
required
assessment specified
in Table 8/15
1 per 400 Required
tonnes or per
Total potential sulfate
location if less
content (N)
than 400
tonnes*
Surface modulus Required
Specified in Clause required
884 (N)
Deformation Required
resistance specified in required
Clause 886
SERIES AGGREGATES FOR BITUMINOUS MATERIALS
900
901 Resistance to Required
Resistance to
925 fragmentation Monthly
fragmentation (N)
(hardness)
937
938 Required
Soundness (N) 1 per source
943 Resistance to
freezing and
thawing (durability) Required
Water absorption (N) 1 per source
Cleanness Sieve test (mass Required

passing 0.063 mm Monthly
sieve) (N)
Required
Shape Flakiness index (N) Monthly
Blastfurnace slag 1 per 500 Required

Bulk density (N)
tonnes
Once every 4 Required

Soundness (N)
months
Dicalcium silicate 1 per 500 Required

disintegration (N) tonnes
Required
Iron disintegration (N)
1 per 500 Required

Bulk density (N)
tonnes
Steel slag
1 per 500 Required
Volume stability (N)
tonnes
Resistance to Required
1 per source
polishing (PSV) (N)
Coarse aggregate
for surface courses Required
Resistance to surface
1 per source
abrasion (AAV) (N)
Binders for 1 per 750 Required

bituminous Penetration (N)
tonnes
materials
1 per 750 Required
Softening point (N)
tonnes
903 to Bituminous Grading (N) For Audit Test Required

907, mixtures purpose only
909 to
912
914, 916
925, 926
929, 930
937, 938
941, 943
946 to
948
For Audit Test Required
Binder Content (N) purpose only
930 EME 2 Permanent Works - In Void content to

Base and Binder situ air void content be measured in
Course Asphalt (N) accordance with
Concrete clause 929.3.
(Design Mixtures)
Permanent Works - As required
Refusal air void
content (N)
Permanent Works – 1 per source
Deformation
resistance
Deformation As required
resistance (design)
921 Surface
Volumetric Patch (N) As required
macrotexture
920 Bond coats, tack coats and other bituminous sprays
Binder 1 per product
Product Identification
per source
1 per product
Vialit cohesion
per source
1 for each
binder and
Accuracy of spread
sprayer per
month
Rate of spread 1 per week
Every
Penetration at 25°C
manufactured
and 5°C (N)
batch
941 Stone Mastic Asphalt Surface Course
SMA surface Permanent Works As required

Course - In situ air void
content (N)
Permanent Works As required
- Deformation
resistance
SERIES Pavement Quality Concrete and Constituents
1000
1001 Portland Source approval 1 per Required
1030 source/month
cement CEM I
1044 Portland
blastfurnace
cement
Blastfurnace
cement CEM
III/A Portland
pfa cement CEM
II/B-V
Pozzolanic
cement CEM
IV/A Portland
cement with
microsilica
Pulverised-fuel 1 per Required
source/month
ash
Ground 1 per Required
source/month
granulated blast
furnace slag
Admixtures 1 per Required
source/month
Mixing Water Sulphate content 1 per Required

source/month
Aggregates Resistance to 1 per source Required

freezing and
thawing
magnesium sulfate
soundness
Water absorption 1 / 1000t
Flakiness index (N) 1 / 1000t
Shell content (N) 1 per source

Source
Resistance to 1 per source approval
fragmentation
Resistance to 1 per source
polishing PSV
Resistance to 1 per source
abrasion AAV
Grading and fines 1/500t
content
Chloride content 1/1000t
Total sulphur (TS) 1/1000t

and acid-soluble
sulphate (AS)
content
Flint coarse Water absorption 1/500t
aggregate
containing white
flints
Sand Acid-soluble 1/500t
material
Blast furnace Bulk density 1/500t
slag
Dicalcium silicate 1/500t
disintegration
Iron disintegration 1/500t
Total Sulphur (TS) 1/500t

and Acis-soluble
sulphates (AS)
content
Pulversied fuel 1/500t
ash
1002, Pavement Air content test As required Required
1003, table 10/10
1004, concrete
1044
Density As required
table 10/10
strength As required
table 10/10
1005 Consistence Degree of As required Required
table 10/10
compatibility.
(Compaction
index)
vebe
slump
1011, Dowel Bars and Load test 1 per
1012 arrangement
supporting
Product
cradles certificate
scheme applies
Sheathed dowel Bond stress 4 bars
bars
See clauses
Cranked tie bars Bend test 4 bars 1011.5 - 7
(coated)
Salt fog cabinet 4 bars
1015 Joint filler board Weathering tests 3 per source Required Normally
undertaken by
manufacturer
Compression 4 per source

recovery
Extrusion
Cork filler board Immersion in water 2 per source
Immersion in acid 2 per source
1016 Applied sealants 1 per 1000m or

1017 1 per day
Resilience 1 per 1000m or

1 per day
Compression Compression set 1 per type of

seal
seals
Immersion in oil 1 per type of
seal
Self expanding Test specified in 1 per type of

seal
cork seal Clause 1017
1026 Surface BS EN 12036-1 1 set per day Required
1044 macrotexture volumetric patch
1027 Aluminised Efficiency index 1 per source Required
curing
compound
1030 Wet lean Density As required in
table 10/9
concrete
Cube strength
1043 Foamed Cube strength 2 cubes per 12
cub m
concrete
1080 Early strength Compressive As required
concrete for strength
slab
replacement
* indicates that the frequency of testing is given for general guidance and is only indicative of the frequency that
may be appropriate. Where materials are known to be marginal or if initial results show them to be such the
frequency of testing will be increased.
Notes:
1 Unless otherwise stated above, all sampling and testing in this Appendix shall be by the Contractor.
2 Tests comparable to those specified in this Appendix will be necessary for any equivalent work, goods
or materials proposed by the Contractor.
3 (N) indicates an accredited laboratory sampling and test report or certificate is required.
4 Unless otherwise shown in this Appendix tests for work, goods or materials as scheduled under any one
Clause are required for all such work, goods or materials in the Works.
5 Cube strength tests are not required for concrete complying with Clause 2602.
6 Unless otherwise shown in this Appendix test certificates for work, goods or materials as scheduled
under any one Clause are required for all such work, goods or materials in the Works.
Appendix G. SERIES 100 CONTRACTOR TESTING

ROAD PAVEMENTS – CONCRETE MATERIALS
Contents
Clause Title
1000 General
1001 Strength Classes of Concrete and Constituent Materials for Pavement Layers
1002 Air Content
1003 Density
1004 Pavement Concrete Strength
1005 Consistence (Workability
1006 Not Used
1007 Separation and Waterproof Membranes
1008 Steel Reinforcement
1009 Transverse Joints
1010 Longitudinal Joints
1011 Dowel Bars
1012 Tie Bars
1013 Joint Grooves
1014 Groove Formers and Bottom Crack Inducers
1015 Joint Filler Board
1016 Preparation and Sealing of Joint Grooves
1017 Joint Seals
1018 Joints at Manhole and Gully Slabs
1019 Inspection of Dowel Bars
1020 Side Forms, Rails and Guide Wires
1021 to 1022 Not Used
1023 Transport and Delivery
1024 Construction by Machine

1025 Construction by Small Paving Machines or Hand Guided Methods
1026 Finished Surface Requirements
1027 Curing
1028 Trial Length
1029 Not Used
1030 Lower Strength Concrete
1039 Summary of Rates for Sampling and Testing Concrete for Pavement Layers
1043 Foamed Concrete
1044 Not Used
1045 Weather Conditions for Laying of Cementitious Materials
1048 Use of Surfaces by Traffic and Construction Plant

1079 Inspection and Testing of Existing Pavement
1090 Crack Sealing
1093 Fine Milling

ROAD PAVEMENTS – CONCRETE MATERIALS
1000 General
1. This Series is part of the Specification. Whilst this Series is particularly relevant to the subject
matter in its title it shall be read in conjunction with all other Series relevant to the Specification
for the Particular works to be undertaken.
2. The Contractor shall undertake the testing of concrete pavements as detailed in the Clauses of
this Series unless detailed otherwise in contract specific Appendix A or Appendix G.
1001 Strength Classes of Concrete and Constituent Materials for Pavement Layers
1. Concrete in rigid or rigid composite pavements shall be one of the classes in accordance with
the pavement design alternatives permitted in contract specific Appendix A.
2. Unless otherwise specified in contract specific Appendix A, concrete shall conform with the
requirements of BS EN 13877-2 and the requirements of this Series. The constituents of the
concrete shall conform with BS EN 206 and BS 8500-1 and BS 8500-2 and BS EN 13877-1 and
the requirements of this Series.
Cement
3. The general term ‘cement’ in this Series means any of the materials in (i) or the combinations in
(ii) below:
(i) Cements Complying with:
(a) Portland-slag cement CEM II/A-S and CEM II/B-S BS EN 197-1
(b) Blast furnace cement CEM III/A and CEM III/B BS EN 197-1
(c) Portland-fly ash cement CEM II/A-V and CEM II/B-V BS EN 197-1
(d) Pozzolanic cement CEM IV/A BS EN 197-1
(ii) Combinations
(a) Portland cement CEM I with ground granulated blast furnace slag (GGBS) for use with
Portland cement CEM I BS EN 197-1, BS EN 15167-1, and BS EN 15167-2
(b) Portland cement CEM I with fly ash (fa) for use as a cementitious component in structural
concrete BS EN 197-1 BS EN 450-1 and BS EN 450-2
(c) Portland cement CEM I with pozzolanic additive having current certification complying
with a product acceptance scheme as described in sub-Clauses 104.15 and 104.16. BS EN
197-1
(iii) In each cubic metre of fully compacted concrete the cement content shall be in accordance with
Appendix A.
(iv) When used, the proportion of silica fume to CEM I shall be 10 ± 1%.
(v) For materials required to comply with BS EN 197-1 and/or BS EN 450-1 the Contractor shall
submit the relevant material declarations of performance to the Overseeing Organisation prior to
the inclusion of the materials into the works. The declarations of performance shall demonstrate
that the materials meet the requirements for the specification.
Water
4. Water from a water company supply may be used without testing. Water from other sources may
be used if it conforms to BS EN 1008. The water content shall be the minimum required to
provide the specified consistence for full compaction of the concrete to the required density, as
determined by trial concrete mixes or other means, and the maximum free water/cement ratio
shall be 0.40 for strength classes C35/45. The requirements for standardised prescribed
concrete shall be in accordance with BS EN 206 and BS 8500-2.
Admixtures
5. Plasticisers or water reducing admixtures shall comply with BS EN 934-2. Admixtures containing
calcium chloride shall not be used.
6. The Contractor shall submit the declaration of performance for each admixture to the
Overseeing Organisation prior to the incorporation of the admixture into the works. The
declaration of performance shall demonstrate that the admixture meets the specification
requirements.
Aggregate
7. Aggregates for all pavement concrete, including Lower Strength, shall comply with BS EN
12620. Crushed concrete, which complies with the quality and grading requirements of BS EN
12620 and Table 2 of BS 8500-2, may also be used in all pavement concretes except aggregate
concrete surface complying with Clause 1044. Alternatively, coarse aggregate may be crushed
air-cooled blast furnace slag complying with BS EN 12620 and shall be Category FI50 or FI35.
FA when used as part of the aggregate shall comply with BS EN 450. Once the appropriate
gradings have been determined they shall not be varied without the approval of the Overseeing
Organisation. Irrespective of source, the aggregate will be considered suitable if:
(i) the resistance to fragmentation complies with category LA35 of BS EN 12620 clause 5.2 for
concrete surface slabs and LA40 of BS EN 12620, clause 5.2 for concrete bases and Lower
Strength concrete.
The Contractor shall submit the declaration of performance for each aggregate to the
Overseeing Organisation prior to the incorporation of the aggregate into the works. The
declaration of performance shall demonstrate that the aggregate meets the specification
requirements.
The water absorption (WA) of the coarse aggregate shall be determined and declared in
accordance with BS EN 12620. Where recycled coarse aggregate or recycled concrete
aggregate is used in this Series, it shall comply with the limits specified in Table 2 of BS 8500-
2 and the constituents shall be declared.
8. The maximum size of coarse aggregate (D) shall not exceed 40 mm. When the spacing between
longitudinal reinforcement is less than 90 mm, the maximum size of coarse aggregate (D) shall
not exceed 20 mm.
9. Sand (i.e., fine aggregate) containing more than 25% by mass of acid-soluble material as
determined in accordance with BS EN 196-2, in either the fraction retained on, or the fraction
passing the 0.500 mm sieve, shall not be used in the top 50 mm of surface slabs. This
requirement will not apply for pavements with an exposed aggregate concrete surface
constructed to Clause 1044 or if it can be shown that the sand (ie fine aggregate) retained on,
or the fraction passing the 0.500 mm sieve, contains less than 25 per cent by weight of calcium
carbonate.
10. The water absorption of flint coarse aggregate containing white flints for use in concrete surface
slabs, when determined in accordance with BS EN 1097-6 shall not exceed:
3.5% for any separate nominal size fraction.
2.0% for the total combination of coarse aggregates in the proportions to be used in the
concrete.
Contract compliance tests shall be carried out during stockpiling or paving, once a week, or at a
lesser rate when authorised by the Overseeing Organisation.
Source of Recycled Aggregates

11. Where recycled coarse aggregate or recycled concrete aggregate is used, only crushed concrete
resulting from reclamation or processing of concrete previously used in construction which
originates from appropriate identified structures with a known history of use shall be used.
Chloride Content
12. The chloride ion content of the aggregate to be used in concrete shall be as stated in BS EN 206.
The chloride class of reinforced concrete or concrete containing embedded metal shall be Cl
0,04 and unreinforced concrete shall be Cl 1,0. The water soluble chloride content of the
aggregates shall be determined in accordance with BS EN 12620 and declared. The acid soluble
chloride content of recycled aggregates shall be determined in accordance with BS EN 12620
and declared.
Chemical Requirement
13. Acid-soluble sulfate: Acid-soluble sulfate content of the aggregates and filler aggregates for
concrete pavements, including Lower Strength Concrete, shall comply with BS EN 12620, clause
6.3.1 and shall be Category AS1,0 for air-cooled blast furnace slag and for other aggregates
Category AS0,2.
13. Total sulfur: Total sulfur content of recycled coarse aggregates, recycled concrete aggregates,
aggregates and filler aggregates, shall comply with BS EN 12620, clause 6.3.2.
1002 not used
1003 Density
The Permanent Works

1. With the exception of the trial length, the density shall be measured by non-destructive
methods.
2. A correlation shall be established for each mix and each measuring device and shall be
established from the trial length where cores have been taken. The correlation established shall
be provided to the Overseeing Organisation before commencement of the permanent works.
The device chosen shall achieve a repeatability of at least 90%.
3. The concrete density measured by the device shall not be less than 95% of the average density
of at least six fully compacted saturated moulded specimens made from the same mix in the
trail area and tested at the same age.
4. The density shall be measured routinely at a distance of 0.8 to 1.2m from the edge of the slab
and at the rate shown in Table 10/12.
5. If a non-compliance in an area is indicated, then cores shall be taken as required in the trial area.
Density measurements shall be taken at the locations at which material is placed that has been
sampled for cube testing.
The Trial Length

6. In the trial length as required in Clause 1028 the density of a saturated core cut from the full
depth of the concrete pavement shall not be less than 95% of the average density of at least six
fully compacted saturated moulded specimens made from the same concrete and tested at the
same age.
7. The density of the concrete pavement shall be determined in accordance with BS EN 13877-2.
The density of a saturated core cut from the full depth of the concrete pavement shall be
determined in accordance with BS EN 12390-7. The determination of the saturated density of
the fully compacted moulded specimens shall be in accordance with BS EN 12350-1, BS EN
12390-1 and BS EN 12390-2.
8. The core shall have an average diameter of at least four times the nominal maximum aggregate
size, and in any case not less than 100 mm diameter. Where different concrete mixes are used
in separate layers, the density of each layer shall be separately determined by splitting or cutting
the cores between the layers.
9. Cores shall be taken at the rate given in Clause 1028 for the trial. If the density of any core is
below the minimum required, the concrete across the whole width of the slab constructed at the
time relating to that core shall be removed. In unreinforced concrete the whole slab length
between joints shall be removed. For reinforced slabs, in order to determine the limit of the
defective area of concrete which shall be removed, additional cores shall be taken at 5 m
intervals on each side of any defective core until concrete of satisfactory density is found.
Defective areas shall be made good with new material in accordance with the specification.
10. In calculating the density, allowance shall be made for any steel in the cores.
11. Core holes shall be reinstated with compacted concrete with mix proportions of 1 part of
Portland cement CEM I: 2 parts of sand: 2 parts of 10 mm single sized coarse aggregate by mass.
1004 Pavement Concrete Strength

1. A trial length shall be constructed in accordance with Clause 1028.
2. Concrete cores of 150mm diameter shall be taken from the trial length, cured and tested in
accordance with BS EN 12504-1 with the exception that the core shall be cured under water at
20°C ±2°C from as soon as practically possible. A minimum of 9 cubes and 6 cores taken and at
a minimum of 3 locations shall be taken from the trial length. For each set of 6 cores, three shall
be tested at 7 days and three at 28 days
3. The end preparation of the core shall be by grinding and the height/diameter (h/d) ratio of the
tested specimen shall be between 1 and 2.
4. The ratio of core density to non-destructive density measurement taken within 1m of the core
location shall be determined from the trial length as described in Clause 1003.
5. If multi-layer construction is being used the cores shall be tested for adequacy of bond between
layer in accordance with BS EN 13877-2 with fv=1mPa at 7 days.
6. Once a satisfactory trial construction has been achieved strength monitoring of the main
construction will be by the use of cubes cast at the rate of a set of 3 cubes for every 400 m2 of
concrete laid. A minimum of 6 sets of cubes shall be taken each day with each set being from a
different delivery of concrete.
7. If the 7-day cube strength fails to conform with the requirements of BS EN 206 table B1
sampling and testing for, and compliance with the specified characteristic core strength of
designed concretes shall be undertaken by compressive strength testing in accordance with BS
EN 13877-2 on cores cut from the full depth of the slab.
8. The strength of the concrete slab shall be evaluated in accordance with BS EN 206 (Annex B –
Identity Testing: Table B.1).
9. To assess the time for use of a concrete slab by traffic, the strength development rate may be
predetermined by cubes stored at 20°C made from trial concrete mixes and maturity meters
placed in the pavement. Alternatively, pairs of cubes may be made for each 400 m² or less and
stored alongside the pavement in containers or in such a way that their sides are well insulated.
If thermal insulation is used for accelerated curing the cubes shall be similarly insulated. Pairs
of cubes shall be tested at the intervals specified in contract specific Appendix A.
1005 Consistence (Workability)
1. The consistence shall be determined by the Degree of Compactibility (Compaction Index) test
in accordance with BS EN 12350-4, or the Vebe test in accordance with BS EN 12350-3.
Alternatively for concrete class C16/20 or below, consistence may be determined by the slump
test in accordance with BS EN 12350-2. The sampling for all concrete classes shall be
undertaken in accordance with BS EN 12350-1 and the rate of testing in accordance with Table
17 of BS EN 206. Consistence shall be carried out at the point of placing, in conjunction with
tests for strength and any tests for air content. The consistence shall be maintained at the
optimum within the limits specified in BS EN 206.
2. If any determination of consistence gives a result outside the tolerance, a further test shall be
made immediately on the next available load of concrete. The average of the two consecutive
results and the difference between them shall be calculated. If the average is not within the
tolerance or the difference is greater than 0.1 for CI or 20 mm for slump, or 6 seconds for Vebe,
subsequent samples shall be taken from the delivery vehicles, which shall not be allowed to
discharge into the works until compliance with the specification has been established.
1006 Not Used
1007 Separation and Waterproof Membranes

1. Over a bound sub-base a waterproof membrane shall be provided, which shall be a bituminous
spray in accordance with Clause 920. Where a bituminous spray has been used to cure cement-
bound material or low strength concrete then only those areas, which have been damaged or
degraded, shall be resprayed after making good.
1008 Steel Reinforcement
General
1. Reinforcement shall comply with any of the following standards and shall be cut and bent in
accordance with BS 8666. The reinforcement materials shall be obtained from an organisation
which has current, valid product acceptance scheme certification, such as CARES certification, in
accordance with sub-Clause 104.16. Re-bending of carbon steel bars and fabric reinforcement
on site shall not be permitted:
Hot Rolled and Cold Worked Carbon Steel Bars
(i) BS EN 10080 and BS 4449 (Grade B500B or B500C).
Steel Wires
(ii) BS EN 10080 and BS 4482 (Ribbed Grade B500).
Steel Fabric
(iii) BS EN 10080 and BS 4483 (Grade B500A, B500B or B500C). Steel fabric reinforcement
shall have a minimum nominal bar size of 6 mm (8 mm for Grade B500A). Steel fabric
reinforcement shall be delivered to site in flat mats or pre-bent.
2. For hot rolled and cold worked carbon steel bars, and for steel fabric reinforcement, the bond
property requirements for BS 4449 shall be complied with based on the surface geometry
requirements of that standard.
For steel wire, the bond property requirements of BS 4482 shall be complied with based on the
surface geometry requirements of that standard
3. Spacing of bars shall not be less than twice the maximum size of aggregate used. Laps in
longitudinal bars shall be not less than 35 bar diameters or 450 mm whichever is greater. There
shall be a minimum of 1.2 m longitudinally between groups of transverse laps or laps in
prefabricated reinforcement sheets.
4. Laps in any transverse reinforcement shall be a minimum of 300 mm. Where prefabricated
reinforcement sheets are used and longitudinal and transverse laps would coincide, no lap is
required in the transverse bars within the lap of the longitudinal reinforcement. These transverse
bars may be cropped or fabricated shorter so that the requirements for cover are met.
Alternatively, prefabricated sheets incorporating splices (ie flying ends) may be used to provide
nesting of reinforcement in both directions at lap positions. The lengths of the laps shall be the
minimum values previously stated.
5. If the reinforcement is positioned prior to concreting, it shall be fixed on chairs conforming with
the requirements of BS 7973 and retained in position at the required depth below the finished
surface and distance from the edge of the slab so as to ensure that the required cover is achieved.
Reinforcement assembled on site shall be tied, or firmly fixed, at sufficient intersections to
provide sufficient rigidity to ensure that the reinforcement remains in the correct position during
construction of the slab.
6. Alternatively, when a reinforced concrete slab is constructed in two layers, the reinforcement in
the form of prefabricated sheets may be placed on or into the bottom layer which shall be spread
and compacted to such a level that it will support the reinforcement without distortion at the
required position in the slab. The sheets shall be tied together at overlaps and after the second
layer has been spread and compacted, the reinforcement shall have the required cover.
7. When a reinforced concrete slab is constructed at maximum width as in Clause 1010 the
transverse reinforcement in the centre of each slab width shall be a minimum of 12 mm nominal
diameter bars at 600 mm centres. This reinforcement shall be at least 600 mm longer than one
third of the width of the slab and be lapped to other transverse reinforcement bars or sheets or
be continuous across the whole width of each slab.
Jointed Reinforced Concrete Slabs

8. The reinforcement shall be so placed that after compaction of the concrete, the cover below the
finished surface of the slab is 50 ± 10 mm for slabs less than 200 mm thick, 60 ± 10 mm for
slabs 200 mm or more but less than 270 mm thick, 70 ± 20 mm for slabs 270 mm thick or more.
The vertical cover between any longitudinal joint groove forming strip and any reinforcement or
tie bars shall be a minimum of 30 mm. Any transverse bars shall be at right angles to the
longitudinal axis of the carriageway.
Any transverse reinforcement shall terminate at 150 ± 25 mm from the edges of the slab and
longitudinal joints, where tie bars as in Clause 1012 are used. No longitudinal bars shall lie within
150 mm of a longitudinal joint. The reinforcement shall terminate 150 mm ± 50 mm from any
transverse joint, excluding emergency construction joints.
1009 Transverse Joints
General
1. Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and
shall be contraction, expansion or warping joints at the spacings described in contract specific
Appendix A, such that for unreinforced concrete slabs the length/width ratio shall be not greater
than 2.0. The spacings may be increased by 20% if limestone coarse aggregate is used
throughout the depth of the slab.
2. Joints in the surface slab and sub-base shall be staggered so that they are not coincident
vertically and are at least 1 m apart.
3. Transverse joints shall be straight within the following tolerances along the intended line of the
joint, which is the straight line transverse to the longitudinal axis of the carriageway, except at
road junctions or roundabouts where the positions shall be as shown on the drawings.
(i) deviations of the filler board or bottom crack inducer from the intended line of the joint
shall be not greater than ± 10 mm;
(ii) the best fit straight line through the joint groove as constructed shall be not more than
25 mm from the intended line of the joint;
(iii) deviations of the joint groove from the best fit straight line of the joint shall be not
greater than 10 mm.
4. Transverse joints on each side of a longitudinal joint shall be in line with each other and of the
same type and width. The position of the joints relative to manholes and gullies shall be in
accordance with Clause 1018.
5. Concrete pavement layers shall be isolated from fixed structures by expansion joints, or
earthworks or a granular layer over the structure, or by bridge-type expansion joints, or by
lengths of fully flexible pavement construction. End of pavement surface slabs shall have a
transition bay as shown on the drawings, leading into the fully flexible construction.
6. Transverse joints shall have a sealing groove which shall be sealed in compliance with Clause
1016.
Contraction Joints
7. Contraction joints shall consist of:
(i) a sawn joint groove complying with Clause 1013;
(ii) dowel bars complying with Clause 1011;
(iii) a sealing groove complying with Clause 1016.
Expansion Joints
8. Expansion joints shall consist of:
(i) a joint filler board complying with Clause 1015;
(ii) dowel bars complying with Clause 1011;
9. The filler board shall be positioned vertically within the prefabricated joint assemblies along the
line of the joint within the tolerances given in sub-Clause 3 of this Clause, and at such depth
below the surface as will not impede the passage of the finishing beams on the paving machines.
The joint filler board together with the sealing groove shall provide a complete separation of
adjacent slabs and any spaces around dowel bars and between the sub-base and the filler board
shall be packed with a suitable compressible material after fixing the joint assembly
Warping Joints
10. Warping joints shall consist of:
(i) a sawn joint groove complying with Clause 1013;
(ii) tie bars complying with Clause 1012;
Construction Joints
11. Construction joints made at the end of a working day in unreinforced concrete slabs and jointed
reinforced concrete slabs shall be contraction joints. In the event of mechanical breakdown of
the concreting machinery, or at the onset of adverse weather, emergency joints may be formed.
12. Emergency joints in unreinforced concrete slabs shall be contraction joints not less than 2.5 m
from the preceding or succeeding joint position.
13. Emergency joints in jointed reinforced concrete slabs shall be not less than 2.5 m from the
preceding or succeeding joint position. The stop end formwork shall be sufficiently rigid to
ensure that dowel bars, tie bars or reinforcement will be held in position in compliance with the
specification, and placed in such a position that it permits the longitudinal reinforcement to
project through the joint for a distance of at least 750 mm.
1010 Longitudinal Joints
General
1. Sawn or wet-formed longitudinal joints shall be provided in surface slabs between or at the
centre of traffic lanes within the allowable positions as shown on the drawings, so that bay widths
are not greater than 4.2 m (or 5.0 m with limestone aggregate) for unreinforced slabs, or 6 m
(or 7.6 m with limestone aggregate) for reinforced concrete surface slabs with transverse
reinforcement as in sub-Clause 1008.7. The aspect ratio of concrete bays shall not exceed
1:1.75.
Joints in the surface slab, base or sub-base shall be staggered so that they are not coincident
vertically and are at least 300 mm apart.
2. Wet-formed longitudinal joints shall consist of wet-formed joint grooves complying with Clause
1013, a bottom crack inducer complying with Clause 1014 and tie bars complying with Clause
1012, except where transverse reinforcement is permitted in lieu.
3. Longitudinal joints shall be constructed within the following tolerances:
(i) deviations of the bottom crack inducer from the intended line of the joint, parallel to the
axis of the road shall be not greater than ± 13 mm;
(ii) the joint groove shall be located vertically above the bottom crack inducers within a
horizontal tolerance of ± 25 mm;
(iii) the best fit line along the constructed joint groove, shall be not more than 25 mm from
the intended line of the joint;
(iv) deviations of the joint groove from the best fit line of the joint shall be not greater than
10 mm.
4. Sawn longitudinal joints shall consist of joint grooves complying with Clause 1013
5. Tie bars may be replaced by continuous transverse reinforcement across the joints in
continuously reinforced concrete slabs which are constructed in more than one lane width in one
operation, provided that the transverse reinforcement is a minimum of 12 mm diameter bars at
600 mm centres. The transverse reinforcement in these circumstances shall be protected by
suitable bituminous paint or equivalent coating for a distance of at least 75 mm either side of
the joint.
1011 Dowel Bars

1. Dowel bars shall meet the requirements of BS EN 13877-3 with a minimum tensile strength of
250MPa and shall be free from oil, dirt, loose rust and scale. They shall be straight, free of burrs
and other irregularities and the sliding ends sawn cleanly with no protrusions outside the normal
diameter of the bar. For expansion joints, dowel bars shall be 32 mm diameter. For contraction
joints, dowels shall be 32mm diameter.
The Contractor shall submit the declaration of performance for the dowel bars to the Overseeing
Organisation prior to the incorporation of the dowel bars into the works. The declaration of
performance shall demonstrate that the dowel bars meet the specification requirements.
2. Dowel bars shall be supported on cradles in prefabricated joint assemblies positioned prior to
construction of the slab. For contraction joints, as an alternative to prefabricated assemblies,
dowel bars may be mechanically inserted with vibration into the concrete by a method which
ensures full re-compaction of the concrete around the dowel bars and the surface finished by a
diagonal finishing beam, or a longitudinal oscillating float travelling across the slab.
3. Dowel bars shall be positioned at mid-depth from the surface level of the slab ± 20 mm. They
shall be aligned parallel to the finished surface of the slab, to the centre line of the carriageway
and to each other within the following tolerances:
(i) for bars supported on cradles prior to construction of the slab and for inserted bars in two
layer construction prior to placing the top layer:
(a) all bars in a joint shall be within ± 3 mm per 300 mm length of bar;
(b) two thirds of the bars shall be within ± 2 mm per 300 mm length of bar;
(c) no bar shall differ in alignment from an adjoining bar by more than 3 mm per 300 mm
length of bar in either the horizontal or vertical plane;
(ii) for all bars, after construction of the slab:
(a) twice the tolerances for alignment as in (i) above;
(b) equally positioned about the intended line of the joint within a tolerance of 25 mm.
4. Cradles supporting dowel bars shall not extend across the line of the joint
5. Dowel bars, supported on cradles in assemblies, when subjected to a load of 110 N applied at
either end and in either the vertical or horizontal direction (upwards and downwards and both
directions horizontally) shall not deflect more than the following limits:
(i) two thirds of the number of bars of any assembly tested shall not deflect more than 2 mm
per 300 mm length of bar;
(ii) the remainder of the bars in that assembly shall not deflect more than 3 mm per 300 mm
length of bar.
6. The assembly of dowel bars and supporting cradles, including the joint filler board in the case
of expansion joints shall have the following degree of rigidity when fixed in position:
(i) For expansion joints the deflection of the top edge of the filler board shall be not greater than
13 mm, when a load of 1.3 kN is applied perpendicular to the vertical face of the joint filler board
and distributed over a length of 600 mm by means of a bar or timber packing, at mid depth and
midway between individual fixings, or 300 mm from either end of any length of filler board, if a
continuous fixing is used. The residual deflection after removal of the load shall be not more
than 3 mm.
(ii) The joint assembly fixings to the sub-base shall not fail under the 1.3 kN load applied for
testing the rigidity of the assembly but shall fail before the load reaches 2.6 kN.
(iii) The fixings for contraction joints shall not fail under a 1.3 kN load and shall fail before the
load reaches 2.6 kN when applied over a length of 600 mm by means of a bar or timber packing
placed as near to the level of the line of fixings as practicable.
(iv) Failure of the fixings shall be deemed to be when there is displacement of the assemblies by
more than 3 mm with any form of fixing, under the test load. The displacement shall be
measured at the nearest part of the assembly to the centre of the bar or timber packing.
7. Dowel bars shall be covered by a flexible polymeric corrosion resistant coating, bonded onto the
previously cleaned bar. The coating shall be smooth and free of indentations. During coating,
the bar shall be supported at each end. Minimum thickness shall be 0.3 mm. The coating shall
also be able to withstand 250 hours immersion in a salt fog cabinet complying with BS EN ISO
7253, without showing any visible crazing or corrosion of the protected bar. The coated bar shall
comply with the following pull out test:
(i) Four bars shall be taken at random from stock and without any special preparation shall be
coated as required in this Clause. The dowel bars which have been coated shall be cast centrally
into concrete specimens 150 x 150 x 450 mm, made of the same concrete mix proportions to
be used in the pavement, but with a maximum aggregate size of 20 mm and cured in accordance
with BS EN 12390-2. At 7 days a tensile load shall be applied to achieve a movement of the bar
of at least 0.25 mm. The average bond stress to achieve this movement shall be not greater than
0.89 N/mm2.
8. For expansion joints, a closely fitting cap 100 mm long consisting of waterproofed cardboard
or suitable synthetic material shall be placed over one end of each dowel bar. An expansion
space 10 mm greater than the thickness of the joint filler board shall be formed between the
end of the cap and the end of the dowel bar.
1012 Tie Bars

1. Tie bars in transverse or longitudinal joints shall conform to Clause 1008, in accordance with the
requirements given below and Table 10/5.
2. Tie bars for use across joints shall have corrosion protection in the form of a flexible polymeric
corrosion resistant coating, bonded centrally onto 200 mm of the previously cleaned centre
section of the bars.
Where tie bars are to be cranked for construction joints and later straightened, the coating shall
be shown to be capable of being straightened through 90 degrees without cracking.
The coating for both straight and cranked bars after straightening shall be able to withstand 250
hours immersion in a salt fog cabinet complying with BS EN ISO 7253, without showing any
visible crazing or cracking, or corrosion of the protected part of the bar
3. Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid
assemblies with adequate supports and fixings to remain firmly in position during the
construction of the slab.
4. Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from
above using a method which ensures re-compaction of the concrete around the tie bars.
5. At longitudinal construction joints, tie bars may be adequately fixed to side forms or inserted
into the side of the slab by a method which ensures re-compaction of the concrete around the
tie bars and adequate bond.
6. Tie bars in warping joints shall be positioned from the top surface of the slab within +20, -10
mm of the mid depth of the slab.
Tie bars in other joints shall be positioned and remain within the middle third of the slab depth,
approximately parallel to the surface and approximately perpendicular to the line of the joint,
with the centre of each bar on the intended line of the joints within a tolerance of ± 50 mm, and
with a minimum cover of 30 mm below any top crack inducer of joint groove for slabs 200 mm
thick or more, or 20 mm for slabs up to 200 mm thick.
7. At transverse construction joints in continuously reinforced concrete, tie bars shall be 1.5 m long
and of the same Grade and size as the longitudinal reinforcement and shall be fixed at twice the
normal spacing midway between the longitudinal reinforcement bars so that 750 mm ± 50 mm
extends each side of the joint at the same level as the longitudinal reinforcement and be tied to
the transverse reinforcement. Where paving from a construction joint is not resumed within 5
days, an extra longitudinal reinforcement bar 8 m long shall be lapped and tied to each tie bar.
These extra bars may be combined with the tie bars. Where the spacing between longitudinal
reinforcement and the extra 8 m long bars is less than 90 mm, the nominal size of aggregate
shall be 20 mm for a sufficient number of concrete batches to complete that section of
pavement.
TABLE 10/5: Tie Bar Details

8. Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be
placed at the same level as the transverse reinforcement and tied to the longitudinal
reinforcement.
1013 Joint Grooves
General
1. Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.
2. Transverse joint grooves which are initially constructed less than the full width of the slab shall
be completed by sawing through to the edge of the slab and across longitudinal joints as soon
as any forms have been removed and before an induced crack develops at the joint.
Sawn Transverse and Longitudinal Joint Grooves

3. Sawing shall be undertaken as soon as possible after the concrete has hardened sufficiently to
enable a sharp edged groove to be produced without disrupting the concrete and before random
cracks develop in the slab. The grooves shall be between 1/4 and 1/3 of the specified depth of
the slab and of any convenient width not less than 3 mm. The sealing groove may be sawn to
the required width later. Expansion joint sealing grooves shall be sealed as soon as practical after
sawing.
Wet-formed Longitudinal Joint Grooves

4. When slabs are constructed in more than one lane width in one operation a joint groove shall be
formed by inserting a groove former ahead of the finishing beams from dispenser. The concrete
so displaced shall be recompacted by a vibrating compactor or similar device, at least 300 mm
wide operating symmetrically along the line of the joint. After finishing the concrete, the groove
forming strip shall be in the correct position and alignment, within 10° of the vertical, and to
sufficient depth below the surface to allow for the passage of the finishing beam within the range
0-3 mm below the finished level of the slab. Groove forming strips in wet-formed longitudinal
joint grooves shall be left in place.
Construction Joint Grooves in Surface Slabs

5. The grooves shall be formed by fixing a groove-former or strip or cork seal along the top edge
of the slab already constructed, before concreting the adjacent slab. Where the edge of the
concrete is damaged it shall be ground or made good before fixing the groove forming strip.
Alternatively, the subsequent slab may be placed adjacent to the first and a sealing groove sawn
later in the hardened concrete to the minimum depth required in Table 10/6 or to the
manufacturer’s instructions if greater, and to sufficient width to eliminate minor spalling of the
joint arris, up to a maximum of 25 mm for longitudinal joints and 40 mm for transverse joints.
The joint shall be sealed in compliance with Clause 1016.
1014 Groove Formers and Bottom Crack Inducers
General
1. Except where joint grooves are sawn, a bottom crack inducer shall be provided at each
longitudinal joint position.
2. The bottom crack inducer shall be triangular or inverted Y-shaped fillet, with a base width not
less than the height, made of timber or rigid synthetic material. It shall be firmly fixed to the
sub-base so as to remain in position during the whole process of constructing the slab.
3. The combined depth of groove formers and bottom crack inducers shall be between 1/4 and
1/3 of the depth of the slab and the difference between the depth of the groove former and the
height of the bottom crack inducer shall not be greater than 20 mm.
Longitudinal Joints
4. Groove forming sealing strips for wet-formed longitudinal joints shall be of firm compressible
strips of ethylene vinyl acetate foam of minimum density 90 kg/m3, or synthetic rubber, or
equivalent material. They shall have a minimum thickness of 5 mm and shall be sufficiently rigid
to remain vertical and straight in the concrete without curving or stretching. They shall be
inserted continuously along the joint.
1015 Joint Filler Board

1. Joint filler board for expansion joints and manhole and gully slab joints shall be 25 mm thick
unless otherwise shown in the drawings, within a tolerance of ± 1.5 mm. It shall be a firm
compressible material or a bonded combination of compressible and rigid materials of sufficient
rigidity to resist deformation during the passage of the concrete paving plant. The depth of the
joint filler board for manhole and gully slabs shall be the full depth of the slab less the depth of
the sealing groove. In expansion joints, the filler board shall have a ridged top as shown on the
drawings, except where a sealing groove former is indicated on the drawings.
Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the
sheathed dowel bar.
2. The joint filler board shall meet the requirements given when tested in accordance with the
procedures in the following sub-Clauses:
(i) Weathering Test

(a) Three specimens, each 115 mm square ± 2.5 mm, shall be placed in a ventilated drying
oven maintained at a temperature of 55°C ± 5°C for 7 days, after which they shall
immediately be immersed in water at room temperature of between 16°C and 21°C for 24
hours. They shall then be subjected to five cycles of freezing and thawing in the following
manner.
(b) The specimens shall be placed in a watertight weathering test pan having a ribbed
bottom and a fitted slotted lid designed to hold the three specimens vertically on edge. The
pan shall be filled with water to half the depth of the specimens and then frozen to minus
7°C or below, for at least four hours after the initial freezing of the water. The pan shall then
be placed in a water bath maintained at 18°C to 38°C without disturbing the specimens and
shall remain there for one hour after thawing has completed. The pan and specimens shall
then be returned to the refrigerator and freezing and thawing shall be repeated in precisely
the same manner until five cycles of the process have been completed. The specimens shall
be removed from the pan and air dried at room temperature for 48 hours before
examination.
(c) The material shall be deemed to have passed the weathering test if the specimens show
no signs of disintegration or shrinkage.
(ii) Compression and Recovery Test

(a) Two of the specimens which pass the weathering test, and two new specimens, each
trimmed to 100 mm square ± 0.5 mm, maintained at room temperature and humidity for 24
hours, shall be subjected to three applications of load at 24 hour intervals in a compression
test machine complying with BS EN ISO 7500-1, with auxiliary platens 100 mm2, minimum
13 mm thick.
During each application of load each specimen shall be compressed to 50% of its original
thickness at a rate of strain of 1.3 mm per minute. The load required to achieve this amount
of compression shall be:
• not less than 0.7 N/mm2 nor more than 10 N/mm2 for material to be used in
pavements; and
• not less than 0.7 N/mm2 and not more than 0.4 N/mm2 for material to be used in bridge
joints.
The load shall be released immediately the required degree of compression is reached and after
the third application a recovery period of 30 minutes shall be allowed after which the thickness
of the specimen shall be measured.
(b) This thickness, expressed as a percentage of the original thickness, is the recovery’ value
of the specimen. The thicknesses shall be measured to an accuracy of 25 micron. The two
new specimens shall be weighed before and after testing. The difference in mass shall be
determined with an accuracy of 0.1% and shall be expressed as a percentage of the original
mass of the specimen.
(c) The material shall be deemed to have passed the test if all four specimens have recovery
values of at least 70% and the two new specimens have not suffered a reduction of mass in
excess of 1%.
(iii) Extrusion Test

(a) The third sample which passes the weathering test shall be trimmed to 100 mm square
± 0.5 mm and be subjected to the following extrusion test.
(b) The extrusion mould shall be 100 mm x 100 mm (+ 0.5 mm, - 0) internally, of sufficient
depth to test the sample as received, open on one side only and fixed rigidly to a base plate.
The mould shall be provided with a closely fitting pressure plate which shall fit without
binding, and with an accurate horizontal measuring dial gauge or measuring device accurate
to 25 microns. The specimen shall be mounted in the extrusion mould and loaded once as
described in the compression and recovery test. The extrusion at the open side of the mould
shall be measured with the gauge when the specimen is compressed to 50% of its original
thickness and before release of the load.
(c) The material shall be deemed to have passed the test if the extrusion of the free edge
does not exceed 6 mm.
1016 Preparation and Sealing of Joint Grooves
General
1. All transverse joints in surface slabs, except for construction joints in CRCP shall be sealed using
one of the joint seals described in Clause 1017. Additionally longitudinal joints which are sawn
or widened, shall be sealed.
Preparation of Joint Grooves for Sealing

2. Joint grooves shall be prepared in accordance with BS 5212 : Part 2 and sub-Clauses 3 to 8 of
this Clause.
3. That part of the groove former used to form the sealing groove, or any temporary seal shall be
removed cleanly without damaging the joint arrises to a minimum depth of 25 mm where
compression seals are used or otherwise to such depth as will provide an applied seal to the
dimensions shown in Table 10/6, after allowing for any necessary caulking material described
in sub-Clause 6 of this Clause. If joint grooves are not initially constructed to provide the
minimum dimensions for the joint seals as given in Table 10/6, they shall be widened by sawing.
Joint grooves formed by tapered formers need not be widened. The sealing grooves shall be
cleaned out immediately after sawing using high pressure water jets, to remove all slurry from
the joint, before the slurry hardens.
4. If rough arrises develop when grooves are made, they shall be ground to provide a chamfer
approximately 5 mm wide. If the groove is at an angle up to 10° from the perpendicular to the
surface, the overhanging edge of the sealing groove shall be sawn or ground perpendicular. If
spalling occurs or the angle of the former is greater than 10° the joint sealing groove shall be
sawn wider and perpendicular to the surface to encompass the defects up to a maximum width,
including any chamfer, of 40 mm for transverse joints and 25 mm for longitudinal joints. If the
spalling cannot be so eliminated, then the arris shall be repaired by suitable thin bonded arris
repair using cementitious materials as specified in Clause 1032.
5. For applied sealants the sides of the joint sealing groove shall be scoured by dry abrasive
blasting. This shall not be carried out before the characteristic compressive strength of the
concrete is expected to reach 15 N/mm². When compression seals are used, the sides of the
groove may be ground, or wire brushed.
6. For hot and cold applied sealants, compressible caulking material, debonding strip or tape or
cord compatible with the sealant, of a suitable size to fill the width of the sealing groove, shall
be firmly packed or stuck in the bottom of the sealing groove to such a depth so as to provide
the correct depth of seal as described in Table 10/6 with the top of the seal at the correct depth
below the surface of the concrete.
7. All grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil-free
compressed air. The groove shall be clean and dry at the time of priming and sealing.
8. For applied sealants the joint grooves shall be primed with the relevant primer for the hot or
cold applied sealant in accordance with the manufacturer’s recommendations and with BS 5212:
Part 2, except that when necessary the joint grooves may be primed and sealed earlier than 14
days after construction, as soon as the grooves have been grit-blasted and cleaned.
TABLE 10/6: Dimensions of Applied Joint Seals
Sealing with Applied Sealants

9. Sealing shall be carried out continuously along the full length of joint in any one rip, except for
remedial areas. When hot or cold applied sealants are used the sealant shall be applied within
the minimum and maximum drying times of the primer recommended by the manufacturer.
Priming and sealing with applied sealants shall not be carried out when the naturally occurring
temperature in the joint groove to be sealed is below 10°C except between 8°C and 10°C it may
be carried out when the temperature is rising.
10. Hot-applied sealants shall be prepared and applied in accordance with the manufacturer’s
instructions.
11. The components of cold-applied sealants shall be thoroughly mixed in the correct proportions
in accordance with the manufacturer’s instructions. As soon as possible after mixing and within
the working life of the sealant, the material shall be dispensed into the joint, or applied using a
caulking gun, to the correct level below the concrete surface. The tack-free time shall be
achieved within 3 hours for machine dispensed material, or within 12 hours for hand applied
material
Testing of Applied Sealants
12. No additional testing of sealants is required provided a declaration of performance for cold-
applied sealants in accordance with BS EN 14188-2 or for. BS EN 14188-1 has been provided
to the Overseeing Organisation.
Sealing with Compression Seals

13. When compression seals are used, the widths of the seal shall be selected in relation to the width
of the sealing groove, the bay lengths and manufacturer’s recommendations so that the
estimated maximum width of the joint opening shall be not more than 70% of the original width
of the seal, the estimated maximum width being calculated on the basis of a movement of 4 mm
per 10 m run of slab. The maximum calculated width of sealing groove shall be 30 mm. The
depth of groove shall be such that the contact face of the seal with the side of the groove shall
be not less than 20 mm and that the top of the seal shall be a minimum of 3 mm below the
surface of the concrete.
14. Compression seals shall be inserted into the grooves without prior extension or rotation and,
where recommended by the manufacturer, with a lubricant adhesive which is compatible with
the seal and the concrete.
The adhesive shall be applied to both sides of the sealing groove or the seal, or to both. The seal
shall be positioned with its axis perpendicular to the concrete surface. Excess adhesive on top of
the seal shall be removed to prevent adhesion of the top faces of the seal under compression.
Except when compression seals are used in longitudinal joints the transverse joint seal shall be
continuous across the slab and the longitudinal joint groove forming strips shall be cut to the
required depth after the concrete has hardened for the transverse seal to be inserted. If
compression seals are used in longitudinal joints where the grooves have been sawn after
construction of the slab they shall be continuous across transverse joints, with the transverse
seals butted and fixed to the longitudinal seals with adhesive.
1017 Joint Seals

1. Joint seals shall consist of hot or cold applied sealants or compression seals complying with this
Clause.
For hot-applied and cold applied sealants the Contractor shall submit the declaration of
performance for each sealant to the Overseeing Organisation prior to the incorporation of the
sealant into the works. The declaration of performance shall demonstrate that the sealant meets
the specification requirements.
Hot-applied Sealants
2. Hot-applied sealants shall be Type N1 or Type F1 or Type F2, as stated in contract specific
Appendix A, and conforming to BS EN 14188-1.
3. For joints between concrete surface slabs and bituminous surfacing, hot applied Type N1
sealants conforming to BS EN 14188-1 shall be used. Alternatively, polymer modified bitumen
sealing strips may be used and shall be applied in accordance with the manufacturer’s
instructions. Hot-applied Type N1 sealants may be used in joints in asphalt kerbs laid on
concrete pavements.
Cold-applied Sealants
4. Cold-applied sealants shall be Type N conforming to BS EN 14188-2 except that Type F shall
be used for lay-bys and hardstandings.
5. For joints in kerbs and joints other than in pavements, seals may be any of the pavement sealants
if they have the suitable characteristics for the application, or gunning grade cold applied
plasticised bituminous rubber sealant or gunning grades of two part polysulphide-based
sealants complying with BS 4254 may be used.
Alternatively, polyurethane-based sealing compounds may be used provided their performance

is not inferior to BS 4254 material
Compression Seals
6. Compression seals shall be pre-compressed neoprene impregnated expanding foam sealing
strip having current product acceptance scheme certification in accordance with sub-Clauses
104.15 and 104.16 such as HAPAS certification, or rubber seals made of polychloroprene
elastomers complying with BS 2752 and conforming with the requirements of ASTM Standard
D2628-91.
Seals of butadiene-acrylonitrile or other synthetic rubbers may be used if certificates are

produced to show that they conform to the performance requirements of ASTM Standard
D2628-91 for oven ageing, oil and ozone resistance, low temperature stiffening and recovery.
Seals made of ethylene vinyl acetate in microcellular form and other synthetic materials may be
used in longitudinal joints and in structures if test certificates are produced to show adequate
resistance to heat ageing when tested in accordance with BS EN ISO 2440 and resistance to fuel
oils. The compression set of any seal shall not be greater than 15% when the specimen is
subjected to a 25% compression in accordance with BS EN ISO 1856. When immersed in
standard oils for 48 hours at 25°C in accordance with BS ISO 1817, the volume change shall not
be greater than 5%.
7. Compression seals shall be shaped so that they will remain compressed at all times in
accordance with Clause 1016 and shall have a minimum of 20 mm contact face with the sides
of the sealing groove. If lubricantadhesive is used, it shall be compatible with the seal and the
concrete and shall be resistant to abrasion, oxidization, fuels and salt.
1018 Joints at Manhole and Gully Slabs

1. Manhole covers, gullies and their frames shall be isolated from the pavement slabs and be
contained in separate small slabs, which shall be larger than the exterior of the manhole and
gully shafts, including any concrete surround less than 150 mm below the underside of the sub-
base layer. The joint around the manhole or gully slab shall be vertical and incorporate joint filler
board as in Clause 1015 but without dowel bars and tie bars.
2. Gully slabs in unreinforced concrete slabs shall be adjacent to or straddle a transverse joint,
extending the gully slab as necessary to a maximum of 2 m. Where this is impractical, an extra
tied warping joint shall be provided adjacent to or within the gully slab and at least 2 m from the
next transverse joint. If the edge of an isolator slab is within 1 m of any longitudinal joint the
isolator slab shall be extended to that joint.
3. Manhole slabs in unreinforced concrete slabs shall be adjacent to or straddle transverse or

longitudinal joints. If the manhole is within the middle third of the bay length a warping joint
shall be constructed on one side of the manhole slab across the whole width of the bay to the
nearest longitudinal joint.
4. Reinforcement as shown on the drawings shall be placed in the main concrete slabs in the
corners between the manhole and gully slabs and the transverse or longitudinal joints. Extra
reinforcement as described in the Contract shall be placed in reinforced concrete slabs around
the manhole or gully slabs.
5. Manhole and gully slabs shall have square corners, at all corners which are not adjacent to a
transverse or longitudinal joint in the main slab.
6. Reinforcement as shown on the drawings shall be placed in the gully or manhole slab and
concrete Class C32/40 shall be placed by hand in the space between the main slab and the
manhole frame. The concrete shall be fully compacted and finished in compliance with Clause
1025.
7. A sealing groove shall be made directly above the joint filler board and sealed in compliance
with Clause 1016
1019 Inspection of Dowel Bars

1. Compliance with Clause 1011 for the position and alignment of dowel bars at contraction and
expansion joints shall be checked by measurement relative to the side form or guide wires.
2. When the slab has been constructed, the position and alignment of dowel bars and any filler
board shall be measured after carefully exposing them across the whole width of the slab. When
the joint is an expansion joint the top of the filler board shall first be exposed sufficiently in the
plastic concrete to permit measurement of any lateral or vertical displacement of the board.
During the course of normal working these measurements shall be carried out at a rate of one
joint per 1500 m length of slab or one per 5 days whichever occurs the sooner. For small areas
the rate shall be one joint for up to each 100 joints. For trial lengths measurements shall be
carried out at two consecutive joints.
3. If the position or alignment of the bars in a single joint in the slab is unsatisfactory then the next
two joints shall be inspected. If only the one joint of the three is defective, the rate of checking
shall be increased to one joint per day until compliance is being achieved. In the event of non-
compliance in two or more successive joints, the Contractor shall revert to the construction of
trial lengths and make any necessary alterations to the concrete mix, paving plant or methods
until the dowel bar position and alignment is satisfactory.
4. After the dowel bars have been examined, the remainder of the concrete shall be removed 500
mm on each side of the line of the joint and reinstated to the requirements of the specification.
Alternatively, if the dowels are examined in the penultimate joint of a day’s work that joint shall
be made a construction joint for the next day’s work and the remainder of the concrete in the
last slab may be discarded.
1020 Side Forms, Rails and Guide Wires
Side Forms and Rails

1. All side forms and rails shall be made of steel or timber and be sufficiently robust and rigid to
support the weight and pressure caused by the paving equipment. Side forms for use with
wheeled paving machines shall incorporate metal rails firmly fixed at a constant height below
the top of the forms.
2. The forms shall be secured by using not less than three pins for each 3 m length having one pin
fixed at each side of every joint. Forms shall be tightly joined together by a locked joint, free
from play or movement in any direction. Forms shall be cleaned and oiled immediately before
each use. The rails or running surface shall be kept clean in front of the wheels of any paving
machines. The forms shall be straight within a tolerance of 3 mm in 3 m.
3. The forms shall be bedded on low moisture content cement mortar or concrete class C6/8 and
set to the pavement surface level as shown on the drawings within a tolerance of ± 3 mm. The
bedding shall not extend under the slab. There shall be no vertical step between the ends of
adjacent forms greater than 3 mm. The horizontal alignment for forms shall be to the required
alignment of the pavement edge as shown on the drawings within a tolerance of ± 10 mm. The
Contractor shall ensure that the forms are set to the correct profile immediately prior to
concreting. The mortar or concrete bedding shall be broken out after use.
4. Side forms shall not be removed earlier than 6 hours after the completion of the construction of
the slab. Care shall be taken to prevent damage to the concrete and any projecting tie bars
during the removal of the forms. If the removal of forms results in any damage to the concrete
the period of 6 hours shall be increased to that which is necessary to avoid further damage and
the Contractor shall make good the damaged areas.
Guide Wires
5. Unless a laser or electronically controlled level system capable of meeting the vertical and
horizontal tolerances stated below is used, a guide wire shall be provided along each side of the
slab to be constructed by slip form paving plant. Each guide wire shall be at a constant height
above and parallel to the required edges of the slab as shown on the drawings, within a vertical
tolerance of ± 3 mm. Additionally one of the wires shall be at a constant horizontal distance
from the required edge of the pavement as shown in the drawings within a lateral tolerance of ±
10 mm.
6. The guide wires shall be supported from stakes not more than 8 m apart by connectors capable
of fine horizontal and vertical adjustment. The guide wire shall be tensioned on the stakes so
that a 500 gramme weight shall produce a deflection of not more than 20 mm when suspended
at the mid-point between any pair of stakes. The ends of the guide wires shall be anchored to
fixing points which shall be not closer to the edge of the slab than the row of stakes and in no
circumstances shall a guide wire be anchored to a stake.
7. The stakes shall be positioned, and the connectors maintained at their correct height and
alignment from 1200 hours on the day before concreting takes place until 36 hours after the
concrete has been finished. The guide wire shall be erected and tensioned on the connectors at
any section for at least two hours before concreting that section.
1023 Transport and Delivery

1. The number of delivery vehicles provided shall be sufficient to ensure a constant supply of
concrete to enable the paving plant to proceed continuously.
1024 Construction by Machine

1. The concrete slab shall be constructed in a continuous process by either slip-form or by fixed
form paving plant in accordance with this Clause or by small paving machines or hand guided
methods as in Clause 1025.
2. The slab may be constructed in either one or two layers. In two layer construction the thickness
of the top layer shall be not less than 40 mm or twice the maximum size of the coarse aggregate,
whichever is the greater, and shall be at least 15 mm thicker than the depth of the groove former,
if used.
Construction by Fixed Form Paving Machines

3. A fixed form paving train shall consist of separate, powered machines which spread, compact
and finish the concrete in a continuous operation.
4. Concrete shall be discharged without segregation into a hopper spreader which is equipped with
the means of controlling its rate of deposition on to the sub-base or on to the lower layer. The
concrete shall be spread in each layer without segregation and to a uniform uncompacted
density over the whole area of the slab. The deposited concrete shall be struck off to the
necessary level by the underside of the hopper as it is traversed across the spreading machine.
The machine shall be capable of being rapidly adjusted for changes in average and differential
surcharge necessitated by changes in slab thickness or crossfall. When the slab is constructed in
two layers, the spreading of the concrete in the top layer shall follow the completion of the
bottom layer within the times given in Table 10/7.
TABLE 10/7: Maximum Working Times

5. Prior to being compacted, the surface level of each loose spread layer shall be adjusted to the
correct surcharge by means of rotating strike-off blades or a screw device.
6. The concrete shall be compacted by vibration or by a combination of vibration and mechanical

tamping so as to comply with Clause 1003 throughout the full depth of the slab. Poker vibrators
shall be used in each layer adjacent to the side forms and the edge of a previously constructed
slab.
7. The initial regulation and finish to the surface of the slab shall be effected by means of a beam
oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam shall be
readily adjustable for both height and tilt.
8. Joint grooves shall be constructed in compliance with Clause 1013. When grooves are wet-
formed, the concrete shall be re-compacted around the former by a handheld vibrating plate
compactor drawn along or on each side of the joint, prior to the final regulation of the surface
by a longitudinal oscillating float.
9. The regulation and finishing of the surface of the slab shall be carried out by a machine which
incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both
height and tilt. The beams shall weigh not less than 170 kg/m, be of rectangular section and
span the full width of the slab. The leading beam shall be vibrated. The beams shall be supported
on a carriage, the level of which shall be controlled by the average level of not less than four
points evenly spaced over at least 3.5 m of the supporting rail, beam, or slab, on each side of the
slab that is being constructed. The final regulation of the surface of the slab shall be provided
by a longitudinal oscillating float, travelling across the slab. After the final regulation and before
the macrotexture is applied, any excess concrete on top of the joint groove former, where
present, shall be removed.
Additionally, the longitudinal oscillating float shall complete the traverse of the slab in both
directions within the length of the float and shall have a total longitudinal stroke of 200 mm to
300 mm.
10. The longitudinal oscillating float shall have a minimum length of 3 m and a minimum constant
width of 250 mm with a maximum weight of 10 kg/m. The edges of the float shall be curved or
chamfered.
11. A minimum length of 500 mm of longitudinal oscillating float shall be within the length of the
machine tracks or wheels.
12. When a concrete slab is constructed in more than one width, flanged wheels on the paving
machines shall not be run directly on the surface of any completed part of the slab. The second
or subsequent slabs shall be constructed either by supporting machines with flanged wheels on
flat-bottom section rails weighing not less than 15 kg/m laid on the surface of the completed
slab, or by replacing the flanged wheels on that side of the machines by smooth flangeless
wheels. Before flangeless wheels or rails are used, the surface regularity of the slab over which
they are to pass shall comply with Clause 702 and its surface shall be thoroughly cleaned and
brushed to remove all extraneous matter. Flangeless wheels or rails shall be positioned
sufficiently far from the edge of the slab to avoid damage to that edge.
Construction by Slip-form Paving Machine

13. A slip-form paving train shall consist of powered machines which spread, compact and finish the
concrete in a continuous operation
14. The slip-form paving machine shall compact the concrete by internal vibration and shape it
between sliding side forms or over fixed side forms by means of either a conforming plate or by
vibrating and oscillating finishing beams.
15. The concrete shall be deposited without segregation in front of the slip-form paver across its
whole width and to a height which at all times is in excess of the required surcharge. The
deposited concrete shall be struck off to the necessary average and differential surcharge by
means of a strike-off plate or a screw auger device extending across the whole width of the slab.
The equipment for striking off the concrete shall be capable of being rapidly adjusted for
changes of the average and differential surcharge necessitated by changes in slab thickness or
crossfall.
16. The level of the conforming plate and finishing beams shall be controlled automatically from
the guide wires by sensors attached at the four corners of the slip form paving machine. The
alignment of the paver shall be controlled automatically from the guide wire by at least one
sensor attached to the paver. The alignment and level of ancillary machines for finishing,
texturing and curing of the concrete shall be automatically controlled relative to the guide wire
or to the surface and edge of the slab.
17. Slip-form paving machines shall have vibration of variable output, with a maximum energy
output of not less than 2.5 kW per metre width of slab per 300 mm depth of slab for a laying
speed of up to 1.5 m per minute or pro rata for higher speeds. The machines shall be of sufficient
mass to provide adequate reaction on the traction units to maintain forward movements during
the placing of concrete in all situations.
18. The final regulation of the surface slab shall be provided by a longitudinal oscillating float
travelling across the slab. The longitudinal float shall comply with the requirements of sub-
Clauses 9, 10 and 11 of this Clause. Additionally, the longitudinal float shall either be a separate
machine closely following a slip-form paver or alternatively it shall be attached to a slip-form
paver in such a manner that it functions effectively and does not adversely affect the
performance of the paver or the surface of the slab.
19. Joint grooves shall be constructed in compliance with Clause 1013. Where grooves are wet-
formed the concrete shall be compacted around the former by a separate vibrating plate
compactor with twin plates. The groove former shall be compacted to the correct level by a
vibrating pan which may be included with the transverse joint finishing beam. Final finishing
shall be carried out in accordance with sub-Clause 18 of this Clause. Any excess concrete on top
of the groove former shall be removed before the surface is macrotextured.
20. Where a concrete slab is constructed in more than one width or where the edge needs to be
matched for one level to another section of surface slab, and the surface levels at the edges are
not achieved, the slab shall be supported by separate side forms placed before or after the paver
to ensure that edge levels meet the required tolerances.
General
21. While the concrete is still plastic its surface shall be treated to comply with the macrotexture
requirements specified in Clause 1026. The surface and edges of surface slabs and CRC bases
shall be cured in compliance with Clause 1027. Lower Strength concrete bases and subbases
shall be cured in compliance with Clause 1030.
22. The spreading, compacting and finishing of the concrete shall be carried out as rapidly as
possible and the paving operation shall be so arranged as to ensure that the time between the
mixing of the first batch of concrete in any transverse section of the slab and the application of
the sprayed curing membrane to the surface of that section shall not exceed those given in Table
10/7. This working time is a function of degree hours see sub-Clause 1054.3.
23. Each bay in jointed concrete surface slabs shall be consecutively numbered near the verge, next
to a transverse joint while the concrete is plastic. In continuously reinforced concrete pavement,
the slab shall be marked with the chainage at intervals not greater than 50 m apart
1025 Construction by Small Paving Machines or Hand Guided Methods

1. As an alternative to fixed form or slip-form paving trains, the concrete slab may be constructed
using parts of trains, small paving machines, truss type finishing beams, roller beams or hand
guided methods. Hand tamping beams may only be used for short lengths or infill bays or tapers.
Reinforcement, dowel bars and tie bars shall be supported in position in accordance with Clauses
1008, 1011 and 1012 respectively, except where two-layer construction is used, and
reinforcement is placed on the bottom layer.
2. The concrete shall be spread uniformly without segregation or varying amounts of pre-
compaction, by conveyor, chute, blade or auger. The concrete shall be struck off by a screed or
auger so that the average and differential surcharge is sufficient for the surface of the slab to be
at the correct levels after compaction of the concrete.
3. The concrete shall be compacted by vibrating finishing beams across the slab and with vibrating
pokers adjacent to the side forms or the edge of a previously constructed slab. In addition,
internal poker vibration shall be used for slabs thicker than 200 mm and may be used for lesser
thicknesses. When used, the pokers shall be at points not more than 500 mm apart over the
whole area of the slab or drawn continuously across the slab in front of the finishing beams.
4. The finishing beams shall be metal with a contact face at least 50 mm wide. They shall be rigid
or supported by a frame or truss without sag across the width of slab being paved. The beams
shall be supported on rails or forms or an adjacent slab and shall be moved forward at a steady
speed of 0.5 m to 2 m per minute whilst vibrating, to compact the concrete and to produce a
smooth surface finished to the correct crossfalls, crowns and levels relative to the top of the
forms or adjacent slab.
5. Joint grooves shall be constructed in compliance with Clause 1013. Any irregularities at wet-
formed joint grooves shall be rectified by means of a vibrating float at least 1.0 m wide drawn
along the line of the joint. The whole area of the slab shall be regulated by two passes of a
scraping straight edge not less than 1.8 m wide or by a further application of a twin vibrating
finishing beam. Any excess concrete on top of the groove former shall be removed before the
surface is macrotextured.
6. The surface shall be brush-textured as described in Clause 1026.
7. The surface shall be cured in compliance with Clause 1027, within the time to completion given
in Table 10/7.
1026 Finished Surface Requirements
Macrotexture of Running Surfaces

1. The macrotexture of running surfaces for pavement widening, partial reconstruction and repair
shall comply with sub-Clauses 2 to 6 of this Clause, other pavements shall comply with sub-
Clause 2 and sub-Clauses 7 to 27 of this Clause.
2. The finished surface of the pavement shall comply with the requirements of Clause 702. Where
a pavement area does not comply with the specification in any respect the full extent of the
surface which does not comply shall be rectified in accordance with Clause 702.
Brush Finish Macrotexture

3. After the final regulation of the surface of the slab and before the application of the curing
membrane, the surface of concrete slabs to be used as running surfaces shall be brush-
macrotextured in a direction at right angles to the predominant traffic flow. The macrotexture
shall be applied evenly across the slab in one direction by a brush not less than 450 mm wide.
The macrotexture shall be uniform both along and across the slab.
1027 Curing
1. Immediately after the surface treatment described in Clause 1026, the surface and exposed
edges of the surface shall be cured, without disturbance, for a minimum period of 7 days, by the
application of a resin based aluminised curing compound, or polythene sheeting or a sprayed
plastic film which hardens into a peelable plastic sheet and which shall be removed before road
marking and opening to traffic. Where the concrete is to receive a thin surfacing overlay, the
surface and exposed edges shall be cured for a minimum of 7 days by the application of a curing
agent. If the concrete is to be overlaid by bituminous surfacing the curing agent shall be
compatible with the bond coat and installation requirements for the thin surfacing in accordance
with Series 900.
2. Resin based aluminised curing compound shall contain sufficient flake aluminium in finely
divided dispersion to produce a complete coverage of the sprayed surface with a metallic finish.
The compound shall become stable and impervious to evaporation of water from the concrete
surface within 60 minutes of application and shall have an efficiency index of 90% when tested
as described in BS 7542.
3. The curing compound shall not react chemically with the concrete to be cured and shall not
crack, peel or disintegrate within three weeks after application.
4. Prior to application, the contents of any containers shall be thoroughly agitated. The curing
compound shall be mechanically applied using a fine spray on to the surface at a rate of at least
0.22 1/m². For the sides of slip-formed slabs or when the side forms are removed within 24
hours and for small areas where mechanical application cannot be used, the compound shall be
sprayed by hand lance at a rate of at least 0.27 1/m². The rate of spread shall be checked during
construction of each trial length and for each 1000 m² of treated slab.
5. The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation
and mixing of the compound in its container during spraying.
6. Continuously reinforced concrete bases shall be cured in accordance with this Clause.
Immediately prior to laying the bituminous surfacing or upper base, a cationic bituminous tack
coat shall be applied in accordance with Clause 920 at a rate between 0.35 l/m² to 0.55 l/m².
7. To achieve high early strength for early use by vehicles, insulation blankets as described in
Clause 1045 may be used for accelerated curing.
1028 Trial Length
General
1. Except in rapid construction projects and unless otherwise described in contract specific
Appendix A, at least 2 weeks prior to the construction of the trial length of surface slabs the
Contractor shall submit a detailed description of the proposed constituent materials, concrete
proportions, plant, equipment and construction methods to the Overseeing Organisation. No
trials of new constituent materials, plant, equipment or construction methods; nor any
development of them shall be permitted either during the construction of the trial length or in
any subsequent paving work, unless they form part of further satisfactory trials.
2. Unless otherwise described in contract specific Appendix A, the Contractor shall demonstrate
the constituent materials, concrete proportions, plant, equipment and methods of construction
that are proposed for concrete paving, by first constructing a trial length of slab, at least 150 m
but not more than 300 m long for mechanised construction, and at least 30 m long for hand
guided methods. The concrete proportions decided by trial concrete mixes may be adjusted
during the trial but shall not be changed once the trial length has been satisfactorily completed
unless the Contractor lays a further trial area to assess the suitability of the proposed changes.
3. The trial length shall be constructed in two parts over a period comprising at least part of two
separate working days, with a minimum of 75 m constructed each day when mechanised paving
plant is used and a minimum of 15 m on each day for hand guided methods. The trial length
shall be constructed at a similar rate to that which is proposed for the main construction in the
permanent works.
4. At least two transverse joints and one longitudinal joint of each type that are proposed for
unreinforced concrete slabs and jointed reinforced concrete slabs in the main construction in
the permanent works shall be constructed and assessed in the trial length. If in the trial length
expansion joints are not demonstrated, the first 2 expansion joints and at least the first 150 m
of longitudinal construction joint for mechanised paving, or 30 m for hand guided method of
construction laid in the main construction in the permanent works, shall be considered the trial
length for these joints.
Assessment
5. The trial length shall comply for strength and density with the specification in all respects, with
the following additions and exceptions:
Surface Levels and Irregularity

(i) In checking for compliance with Table 7/1 the levels shall be taken at intervals of not
more than 2.5 m along any line or lines parallel to the longitudinal centre line of the trial
length.
(ii) The maximum number of permitted irregularities of pavement surfaces shall comply with
the requirements of Table 7/2 for 300 m lengths. Shorter trial lengths shall be assessed pro-
rata based on values for a 300 m length.
Joints
(iii) At least 3 cores of minimum diameter 100 mm shall be taken from the slab at joints to
check the lateral and vertical location of joint grooves and bottom crack inducers.
(iv) Alignment of dowel bars shall be inspected as described in Clause 1019 in any two
consecutive transverse joints. If the position or alignment of the dowel bars at one of these
joints does not comply with Clause 1011 but if that joint remains the only one that does not
comply after the next 3 consecutive joints of the same type have been inspected, then the
method of placing dowels shall be deemed to be satisfactory. In order to check sufficient
joints for dowel bar alignment without extending the trial length unduly, the Contractor may
construct joints at more frequent joint intervals than the normal spacing required in contract
(v) If there are deficiencies in the first expansion joint that is constructed as a trial the next
expansion joint shall be a trial joint. Should this also be deficient further trial expansion joints
shall be made as part of a trial length. Deficient expansion joints shall not form part of the
permanent works.
Position of Reinforcement and Tie Bars

(vi) Compliance with Clause 1008 for the position of steel reinforcement and Clause 1012
for the position and alignment of tie bars shall be checked by drilling additional cores from
the slab unless they can be determined from cores taken for density assessment.
Completion of Trial
6. The Contractor shall not proceed with normal working unless the trial length complies with the
specification and any earlier defective trial lengths have been removed, unless they can be
remedied to comply with the specification.
7. After satisfactory completion of the trial length, the constituent materials, concrete proportions,
plant, equipment and construction methods shall not thereafter be changed, except for normal
adjustments and maintenance of plant, unless the Contractor lays a further trial length as
described in this Clause to demonstrate that the changes will not adversely affect the permanent
works or agrees the changes with the Overseeing Organisation.
Rejection and Further Trials

8. Trial lengths which do not comply with the specification, with the exception of areas within the
pavement surface which can be remedied in accordance with Clause 1029, shall be removed and
the Contractor shall construct a further trial length.
1029 not used
1030 Lower Strength Concrete
Grades and Constituents

1. The strength for Lower Strength concrete shall be as described in Clause 1001 with the following
constituents:
(i) cements as described in sub-Clause 1001.3 and water/cement ratio as described in sub-
Clause 1001.4;
(ii) aggregate shall be in accordance with sub-Clause 1001.6.
Consistence (Workability)
2. Consistence shall comply with Clause 1005.
Placing
3. Lower Strength concrete shall be spread uniformly, without segregation and without varying
degrees of pre-compaction. The concrete shall be struck off to a level so that the surcharge is
sufficient to ensure that after compaction the surface is at the required level
Compaction
4. The spread Lower Strength concrete shall be compacted using internal or external vibration, or
a combination of both to meet the required density. Compaction and finishing to level shall be
completed within the times given in Table 10/7.
Joints
5. At transverse and longitudinal construction joints between two separately constructed slabs, the
previously laid slab end or edge shall present a vertical face before construction of subsequent
slabs.
6. Longitudinal joints in Lower Strength concrete shall be staggered by at least 300 mm from the
position of longitudinal joints in any superimposed concrete slab, and by 1m for transverse
joints.
Curing
7. The surface shall be cured, without disturbance, for a minimum period of 7 days, by the
application of a resin based aluminised curing compound, or polythene sheeting or a sprayed
plastic film which hardens into a peelable plastic sheet.
Sampling for Testing

8. Sampling shall be as specified in Clause 1003.
Density
9. The density shall be determined as required in Clause 1003.
Strength
10. The strength shall be determined as in Clause 1004.
Trial Concrete Mixes

11. Trial concrete mixes shall conform with BS 8500-2 for designed concretes for strength class
C12/15 and above or CC14 and above, unless recent data relating entirely to the proposed
concrete, satisfies the requirements of the specification.
Trial Length
12. At least 10 days before the start of the main Lower Strength concrete works a trial length of at
least 400 m2 for mechanised construction and 30 m for hand-guided methods shall be
constructed. The trial length shall be laid to assess the suitability of the proposed material, plant,
equipment and construction methods to meet the requirements of the specification. The main
construction in the permanent works shall not start unless the trial length complies with the
specification. If any trial length does not conform to the specification another trial length shall
be constructed. Trial lengths not complying shall be removed unless they can be rectified to
comply with the specification.
13. After satisfactory completion of the trial, the material, plant, equipment and construction
methods shall not be changed unless the Contractor lays a further trial length to assess the
suitability of the proposed changes or agrees the changes with the Overseeing Organisation.
Surface Finish
14. The surface of the Lower Strength concrete after compaction and finishing and before overlaying
shall be free from ridges, loose material, pot holes, ruts or other defects.
1039 Summary of Rates for Sampling and Testing Concrete for Pavement
Layers
1. Unless otherwise stated in contract specific Appendix G, Table 10/12 summarises the minimum
rates of sampling and testing of specimens to the specification.
2. Samples for testing shall be taken at the point of placing or from the relevant pavement layer.
TABLE 10/12: (01/20) Rates for Sampling and Testing Concrete for Pavement Layers
1048 Use of Surfaces by Traffic and Construction Plant

1. Construction plant and traffic used on pavements under construction shall be suitable in relation
to the material, condition and thickness of the courses it traverses so that damage is not caused
to the subgrade or the pavement courses already constructed. The wheels or tracks of plant
moving over the various pavement courses shall be kept free from deleterious materials.
2. Concrete slabs may be used by traffic when the cube compressive strength is assessed to have
reached 25 N/mm2 for pavement surface slabs, or 20 N/mm2 for bases with asphalt surfacing.
The method of assessing the time when this strength is reached shall be as described in Clause
1004.
3. In the absence of test data establishing compliance with sub-Clause 2 of this Clause, no vehicle
with an axle loading greater than 2 tonnes shall run on concrete slabs within a period of 14 days
after placing the concrete.
Vehicles with rubber tyres with an axle loading less than 2 tonnes, or wheels or tracks of
concreting plant, shall not use any part of a newly constructed pavement within 7 days. The
above periods before traffic may run on the pavement shall be increased if the 7 day cube
strength is below that required in the specification. These periods shall be extended by one day
for each night on which the temperature of the layer falls to 0ºC or below.

The section should be read in conjunction with Section 4.5 of this specification.
1079 Visual Condition Survey and Inspection

The Contractor shall complete a detail visual inspection of the area of existing concrete pavement
identified on the drawings for repair. The Contractor shall determine the location and condition of
each concrete bay and should provide a schedule of required treatments together with a plan
drawing identifying the location of each bay and type treatment required. The contractor should
verify the construction of the existing pavement and its supporting foundation as per Volume 5 Site
Data and visual inspections.
The Contractor should provide the following information:
• Schedule of types of defects, crack widths and proposed treatments

• Plan drawing showing the location and type of treatment
• Depth of existing concrete pavement
• Depth and type of subbase beneath concrete pavement
• In-situ CBR or surface modulus of subgrade below the subbase
General
1. Early strength concrete shall conform to the requirements of contract specific Appendix A or
either:
(i) BS 8500-2 and BS EN 206 and meet the requirements of sub-Clauses 1001.3 for cement,
1001.6 to 1001.9 for aggregate, 1001.12 chloride class, 1001.13 acid soluble sulfate
and 1001.14 for total sulfur.
Or
(ii) Proprietary concrete conforming to BS 8500-2 and alternative materials shall be

certified in accordance with sub-Clauses 104.15 and 104.16 of the specification. The
certification shall include the assessment of a 2-year trial installation that demonstrates
defect free performance and a declaration of the traffic levels to which the product has
been assessed. Defects to be assessed shall include: Surface Texture Retention, Cracking,
Spalling and Loss of Material.
2. The minimum strength class shall be C35/45 and maximum free water content (w/c) 0.40.
3. The concrete shall not be air entrained.
4. Early strength concrete shall be designed to achieve a minimum compressive strength of 25

MPa at 4 hours or earlier.
5. The requirements of Clause 1004 shall not apply to this Clause.
In situ strength
6. The development of in situ concrete strength shall be based on the relationship of compressive
strength to maturity. Detailed estimates of the development of concrete properties may be
based on one of the following:
(i) maturity calculation from temperature measurements taken at a maximum depth of 75
mm below the surface;
(ii) (ii) maturity calculation based on the daily average air temperature;
(iii) (iii) non-destructive technologies to monitor strength gain.
Preparation
7. Grout for new dowel and tie bars shall be set before the slab is poured.
1. Where individual bays are to be replaced, they shall match the design thickness of the original
concrete including reinforcement if originally included.
2. The replacement bay shall be connected to the surrounding concrete with new dowel or tie bars
at transverse and longitudinal joints in accordance with Clause 1011.
3. Grooves shall be formed in accordance with Clause 1013.
4. A surface texture as specified in Clause 1026 shall be applied and a curing compound as
specified in Clause 1027.
5. Joints surrounding the new bay shall be sealed as specified in Clause 1016.
6. The type and functionality of the existing bay joints should remain the same
General
1. Full depth repairs shall be repairs which will require full depth reinstatement of the concrete
slab in-accordance with this Clause. Repairs may also require reinstatement of subbase.
2. Full width repairs to jointed pavements (JUC and URC) shall be repairs over the full width of a
bay or bays. Part width repairs shall be repairs over part of the width of a bay or bays. A bay shall
be that portion of the concrete pavement bounded by adjacent longitudinal and transverse
joints.
3. Not used
Part Width Repairs

4. Providing all the following criteria are met, part width repairs may be carried out in accordance
with sub-Clause 3 of this Clause:
(i) the transverse width of the repair shall not exceed 45% of the width of the slab under repair;
and
(ii) the longitudinal or transverse joint which would be formed by the repair shall not occur within
the wheel track; and
(iii) the minimum transverse width of the repair shall not be less than 1.5 m.
5. If the criteria in sub-Clause 4 and those in sub-Clause 3 of this Clause cannot be met, a full-width
repair shall be made in-accordance with this Clause.
Full Width Repairs

6. For full width repairs the following criteria shall apply:
(i) Mid-bay repairs which do not replace an existing transverse joint shall be constructed with
two tied transverse joints.
(ii) Repairs which replace a single transverse joint shall be constructed with two tied transverse
joints and a replacement transverse movement joint of the same type and function as the
original joint.
(iii) Repair lengths which replace more than one existing transverse joint shall be constructed
with transverse joints to match expansion and contraction joints in the adjacent bay(s).
(iv) Except for the end joints all bay joints shall be formed to coincide with the existing bay joints.
Repair Work
7. Any replacement dowels and tie bars shall comply with the requirements of Clauses 1011 and
1012 respectively. Epoxy mortar shall be to the manufacturer’s recommendation for this specific
application. Where repairs straddle a movement joint with an adjacent slab, tie bars shall be
omitted and the joint between the slabs de-bonded to ensure that movement patterns are not
restricted.
8. A surface texture as specified in Clause 1026 shall be applied and cured as specified in Clause
1027.
General
1. Thin bonded repairs shall be as described in Section 4.3.
Materials
2. Cement mortar shall be used for depths less than 20 mm and fine concrete for greater depths.
Resin mortar may be used for patch repairs where insufficient time for adequate curing of a
cementitious mortar exists.
3. The cements, aggregates, admixtures and water shall comply with Clause 1001. Mortars or fine
concrete shall be within the limits of 0/4 (CP), 0/4 (MP), 0/2 (MP) or 0/2 (F/P) of BS EN 12620.
Coarse aggregate for fine concrete shall be (4/10) single sized aggregate complying with BS EN
12620. All aggregates shall be of the same type as the aggregate in the original concrete, so
that they have the same thermal properties. Filler and aggregate for resin mortars shall be
prepacked in the correct proportions and mixed with the resin all in accordance with the
manufacturer’s instructions.
4. The proportions of cement, admixtures, additives to water and aggregates shall be sufficient to
provide high early strength mortar or fine concrete or concrete complying with Clauses 1001,
1003 and 1004. For cement mortar the fine aggregate to cement ratio shall not be greater than
3. For resin mortar the fine aggregate content shall be in accordance with the manufacturer’s
requirements in the range between 7 and 11 to 1 of resin. Early strength concrete shall have a
design compressive strength of 25 MPa at 4 hours or earlier. For thin bonded repairs using early
strength concrete, air entrainment is not required.
1027.
General
1. The maximum depth of repair to a concrete slab shall not exceed 33% of slab thickness.
2. The maximum aggregate size in the concrete shall not exceed the thickness of the repair divided
by 2.5.
3. The repair shall not span an existing crack or joint.
4. Early strength concrete shall conform to the requirements of contract specific Appendix A or
either.
(i) BS 8500-2 and BS EN 206 and meet the requirements of sub-Clauses 1001.3 for cement,
1001.6 to 1001.9 for aggregate, 1001.12 chloride class, 1001.13 acid soluble sulfate and
1001.14 for total sulfur.
Or
(ii) Proprietary concrete conforming to BS 8500-2 and alternative materials shall be certified in
accordance with sub-Clauses 104.15 and 104.16 of the specification. The certification shall
include the assessment of a 2-year trial installation that demonstrates defect free performance
and a declaration of the traffic levels to which the product has been assessed. Defects to be
assessed shall include: Surface Texture retention, Cracking, Spalling and Loss of Material
5. The minimum strength class shall be C35/45 and maximum free w/c 0.40.
6. The concrete shall not be air entrained.
7. The requirements of Clause 1004 shall not apply to this Clause.
In situ strength
8. Early strength concrete shall have a design strength of 25 MPa at 4 hours.
9. The method to determine the minimum strength of the concrete may be based on the
relationship of compressive strength to maturity. Detailed estimates of the development of
concrete properties may be based on one of the following:
(i) maturity calculation from temperature measurements taken at a maximum depth of 75 mm

below the surface;
(ii) maturity calculation based on the daily average air temperature; and
(iii) temperature-matched curing.
1027.
1. The maximum depth of a shallow repair of a concrete slab shall not exceed 33% of slab
thickness.
2. All polymeric repair materials used for shallow repairs shall be certified in accordance with sub-
Clauses 104.15 and 104.16 of the specification for use at declared traffic levels.
3. All polymeric repair materials shall undergo an independently verified SIPT (System Installation
Performance Trial
4. The SIPT shall determine that the following requirements are met:
(i) Repair to remain intact, un-cracked and visibly bonded to surrounding concrete for a period
of two years;
(ii) A statement as to the maximum traffic level for which the material has been assessed;
(iii) A statement as to the maximum repair thickness to which the material has been assessed.
(iv) The polymeric repair material to retain after 2 years a minimum Skid Resistance Value (SRV)
of 60 when measured in accordance with BS 7976; and
(v) The difference in surface level between the material and the concrete to either side to be no
more than 5mm at the time of installation and after 2 years.
5. The manufacture’s guidance shall be followed with regards to preferred aggregate size which
will be related to width and depth of repair
6. A primer shall be used if recommended by the manufacturer.
7. The maximum thickness of the repair shall not exceed the product manufacturer’s
recommendation.
8. The minimum SRV before opening to traffic shall be 60 when measured in accordance with BS
7976.
1086 to 1089 not used
1090 Crack Sealing

1. Crack sealing shall be carried out using a polymeric compound designed for the purposes of
flexibly sealing cracks in concrete road pavements, certified in accordance with sub-Clauses
104.15 and 104.16 of the specification for use at the declared traffic levels.
2. Only inlaid systems are permitted.
3. Minimum inlay thickness shall be in accordance with the manufacturer’s requirements.
4. The Contractor shall declare the minimum time between installation of repair material and
trafficking.
5. The Contractor shall declare any limiting ambient temperature or road temperature or weather
conditions for the installation of the sealant.
6. The sealing product shall be installed in accordance with the manufacturer’s instructions.
7. Crack sealing materials shall undergo an independently verified SIPT (System Installation
Performance Trial) as part of the certification requirements in sub-Clause 1.
8. The SIPT shall determine that the following requirements are met:
(i) repair to remain intact, un-cracked and visibly bonded to surrounding concrete for a period
of two years;
(ii) a statement as to the maximum traffic level for which the seal has been assessed;
(iii) a statement as to which orientation cracks (transverse, longitudinal or diagonal) the seal has
been assessed for;
(iv) the sealant to retain after 2 years a minimum Skid Resistance Value (SRV) of 60;
(v) the difference in surface level between the sealant and the concrete to either side to be no
more than 5 mm (increased to 10 mm if ambient temperatures less than 10°C) at the time of
installation and after 2 years.

1. Stitched crack repairs shall be either:
(i) Type 1 - Staple Tie Bar Repair; or
(ii) Type 2 - Diagonal Tie Bar Repair.
3. For Type 1 crack repairs, slots 25 - 30 mm wide by 470 mm long at 600 mm centres and at right
angles to the line of the crack shall be chased out to a depth such that, when bedded, the tie
bars lie between ⅓ and ½ of the depth of the slab below the surface.
4. For Type 2 crack repairs drilling points shall be at a distance from the crack equivalent to the
depth of the slab, at 600 mm intervals along the crack with alternate points on opposite sides
of the crack.
General
1. This specification provides requirements for the longitudinal diamond grinding (LDG) of a
Pavement Quality Concrete surface to restore texture, skid resistance and ride quality on
structurally sound concrete pavements.
Preparation
2. Where concrete repairs are required, they shall be undertaken in accordance with Clauses 1082
to 1091 of the specification and contract specific Appendices appropriate to the repairs required
prior to the application of LDG.
3. Any transverse steps between adjacent slabs shall be reduced to a maximum of 10 mm prior to
the application of LDG by grouting under slabs to Clause 1089.
4. Where the joint and loops seals are no longer effective or are damaged, they shall be replaced
prior to the diamond grinding and installed in a recessed condition in compliance with Clause
1017.
Equipment
5. Grinding shall be accomplished using diamond blades mounted on a self-propelled machine
designed specifically for diamond grinding of the pavement.
6. The equipment shall weigh a minimum of 16,000 kg including the grinding head and be of a
size that will grind a strip at least 1200 mm wide in a single pass.
7. The effective wheelbase of the machine shall be no less than 3.6 m. The effective wheelbase is
defined as the distance from the front wheel assembly transverse pivot point to the transverse
pivot point of the profile/depth control/ground drive wheels.
8. Diamond grinding equipment uses diamond blades mounted in series on a cutting head. The
width of the cutting head shall be at least 1200 mm.
9. The spacing of the diamond blades shall be selected based on the hardness of the aggregates
in the existing concrete to achieve the required end performance.
1093 Fine Milling
General
1. This specification provides requirements for the fine milling (FM) of a Pavement Quality
Concrete surface to restore texture and skid resistance on structurally sound concrete
pavements.
Preparation
2. Where concrete repairs are required, they shall be undertaken in accordance with Clauses 1082
to 1091 of the specification and contract specific Appendices appropriate to the repairs required
prior to the application of FM.
3. Any transverse steps between adjacent slabs shall be reduced to a maximum of 20 mm prior to
the application of FM.
4. Where the joint seals are no longer effective or are damaged, they shall be replaced after FM
and installed in a recessed condition in compliance with Clause 1017.
Equipment
5. FM shall be accomplished using a planing machine fitted with diamond tip picks at a maximum
spacing of 6 mm.
6. FM shall be performed continuously along a traffic lane to produce a uniform homogeneous
finish.
Performance Requirements
7. Surface macro-texture of the textured surface shall be measured using the volumetric patch
method described in BS EN 13036-1.
8. Texture depth shall be measured by 10 individual measurements taken at approximately 5 m
spacing along a diagonal line across the lane width. At least one set of 10 measurements shall
be made for each 250 m section of carriageway lane. The average texture depth for each set of
10 individual measurements and the average texture depth of each 1,000 m section or complete
area where this is less than 1,000 m shall be a minimum of 0.7mm and a maximum of 1.2mm
unless otherwise specified in contract specific Appendix 7/31
9. The finished surface of the treated pavement shall comply with the requirements of sub-Clauses
702.5 to 702.9.
10. A minimum of 95 percent of any 20m2 section of pavement surface shall be textured

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Consolidation Works at First and Second Container Terminals

King Abdulaziz Port in Dammam

Civil and Yard Structures Specifications

Saudi Global Ports Company

Project No: SA1980PMD

CH2M Saudi Ltd

Document history and status

Revision Date Description Author Checked Reviewed Approved

Appendix A. PERMITTED PAVEMENT OPTIONS

Figure 1.1: First and Second Terminal Masterplan

1.2 Jacobs’ Role

1.3 Reference Documents

1.4 First Terminal Works

1.5 Second Terminal Works

1.5.1 Second Terminal Options

The order of precedence, in case of conflict, shall be as given below:

• Employers Requirements (all parts)

• European Standards (EN)

• International Standards and Guidance

• Kingdom of Saudi Arabia Standards

2.1.2 Primary Design Codes and Standards

Table 2-2: Acceptable Alternative British Standards

Table 2-3: Acceptable American Standards

Table 2-4: Guideline Documents

2.2.2 Service Conditions

2.2.3 Precast Concrete

(c) Pulverised fuel ash (PFA) complying with BS EN 450-1.

2.3.2 Silica Fume

2.3.3 Cementitious Materials Certification and Testing

ii. Setting time.

iv. Moisture content.

iii. Water content (slurry),

iv. Relative density (slurry).

2.3.4 Delivery and Storage of Cementitious Materials

2.4.2 Quality and Testing

Table 2-8: Aggregate Testing Frequency

Aggregate Testing Frequency

Flakiness Index BS EN 933-3 7 -

Resistance to wear BS 1097 -1 Initial and every 90 days

Table 2-9: Aggregate Testing Limits

2.4.3 Alkali-Reactivity Potential

2.4.4 Storage of Aggregates

Storage bins shall be emptied and cleaned regularly.

2.4.5 Aggregate for Control of Early-age Thermal Cracking

Epoxy coated reinforcement shall not be used.

2.5.2 Tying Wire

2.5.4 Stainless Steel

Under no circumstance shall seawater be used for mixing or curing concrete.

2.6.3 Sulphate and Chloride Content

• Controlling and retarding setting

• Reducing bleeding and associated plastic settlement and cracking

• Inhibiting corrosion of embedded steel

• Controlling wash-out in underwater concrete.

Admixtures containing chlorides or other corrosive agents shall not be used.

2.7.2 Corrosion Inhibitor

2.8 Concrete Mix Design Requirements

Table 2-10: Table of Mixes (reinforced concrete)

Reference C45A C45A

IIB-V (25-30% FA) IIB-V (25-30% FA)