Standard Specification JKR Road

FOR INTERNAL USE ONLY
Standard Specification For Road Works
KERAJAAN MALAYSIA
JABATAN KERJA RAYA MALAYSIA
STANDARD SPECIFICATION
FOR
ROAD WORKS
CAWANGAN JALAN KETUA PENGARAH KERJARAYA

IBU PEJABAT JABATAN KERJARAYA MALAYSIA JABATAN KERJARAYA MALAYSIA
JALAN SULTAN SALAHUDDIN, JALAN SULTAN SALAHUDDIN
50582 KUALA LUMPUR. 50582 KUALA LUMPUR
Cawangan Jalan, Ibu Pejabat JKR, K.L Page 1

FOR INTERNAL USE ONLY Standard Specification For Road Works
ADDENDUM NO. 1
This Addendum shall be made part of the ‘JKR Standard Specification For Roads Works’
1. Table 4.8 - Gradation Limit For Asphaltic Concrete Clause 4.2.4.2, page S4 – 21
should read as follows :
Mix Type Wearing Course Binder Course
Mix ACW 20 ACB 28

Designation
B.S Sieve % Passing by weight
37.5 mm 100
28.0 mm 100 80 - 100
20.0 mm 76 - 100 72 - 93
14.0 mm 64 - 89 58 - 82
10.0 mm 56 - 81 50 - 75
5.0 mm 46 - 71 36 - 58
3.35 mm 32 - 58 30 - 52
1.18 mm 20 - 42 18 - 38
425 um 12 - 28 11 - 25
150 um 6 - 16 5 - 14
75 um 4 - 8 3 - 8
2. Table 4.9- Design Bitumen Contents Clause 4.2.4.3, page S4 - 23 should read as follows :
ACW 20 - Wearing Course 4.5 - 6.5 %
ACW 28 - Binder Course 4.0 - 6.0

ADDENDUM NO. 2
6.2.5.5 Sign Faces
Sign faces for permanent traffic sign shall be as where shetting is applied to the extruded
shown on the Drawing and shall comply with section by pressure roller, it shall extend over
the Malaysian Standard Specification for the top and bottom edges of this sections by not
Reflective Sign Faces Materials (MS 1216). All less than 3 mm.
retro-reflective sheeting shall be fixed in accor-
dance with the manufacturer’s instruction. Any cut-outlet letters, numerals, symbols and
borders shall be of material compatible with the
Unless otherwise agreed by the S.O., sign sheeting to which they are applied. They shall
faces shall be formed from a single piece of be applied in accordance with the sheeting
retro-reflective sheeting. manufacturer’s instruction.
Where, with the aggrement of the S.O., more The finish of all sign faces shall be capable of
than one retro-reflective sheeting is used, the passing the tests described in MS 1216, and
number of sheets shall be kept to a minimum. and standard of fabrication and workmanship
All faces up to 1 m in size shall be produced shall be such that under normal conditions of
with a single sheet and no joint will be service and proper maintenance, the sign faces
accepted. shall last not less than 5 years without any
seriousblemishes or defects for Engineering
Only vertical and horizontal joint shall be per- Grade retro-reflective sheeting and 8 years for
mitted and all join in retro-reflective shetting High Intensity and prismatic retro-reflective
shall be overlapped by not less than 6 mm. The sheeting.
overlap in the horizontal joint shall be from the
top and the vertical joint shall be from the left; The Contractor shall furnish to the S.O. a letter
but joints will be only be accepted for prismatic of warranty for the specified period for all sign
retro-reflective sheeting. faces from the manufacturer of the sheeting or
the sign fabricator.
Retro-reflective sheeting shall be applied
evenly over the whole surface of the sign plate The retro-reflective sheeting manufacturer shall
and shall adhere fully. it shall be free from furnish the S.O. written warranty that the fluo-
twists, cracks, folds or cuts, air bubbles and rescent colours shall be durable for a minimum
other blemishes. 3 years for temporary signs.
All retro-reflective sheeting used on the same

sign shall be carefully matched for colour to
produce a uniform appearance both by day and
by night. Non-uniform shades of colour on any
one sign will not be accepted.
The edges of all the retro-reflective sheeting

shall be properly fitted to ensure no
delimination of the sheeting from the base
substrate.

ADDENDUM NO. 3
6.2.6.1 FLUORESCENT ORANGE WIDE ANGLE PRISMATIC RETRO-

REFLECTIVE SHEETING FOR THE WORK ZONE
6.2.6.1.1 Description 6.2.6.1.2 Requirements
The flurescent orange wide angle prismatic i) Photometric - Coefficient of

retro-reflective sheeting is specifically designed Retroreflection RA
for use on rigid substrade work zone signs to
provide high visual impact under nighttime and when the sheeting applied on aluminium
daytimedriving condition, including low test panels is measured in accordance
visibility periods such as dawn, dusk, and wth ASTM E 810, it shall have
overcast days. The sheeting shall consist of minimum coefficient of retro-reflective
prismatic lenses formed in a transparent value as shown in Table I. The rotation
flurescent orange synthetic resin, sealed, and angle shall be *90° , the observation
baked with and aggressive presure sensitive angles shall be 0.2° and 0.5°, the
adhesive protected by a removable liner. The entrance angles and +50°, and the
sheeting shall have a smooth surface with a entrance angle (component ß1) shall be
distinctive interlocking diamond seal pattern - 4°, +30°, and +50°, and the entrance
and orrientation marks visible from the face. angle component ß2 = 0°.
TABLE I
Minimum Coefficient of Retroreflection RA

(Candelas per footcandle per square foot)
(90° Rotation Angle*)
Observation Angle ( ° ) Entrance Angle ( ° ) Orange
0.2 -4 200
0.2 +30 120
0.2 +50 50
1.5 -4 80
0.5 +30 50
0.5 +50 20
* The datum mark (arrow) imprinted on the face of the sheeting shall be the datum mark for test
purposes. For the specified 90° rotation angle, the sheeting shall be positioned on the goniometer
so that the direction of this datum mark is perpendicular to the observation plane (this geometry is
equivalent to a 90° orientation angle with a presentation angle of 0° in the measurement geometry
described in Fed. Test Method Standard 370).

i) Daytime Color
Color shall conform to the reqiurement The value shall be determined on a HunterLab
of Table II. Daytime color and Labscan 6000 0/45 spectrocolorimeter with
maximum spectral radiance factor (peak option CMR 559 [or approved equal 0/45
reflectance) of sheeting mounted on (45/0) instrument withcircumferential viewing
aluminium test panels shall be (illumination)]. Computation shall be done in
determined instrumentally in accordance accordance with ASTM E 308 for the 2°
with ASTM E 991. observer.
TABLE II
Color Specification Limit ** (Daytime)
Color 1 2 3 4 Reflectance
Limit Y (%)
X Y X Y X Y X Y Min. Max.
Orange .583 .416 .523 .397 .560 .360 .631 .369 30 -
(New)
Orange
.583 .416 .523 .397 .560 .360 .631 .369 20 45
(Weathered)
Maximum spectral radiance factor, new : 110%, min.
weathered : 60%, min.
** The four pairs of chromaticity coordinates determine the acceptable color in terms of the CIE
1931 standard colorimetric system measured with standard illuminatant D65.
iii) Nighttime Color.
Nighttime color of the sheeting applied to alumium test panel shall be determined
instrumentally in accordance with ASTM E 881 and calculated in the u’, v’ coordinate
system in accordance with ASTM E 308. Sheeting shall be measured at 0.33° observation
and - 4° entrance at 90° rotation. Color shall conform to the requirements of Table III.
TABLE II
Color Specification Limit ** (Nighttime)
Color 1 2 3 4
u’ v’ u’ v’ u’ v’ u’ v’
Orange
(New and .400 .540 .475 .529 .448 .522 .372 .534
Weathered)

iv) Resistance to Accelerated Weathering. vi) Resistance to Heat.
The retro-reflective surface of the sheeting The retroreflective sheeting, applied to a

shall be weather resistant and show no test panel as in E., above and conditioned
appreciable cracking, blistering, crazing, or for 24 hours, shall be measured in
dimensional change after 1 year’s accordance with paragraph. A. at 0.2°
unprotected outdoor exposure in south observation and - 4° entrance angles at 90°
Florida, south-facing and inclined 45° rotation and exposed to 170 + 5°F (77 +
from the vertical, or after 1500 hours’ 3°C) for 24 hours in an air circulating
exposure in a xenon arc weatherometer in oven. After heat exposure the sheeting
accordance with ASTM G 26, Type B, shall retain a minimum of 70% of the
Method A. Following exposure, panels original coefficient of retroreflection.
shall be washed in a 5% HCL solution for
45 seconds, rinsed throughly with clean
water, blotted with a soft clean cloth and vii) Field Performance
brought to equilibrium at standard
conditions. After cleaning, the coefficient Retroreflective sheeting processed and
of retroreflection shall be not less than 100 applied to sign blank materials in
when measured as in D.2, below, and the accodance with the sheeting
color is expected conform to the manufacturer’s recommendations, is
requirements of Table II and III for expected to perform effectively for a
weathered sheeting. The sample shall : minimum of 3 years. the retroreflective
sheeting will be considered unsatisfactory
a) Show no appreciable evidence of if it has deteriorated due to natural causes
cracking, scaling, pitting, blistering, to the extent that : (1) the sign is ineffective
edge lifting or curling or more than 1/32 for its intended purposed when viewed
inch (0.08 cm) shrinkage or expansion. from a moving vehicle under normal day
and night driving conditions; or (2) the
b) Be measured only at angles of 0.2° coefficient of retroreflection is less than
observation, - 4° entrance and 90° 100 when measured at 0.2° observation
rotation. Where more than one panel of and - 4° entrance at 90° rotation. All
a color is measure, the coefficient or measurements shall be made after sign
retroreflection shall be the averange of cleaning according to the sheeting
all determinations. manufacturer’s recommendations.
v) Impact Resistance.
The retroreflective sheeting applied

according to the sheeting manufacturer’s
recommendations to a test panel of alloy
6061-T6, 0.040” (0.10 cn) by 3” (7.6 cm)
by 5” (12.7 cm) and conditioned for 24
hours, shall show no cracking outside the
impact of 100 inch-pounds (11.3Nm) using
a weight with a 5/8 in. (15.8 mm) diameter
rounded tip dropped from a height
necessary to generate an impact of 100
inch-pounds, at test temperatures of both
32° F (0° C) and 72° F (22° C).

STANDARD SPECIFICATION FOR ROADS WORKS
CONTENT PAGE
SECTION 1 General S1-11 to S1-31
SECTION 2 Earthworks S2-1 to S2-20
SECTION 3 Drainage Works S3-1 to S3-31
SECTION 4 Flexible Pavement S4-1 to S4-55
SECTION 5 Portland Cement Concrete Pavement S5-1 to S5-21
SECTION 6 Road Funiture S6-1 to S6-22
SECTION 7 Street Lighting S7-1 to S7-19
SECTION 8 Traffic Signals S8-1 to S8-33
SECTION 9 Concrete S9-1 to S9-39
SECTION 10 Piling Works S10-1 to S10-35

SECTION 1
GENERAL

SECTION 1 - GENERAL
Page
1.1 GENERAL DESCRIPTION OF THE PROJECT S1-11

1.2 SCOPE OF WORKS S1-11
1.3 NOTES, ABBREVIATIONS AND UNITS OF MEASUREMENT S1-11
1.3.1 Notes S1-11
1.3.2 Abbreviations S1-11
1.3.3 Units of Measurement S1-11
1.4 PROGRAMME OF WORKS S1-12
1.5 LIMITATION OF SITE S1-12
1.6 SUPPLY OF MATERIALS S1-12
1.7 MATERIALS OF MALAYSIAN ORIGIN S1-12
1.8 SETTING OUT S1-13
1.9 DIMENSIONS AND LEVELS S1-13
1.10 PROTECTION OF WORKS S1-13
1.11 DESIGN OF TEMPORARY WORKS BY THE CONTRACTOR S1-13
1.12 CONTRACTOR'S SUPERINTENDENCE S1-14
1.13 INSPECTION AND TESTS S1-14
1.14 COVERING UP OF WORK S1-14
1.15 OFFICE ACCOMMODATION FOR S.O. AND HIS STAFF S1-14
1.16 VEHICLES FOR THE S.O.'S STAFF S1-16
1.17 CONTRACTOR'S OFFICE AND ACCOMODATION S1-16
1.18 MATERIAL TESTING LABORATORY AND STAFF S1-16
1.19 PROVISION FOR SURVEY INSTRUMENTS AND CHAINMEN S1-17
1.20 MAINTENANCE OF EXISTING ROADS AND PROTECTION
OF TRAFFIC S1-17
1.20.1 Maintenance of Existing Roads, Bridges, Culverts, etc. S1-17
1.20.2 Temporary Diversions S1-17
1.20.3 Half-width Construction and Traffic Control S1-18
1.20.4 Temporary Traffic Signs S1-19
1.20.5 Temporary Works S1-19
1.21 LOCATION, TEMPORARY PROTECTION AND TEMPORARY
DIVERSION OF PUBLIC UTILITY INSTALLATIONS AND
OTHER SERVICES S1-19
1.22 WATER AND ELECTRICITY SUPPLY S1-20
1.23 PROJECT SIGNBOARD S1-20
1.24 PHOTOGRAPHIC RECORD OF WORKS S1-20
1.25 AS-BUILT DRAWINGS AND MICROFILMING S1-21
1.26 CLEARING UP OF SITE S1-21
1.27 OPPORTUNITIES FOR OTHER CONTRACTORS S1-21

Page
APPENDIX 1A GENERAL DESCRIPTION OF PROJECT S1-22
APPENDIX 1B SCOPE OF WORKS S1-23
APPENDIX 1C VEHICLES FOR S.O. AND HIS STAFF S1-24
APPENDIX 1D LIST OF LABORATORY EQUIPMENT
(a) Soil Testing Equipment S1-25

(b) Concrete Testing Equipment S1-27
(c) Flexible Pavement Testing Equipment S1-27
APPENDIX 1E SURVEY EQUIPMENT S1-30
FIGURE 1-1 APERTURE CARD FOR MICROFILM S1-31

SECTION 1 - GENERAL iv) The terms "Engineer" and

"Superintending Officer" shall be
synonymous.
1.1 GENERAL DESCRIPTION OF
THE PROJECT
1.3.2 Abbreviations
The general description of the project is as
given in Appendix 1A. a) M.S. means Malaysian Standards
published by the Scientific and
1.2 SCOPE OF WORKS Industrial Research Institute of
Malaysia (SIRIM).
The Works covered in this Contract comprise
the provision by the Contractor at his own risk b) B.S. means British Standards
and cost of all materials, tools, plants, labour, published by the British Standard
transport and everything else necessary for the Institution.
construction and completion of the Works as
given in Appendix 1B all to the approval of the c) A.A.S.H.T.O. means The American
S.O. Association of State Highway and
Transportation Officials.
1.3 NOTES, ABBREVIATIONS AND
UNITS OF MEASUREMENT d) A.S.T.M. means The American
Society for Testing and Materials.
1.3.1 Notes
e) M.D.D. means Maximum Dry
i) Any clause in this Specification which Density.
relates to work or materials not included
in the Works shall be deemed not f) O.M.C. means Optimum Moisture
applicable. Content.
ii) Unless stated to the contrary, any g) C.B.R. means California Bearing
dimension of material described means Ratio.
the finished or fully compacted
dimension. h) S.O. means Superintending Officer.
iii) All Standards and Codes of Practice i) B.Q. means Bill of Quantities.
referred to in this Specification shall be
deemed to be the editions current at the
time of Tender. If the Malaysian 1.3.3 Units of Measurement
Standard exists, which the S.O. deems to
be equivalent to the British or other All units of measurement used in this
Standard specified, then the Malaysian Specification and in the Bill of
Standard shall be followed. Quantities shall be in accordance with
the metric system unless otherwise
In the event of any discrepancy between stated.
the provision of this Specification and
the provision within the relevant Where British Imperial units are shown
Standards or Codes of Practice as or stated the following conversions shall
mentioned in this Specification, then the apply :-
provision of this Specification shall take
precedence.

1 inch = 25.40 millimetres Should the Contractor require additional

1 foot = 0.3048 metres land outside the Site for his workyards,
1 lb = 0.4536 kilograms stores, offices, temporary haul roads or
1 gallon = 4.5461 litres any other temporary structures, he shall,
1 lb/sq.in = 6.895 x 10-3 N/sq.mm on his own, purchase or rent any
additional area he may need.
1.4 PROGRAMME OF WORKS Areas or area to be rendered as part of

the Site shall be subject to the S.O.'s
Within thirty (30) days after the receipt approval.
of the Letter of Acceptance of Tender,
the Contractor shall submit to the S.O. 1.6 SUPPLY OF MATERIALS
for his approval a programme showing
the order of work activities and time The Contractor shall place orders for
schedule in which the Contractor specified materials at such times as
proposes to carry out the Works and will enable him to execute the Works in
shall, whenever required by the S.O. or accordance with his approved
the S.O.'s representative, furnish in programme.
writing, particulars of the Contractor's
arrangement for carrying out such works If the Contractor's failure to supply any
and of the construction plants and material causes any interruption or delay
temporary works, if any, which the in the progress of the Works, the
Contractor intends to supply, use or Government may supply any portion
construct as the case may be. The or all of the materials and the cost
submission to and approval by the S.O. borne by the Contractor shall be either
or the S.O.'s representative of such a that as calculated at the current market
programme or the furnishing of such rates or the actual cost to the
particulars shall not relieve the Government at the date of supply,
Contractor of any of his duties or including overheads or any other
responsibilities under the Contract. charges, whichever is the greater.
If at any time it should appear to the Any costs incurred under this Section
S.O. that the actual progress of the shall be deducted from the Contract
Works does not conform to the approved Sum. No claim for loss of profit under
programme referred to herein before, the the conditions of this Contract shall be
Contractor shall submit for approval, a deemed to have arisen. No action taken
revised programme showing the under this Section shall in any way
modifications to the previously affect or modify the right of the
approved programme necessary to Government to claim for damages in the
ensure the completion of the whole event of the Contractor's failure to
Works within the time set for complete the Works by the agreed date.
completion.
1.7 MATERIALS OF MALAYSIAN
ORIGIN
1.5 LIMITATION OF SITE
Materials of Malaysian origin where
The Contractor shall ensure that all his available must be used by the Contractor
plants, materials, temporary workshops, to the exclusion of imported materials
stores and offices are kept within the and this requirement shall be allowed
Site at locations approved by the S.O. for in his tender.

Under no circumstances shall the Before the Works or any part thereof are
Contractor be permitted to use imported commenced, the Contractor shall verify
materials unless he can prove to the the levels of the existing ground surface
satisfaction of the S.O. that the within areas where earthworks are to be
materials are not available locally, or if performed and the locations and bed
available are not of an acceptable levels of water-courses. These may
standard. differ from the locations and levels
shown on the Drawings owing to
changes which could have taken place
1.8 SETTING OUT during the interval between the original
survey and construction.
Before commencing the Works at any
location, the Contractor shall provide The levels and dimensions taken by the
and install precast concrete reference Contractor jointly with the S.O. shall
beacons on both sides of the road form the basis of measurement of the
centre-line at a spacing of 300 metres. relevant work quantities.
The beacons shall be firmly sited at right
angles to the centre-line at a distance
from the centre-line of 15 metres or such 1.10 PROTECTION OF WORKS
other distance as directed by the S.O.
The beacons shall be not less than 75 From the commencement of the Works
mm square in plan and shall project at to the date the Works are taken over by
least 600 mm above the surrounding the Government, the Contractor shall
ground. Each beacon shall be clearly take full responsibility for the care there
marked with its chainage and elevation of together with all temporary works
above datum. and in case any damage, loss or injury
shall happen to the Works or to any part
The Contractor shall take all practicable thereof or to any temporary works from
steps to safeguard the beacons including any cause whatsoever, he shall at his
fencing and concreting-in where own cost repair and make good the
necessary in the opinion of the S.O. and same so that at completion, the Works
shall immediately replace any damaged shall be in good order and condition and
beacons. The Contractor shall give the in conformity in every respect with the
S.O. not less than 24 hours notice of his requirements of the Contract and the
intention to set out or give levels for S.O.'s instructions. The Contractor shall
any part of the Works in order that also be liable for any damage to the
arrangements may be made for Works occasioned by him in the course
checking. of any operations carried out during the
Defects Liability Period.
1.9 DIMENSIONS AND LEVELS 1.11 DESIGN OF TEMPORARY

WORKS BY THE CONTRACTOR
All temporary benchmarks, reference
markers and levels as shown on the Unless otherwise provided in the
Drawings shall be checked on the Site Drawings, the Contractor shall submit to
by the Contractor at his own expense the S.O. for his approval, 2 copies of all
and be confirmed by the S.O. working or shop drawings produced by
him including all drawings made by his
approved sub-contractors for all
temporary works.

Such submission shall be made at least The Contractor shall provide the
two weeks before the temporary work is necessary attendance whenever required
scheduled to commence. by the S.O. or his representative.
Notwithstanding the approval by the
S.O., the Contractor is solely responsible Notwithstanding any tests which may
for the adequacy and safety of his work have been carried out off the Site, the
and for any necessary modification or S.O. shall be empowered to order
addition whenever found necessary by further tests of any materials or goods to
the S.O. be made on the Site and to reject such
materials or goods should they fail to
pass such tests on Site.
1.12 CONTRACTOR'S
SUPERINTENDENCE When required by the S.O., the
Contractor shall submit a copy of the
The Contractor shall provide all result of any quality control test carried
necessary superintendence during the out by the Contractor on his own during
execution of the Works and as long the progress of the Works.
thereafter as the S.O. may consider
necessary for the proper fulfillment of 1.14 COVERING UP OF WORK
the Contractor's obligations under the
Contract. Before any part of the Works is
permanently covered up, the Contractor
A competent Site Agent, whose shall give due notice to the S.O. for the
appointment shall be approved by the inspection and measurement of
S.O., shall be employed by the dimensions. The S.O. shall attend
Contractor for management on Site. without unreasonable delay for the
The Site Agent shall have the authority purpose of examination and
to receive instructions from the S.O. and measurement unless he considers it
to act on behalf of the Contractor. The unnecessary and advises the Contractor
Site Agent shall be stationed on Site for accordingly.
the whole duration of the Contract and
shall not be replaced without the 1.15 OFFICE ACCOMMODATION FOR
approval of the S.O. S.O. AND HIS STAFF
If the Site Agent needs to be absent from The Contractor shall provide and
Site for more than three (3) consecutive maintain a site office for the use of the
days, he shall give prior notice to the S.O. and his supervisory staff, all in
S.O. who may require the Contractor to accordance with the relevant Drawings
temporarily appoint another Site Agent. inclusive of all furniture and fittings as
shown on the Drawings.
1.13 INSPECTION AND TESTS
The Contractor is permitted to provide a
The S.O. or his representative may at relocatable site office as an alternative to
any stage of the Works carry out the JKR designed type shown on the
inspection, measurement and tests on Drawings.
any part of the Works to ensure
compliance with the requirements of this
Specification and of the Drawings.

The quality of such a relocatable site Sanitary facilities with disposal to

office shall be of equivalent standard but septic tanks located not nearer than 5 m
not inferior to the JKR designed type from the building shall be provided.
and shall be equipped with similar
furniture and fittings as indicated in the The office shall be illuminated by
JKR designed site office. fluorescent fittings giving a general level
of illumination of at least 2 lumens/
Where a relocatable site office is to be sq.m. Additional lighting in the form of
provided, the Contractor shall submit wall or deck lamps shall be provided
details of the relocatable site office where required by the S.O. Lighting to
together with his tender. Such details toilets and corridors may be by tungsten
should include the name of the filament bulbs.
manufacturer, floor area and layout, list
of furniture and fittings and brochures if Thermostatically controlled air-
available. The Contractor shall also conditioners capable of maintaining a
indicate whether the proposed site office temperature below 23°C in the office
is new or otherwise. shall be provided.
Unless otherwise shown on the The Contractor shall arrange for the
Drawings, the site office is to be sited, installation of a telephone with a
constructed and positioned as approved separate connection to the telephone
by the S.O. exchange for the exclusive use of the
S.O. at all times. The telephone shall
The Contractor shall make proper also be be fitted with 4 extensions unless
arrangements for and pay all charges in not required by the S.O. The Contractor
connection with conservancy. The site shall be responsible for the connection
office shall comply with local building to such exchange and the payment of
by-laws. It shall be erected or provided rental for the telephone services but the
by the Contractor within four (4) weeks Government shall reimburse the
from the date of possession of Site. Contractor for the cost of making calls.
On completion of the Works, the Where a telephone exchange is not

Contractor shall further maintain the site within practical distance, an automatic
office till the end of the Defects Liability mobile telephone such as the ATUR
Period unless otherwise directed by the (Automatic Telephone Using Radio)
S.O. and thereafter remove from the Site service shall be provided.
the site office with all furniture and
fittings which become the property of The Contractor shall keep the offices
the Contractor. accessible at all times and in every way
habitable for working purposes
Where electricity and piped water are throughout the duration of the Contract.
available from public utility authorities, The Contractor shall also provide such
the Contractor shall arrange for the site labour and cleaning materials as are
office to be connected to the electricity required to maintain the site office in a
and water supplies.Otherwise, the thoroughly clean and sanitary condition.
Contractor shall supply the site office
with electric power from generators and
shall provide an adequate supply of
water for washing and potable filtered
water for drinking purposes.

1.16 VEHICLES FOR THE S.O.'S When instructed by the S.O., the
STAFF Contractor shall remove all such
buildings and appurtenant works from
The Contractor shall provide new the Site, clean up the area and restore it
vehicles as listed in the B.Q. and to its original condition.
Appendix 1C for the sole use of the S.O.
and his staff at all times. All necessary The Contractor shall provide adequate
fuel, oil and lubricants, general first aid facilities appropriate to the size
maintenance, comprehensive insurances and composition of his staff and labour
and roadtax shall be provided by the force. The Contractor shall afford the
Contractor together with a licensed and S.O.'s site staff full use of the services
competent driver for every vehicle. and facilities as and when required.
Replacement vehicles shall be provided
when normal vehicles are not available 1.18 MATERIAL TESTING
such as during periods of servicing, LABORATORY AND STAFF
maintenance or repair. The vehicles will
revert to the Contractor at the The Contractor shall provide and
completion of the Contract unless maintain a laboratory at the Site
otherwise stated in the B.Q. throughout the duration of the Contract.
Earthworks and pavement construction
1.17 CONTRACTOR'S OFFICE AND will not be permitted to commence until
ACCOMODATION the laboratory and necessary equipment
have been provided.
The Contractor shall provide and
maintain a suitable office for himself The said laboratory shall be in
and his staff in a position or positions to accordance with the Drawings and shall
be approved by the S.O. be equipped as indicated in Appendix
1D. It shall be maintained in a clean
In addition, the Contractor shall provide and tidy condition to the satisfaction of
and maintain temporary accomodation the S.O. The laboratory shall be
and living facilities, stores, workshops, adequately supplied with water and
etc., including all necessary services for electricity.
water supply, drainage and lighting for
his staff. Before any work can The laboratory shall be used exclusively
commence the Contractor shall submit by the S.O. and his staff. However the
to the S.O. details of the proposed Contractor shall provide helpers to assist
buildings and services and shall obtain the S.O. as and when requested.
the S.O.'s approval together with any
necessary approval in writing from the All laboratory equipment shall become
relevant statutory authority. the property of the Contractor on
completion of the Works.
The Contractor shall be responsible for
all fees and other charges or expenses On completion of the Works, the
incurred in connection with such office building shall be removed from the Site
and housing and shall keep the whole and the Site left in a neat and tidy
area in a clean, tidy and well drained condition.
condition.

1.19 PROVISION FOR SURVEY He shall also be responsible for

INSTRUMENTS AND CHAINMEN maintaining the free flow of traffic on
these sections of existing road.
The Contractor shall provide for the sole
use of the S.O. and his staff all such The Contractor shall arrange for the
instruments, equipment and chainmen as conveyance of materials and plants so as
the S.O. may require to enable him to to cause minimum damage to existing
check the accuracy of the Contractor's roads and installations and minimum
setting out and any measurements taken. inconvenience to the public. He shall
The chainmen shall have knowledge of not deposit any earth, rubbish or
Bahasa Malaysia or English and as far materials upon any road, street,
as possible the same men shall be pavement or footway to cause hindrance
provided throughout the Contract or obstruction of vehicles or pedestrians.
period.
The instruments and equipment to be any damage caused by any work carried
provided are as listed in Appendix 1E. out by him or by construction traffic to
any existing roads or installations from
The Contractor shall be responsible whatsoever cause arising thereof and
throughout the Contract period for all shall repair, maintain and reinstate the
such instruments, equipment and same to their original condition to the
chainmen and shall ensure that the satisfaction of the S.O. The Contractor
instruments and equipment are at all shall also keep such roads clear of
times in good working condition and slurry, boulders and loose earth which
adjustment. All instruments and may be dropped in the course of
equipment shall remain the property of transportation.
the Contractor on completion of the
Works. Upon failure on the part of the
Contractor to fulfill his obligations
under this Section, the S.O. may take
1.20 MAINTENANCE OF EXISTING whatever action and any means
ROADS AND PROTECTION necessary to satisfy the requirements
OF TRAFFIC and all costs incurred by the S.O. shall
be deducted from any monies due or to
1.20.1 Maintenance of Existing Roads, become due to the Contractor under this
Bridges, Culverts, etc. Contract.
The Contractor shall maintain all 1.20.2 Temporary Diversions

sections of existing roads and all
bridges, drains and culverts included Temporary diversions shall be
therein within the Site to the constructed wherever the Site is
conditions at the time of possession intersected by existing roads, footpaths,
of Site for the full duration of the cycle tracks, access to properties, etc.
Contract. Such maintenance shall
include routine activities such as Such diversion ways shall be of a
grass cutting, clearing of drains, standard of construction at least
patching of potholes, etc. equivalent to that of the original road,
path, track or access.

They shall be constructed in advance If the Contractor fails to maintain

of the closure of the existing ways and/or reinstate these temporary
and regularly maintained, for as long diversion ways to the satisfaction of
as required, in a satisfactory the S.O., the S.O. shall have the right
condition. On completion of the to carry out these works himself and
work, the original ways shall be all costs incurred shall be deducted
reinstated to their original condition from the Contract Sum.
to the approval of the S.O. At least
fourteen (14) days notice in writing Where, in the opinion of the S.O., a
of any proposed temporary detour is not feasible, construction
diversions of traffic shall be given to on existing public roads shall be
the S.O. for his approval. undertaken only over half of the full
width of the roadway at any time.
Where access roads are to be The lengths of such half-width
permanently closed by the construction shall be kept as short as
construction of the Works, as shown is practicable.
on the Drawings, diversion ways
shall not be required. Such For all temporary diversions, the
closures shall not be effected until Contractor shall provide, install and
any specified alternative access has maintain adequate temporary
been provided and only with the construction signs in accordance
written approval of the S.O. with Sub-Section 1.20.4.
The Contractor shall maintain 1.20.3 Half-width Construction and Traffic

reasonable access to all properties Control
adjoining the Works where such
access exists during construction, Where half-width construction is
and shall ensure that all the necessary, work on culverts shall be
necessary fences, planking and completed and the embankment
gangways are adequately lit to the adjacent to them must be reinstated
satisfaction of the S.O. so that at least half the full width
shall be available for use by the
Where the Contractor proposes to public at all times.
use existing local streets as
temporary diversion ways, he shall In the event of the operation of
give at least fourteen (14) days single-way traffic becoming
notice in writing of his proposal to necessary and when approved by the
the S.O. for his approval. The S.O. on any particular length of the
Contractor shall maintain and/or Works or on the Works or on the
reinstate these temporary diversion approaches to the Works, the
ways to their original condition Contractor shall maintain through
throughout the entire duration of the traffic routes by providing a width of
temporary diversion, all to the at least 3 metres for single-way
satisfaction of the S.O. traffic. He shall also provide
approved electrically operated
signals for traffic control on each of
the affected lengths and any
additional traffic signs as may
be directed.

The electrical signal lights shall be Construction and excavation shall be

automatic in operation, but the sign posted and, during periods of
S.O. may, at any time, require them darkness, shall be lit to the approval
to be hand operated by a competent of the S.O.
operator.
Temporary traffic signals shall
The Contractor shall make suitable comply with the requirements of the
arrangements for emergency ARAHAN TEKNIK (JALAN)
servicing of the electrically operated 2C/85 published by Cawangan
traffic signals to be available at all Jalan, Ibu Pejabat JKR, Kuala
times. Manually operated "Stop/Go" Lumpur and shall be reflectorised
signs shall only be used with the and kept clean and legible at all
prior approval of the S.O.; and shall, times.
if so approved, be of the size, colour
and type as shown on the Drawings The Contractor shall position, cover
and complying with the requirements or remove these signs as may be
of the ARAHAN TEKNIK(JALAN) directed by the S.O.
2C/85 (Manual on Traffic Control
Devices for Temporary Signs and 1.20.5 Temporary Works
Work Zones Control), published by
Cawangan Jalan, Ibu Pejabat JKR, The Contractor shall provide,
Kuala Lumpur. maintain and remove on completion
of the Works all temporary works
At least fourteen (14) days notice in including diversion ways, tracks,
writing of any proposed single-way staging, bridging, etc., and shall
traffic system shall be given to the make them safe and suitable in every
S.O. for his approval before such a respect for carrying all plants and
system can be implemented. materials and for all purposes related
to the Works.
1.20.4 Temporary Traffic Signs
1.21 LOCATION, TEMPORARY
The Contractor shall at all times take PROTECTION AND
full and sufficient precautions to TEMPORARY DIVERSION OF
ensure the safety of all traffic PUBLIC UTILITY
through and around the Work Site INSTALLATIONS AND OTHER
and of traffic that is diverted owing SERVICES
to the Works.
To this end the Contractor shall erect locating the positions of all public utility
and maintain on the Site and at installations, including water mains,
prescribed points on the approaches overhead and underground cables, pipes,
to the Site, all traffic signs, signals sewers and drains and all service
and warning lights necessary for the connections to buildings, and where
direction and control of traffic. The necessary, shall adopt such methods of
sizes of all such signs and the excavation as may be required by the
lettering and wording thereon shall appropriate authorities or owners to
be as shown on the Drawings and ensure that no damage is caused to
approved by the S.O. before erection. them.

The Contractor shall make good, at his 1.22 WATER AND ELECTRICITY
own expense, any damage caused by him SUPPLY
to the existing services to the approval of
and in accordance with the instruction of The Contractor shall provide at his own
the appropriate authority or owner risk and cost all water, lighting and
concerned, and shall keep the Government electric power where required for use in
indemnified at all times from all claims, the Works and shall pay all costs, fees
costs and expenses which may arise on and charges and comply with all safety
account of any damage (whether regulations and statutes in connection
permanent, temporary or recurring) to the therewith.
said services.
The Contractor shall also provide and
All such installations which are maintain temporary water storage
encountered in the course of the Works together with any distribution piping
shall be adequately supported, slung-up, which may be necessary.
strutted or otherwise protected from injury
to the satisfaction of the respective
authority. 1.23 PROJECT SIGNBOARD
The temporary diversion or relocation of The Contractor shall provide, erect and
any service within or outside the Works to maintain signboards at locations to be
permit the construction of the Works shall decided by the S.O. and pay all charges
be the responsibility of the Contractor. in connection with this, including
Where a service is required to be obtaining permission, licences and fees,
interrupted or relocated the Contractor etc. Each sign board shall comply with
shall inform and obtain the approval of the the design and specification as shown on
S.O. who shall notify the appropriate the Drawings. On completion of the
authority or owner of the required removal project, the Contractor shall dismantle
and/or relocation. and clear away the signboards as
directed by the S.O.
Temporary diversion shall mean works
involved in the diversion of services that 1.24 PHOTOGRAPHIC RECORD OF
will be reinstated to their original position WORKS
and condition on completion of the works
in the affected areas. In planning his work The Contractor shall provide a camera
for the diversion or relocation of services, of reasonable quality for the purpose of
the Contractor shall make reasonable taking record photographs and slides of
allowance for the time necessary to obtain the Works as and when directed by the
the S.O.'s approval for the work and for the S.O. The Contractor shall bear the costs
appropriate authorities or owners to of providing the film, development of
authorise the work, obtain the necessary film, printing two (2) copies of each
materials and carry out the work. exposure in 3R size and documenting
the photographs in suitable albums.
The Contractor shall not be entitled to any
extension of time due to his failure to The negatives of the photographs shall
allow for a reasonble period of time be the property of the Government and
necessary for obtaining approval and no prints from these negatives may be
completing the work. supplied to any person or persons except
with the approval of the S.O.

A suitably typed caption shall be affixed On completion of the Works, the

to the reverse side of each photograph Contractor shall remove all rubbish,
describing the subject and the time at debris and surplus materials from the
which it was taken. One copy of each Site and leave the whole Site in a neat
photograph shall be signed by the and tidy condition to the satisfaction of
Contractor and the S.O. the S.O.
1.25 AS-BUILT DRAWINGS AND 1.27 OPPORTUNITIES FOR OTHER

MICROFILMING CONTRACTORS
Drawings for recording as-built The Contractor shall, when required by

construction details of the Works shall the S.O., afford all reasonable
be prepared by the Contractor and shall opportunity to any other Contractors
be certified by the S.O. or his employed by the Government and their
representative. The originals, in good workmen and to the workmen of the
quality transparencies, and two (2) Government and of any other duly
printed copies of all as-built drawings constituted authorities who may be
shall be supplied by the Contractor to employed in the execution on or near
the S.O. progressively as sections of the the Site of any work not included in the
Works become completed. All drawings Contract.
shall be completed within one month
after the completion of the respective
section.
As-built drawings shall be A1 size (838

mm x 584 mm) unless otherwise
approved by the S.O.
The Contractor shall also microfilm the

as-built drawings using 35.0 mm film
with the aperture card format as shown
in Figure 1-1 and submit the same to the
S.O.
1.26 CLEARING UP OF SITE
The Contractor shall make every effort

to keep the Site in a reasonably clean
and tidy condition for the duration of the
Works. He shall, in addition, from time
to time on the completion of any area of
the Works or where directed by the S.O.,
remove rubbish, surplus materials, or
any other construction debris from such
areas as may be attributable to his work
under this Contract and generally leave
them in a satisfatory condition, to the
approval of the S.O.

APPENDIX 1A
GENERAL DESCRIPTION OF PROJECT

APPENDIX 1B
SCOPE OF WORKS

APPENDIX 1C
VEHICLES FOR S.O. AND HIS STAFF
All vehicles shall be NEW and of the types listed below :-
Type A - 2000 c.c. four-door, air-conditioned saloon car;
Type B - 1600 c.c. five-door, air-conditioned estate car;
Type C - 1500 c.c. four-door, air-conditioned Proton Saga;
Type D - 2000 c.c. four-wheel-drive, air-conditioned Trooper or equivalent with hard top;
Type E - 2250 c.c. four-wheel-drive, air-conditioned long-wheel- base Land Rover or

equivalent with hard top.

APPENDIX 1D
LIST OF LABORATORY EQUIPMENT
The Contractor shall provide and maintain the following testing laboratory equipment which shall
become the property of the Contractor at the end of the Contract :-
No.
(a) Soil Testing Equipment
(1) Moisture content tins - 76 mm x 25 mm with lids. 25
(2) Electric balance of 1 kg capacity, accurate to 0.1 g with a tare correction of

not less than 100 g. 1
(3) Electric forced draught oven, capacity of 0.08 cu.m. 1
(4) Atterberg limit machine calibrated with a grooving device as specified in B.S. 1377. 1
(5) Glass plates - 457 mm x 609 mm x 6 mm. 2
(6) Linear shrinkage moulds - 254 mm. 5
(7) Spatulas - 152 mm. 2
(8) 203 mm diameter B.S. sieves - 75 mm, 63 mm, 50 mm, 37.5 mm,
28 mm, 25 mm, 20 mm, 14 mm, 12.5 mm, 10 mm, 9.5 mm, 6.3 mm,
5 mm, 4.75 mm, 3.35 mm, 2.36 mm, 2 mm, 1.18 mm, 600 um,
425 um, 300 um, 212 um, 150 um, 75 um. Lid and pan together with
vibrating machine. 1 of each
(9) 203 mm diameter B.S. sieves - 75 um, 425 um. 2 of each
(10) Wash sieves - 75 um. 2
(11) Sample splitter - 50 mm. 2
(12) Sample splitter - 12 mm. 2
(13) Balance of 10 kg capacity, accurate to 1 g. 1
(14) Standard compaction hammer, electric motor operated, as specified in B.S. 1377. 1

No.
(15) Standard compaction mould as specified in B.S. 1377. 1
(16) Compaction mould extruder as specified in B.S. 1377. 1
(17) Steel scoop. 1
(18) Rubber mallet. 1
(19) Measuring flasks - 1000 c.c. 2
(20) Vernier calipers - 152 mm. 1
(21) Steel rule - 305 mm. 1
(22) Compression machine suitable for laboratory and field C.B.R.'s with all
fittings necessary for field and laboratory operation as specified in B.S. 1377. 1
(23) C.B.R. moulds fitted with collars and base plates for compaction and soaking
and tripods for small measurement fitted with dial gauges having 0.01 mm
divisions and 25 mm travel as specified in B.S. 1377. 10
(24) 2.26 kg surcharge weights - ring type. 6
(25) 2.26 kg surcharge weights - horseshoe type. 9
(26) Complete field density kit, sand replacement type suitable for volume
measurement of 0.005 cu.m to an accuracy of not less than 0.0001
cu.m as specified in B.S. 1377. 2
(27) Hand auger suitable for boring to depths of 3 m and supplied with 100 mm
diameter heads suitable for boring in cohesive and cohesionless soils. 1
(28) Crowbar, pick and spade. 1 of each
(29) Drying pans - 406 mm x 406 mm x 76 mm. 6
(30) British Standard 1377 - "Methods of Test for Soils for Civil Engineering
Purposes", latest edition. 1

(b) Concrete Testing Equipment
No.
(1) 152 mm x 152 mm x 152 mm standard concrete test cube steel moulds
as specified in B.S. 1881. 6
(2) Slump cones with tamping rods as specified in B.S. 1881. 2
(3) Compacting factor apparatus as specified in B.S. 1881. 1
(4) Tank for curing of concrete specimens to accomodate 50 Nos. x 152 mm

cubes in layers not more than 50 mm deep. 1
(c) Flexible Pavement Testing Equipment
(1) Metal tray, 0.6 m square or similar suitable for measuring spray rates of
bituminous materials and spread rates of cover aggregate for surface dressing. 4
(2) Metal thickness gauge (or set of slotted sleeves) as specified in M.S. 30 for
determination of aggregate flakiness index. 1
Additional items required for asphaltic concrete and/or bituminous Macadam :-
(3) Balance of 2 kg capacity, accurate to 0.1 g suitable for weighing samples

suspended in liquid. 1
(4) Steel moulds for Marshall test specimens (100 mm diameter) with base,
extension collar, extraction collar and extraction plate as specified in B.S. 598. 6
(5) Extractor for removing Marshall test specimens from moulds without distortion
or shock as specified in B.S. 598. 1
(6) Compaction hammer and automatic compactor for Marshall test specimens as
specified in B.S. 598. 1 of each
(7) Compaction pedestal and mould holder for Marshall test as specified
in B.S. 598. 1 of each
(8) Thermostatically controlled hot plate. 1
(9) Thermometers for use in laboratory and in asphaltic mixes for Marshall test as
specified in B.S. 598. 2 of each

No.
(10) Rubber and heat resistant gloves. 2 pairs of each
(11) Filter papers - 100 mm diameter. As needed
(12) Containers for heating aggregates and bituminous materials. As needed
(13) Pavement coring machine of the thin-walled diamond bit type for
obtaining 100 mm diameter samples of bituminous surfacings. 1
(14) 100 mm diameter thin-walled diamond bits for use with pavement
coring machine. As needed
(15) Tools for cutting and trimming pavement cores. As needed
(15) Metal bottles of suitable capacity for bitumen extraction by direct

determination as specified in B.S. 598. As needed
(16) Machine to rotate the bottles about their longitudinal axes at a speed of
between 10 rev/min to 30 rev/min as specified in B.S. 598. 1
(18) Volumetric flasks of suitable capacity. As needed
(19) Centrifuge capable of developing an acceleration of 25,000 m/sq.

second as specified in B.S. 598. 1
(20) Filtration apparatus for extraction of bitumen by direct determination as

specified in B.S. 598. 1
(21) Recovery apparatus for extraction of bitumen by direct determination

as specified in B.S. 598.
(22) Pressure filter of appropriate size, air pump and funnel for extraction
of bitumen by direct determination as specified in B.S. 598. 1 of each

No.
Further items required for asphaltic concrete :-
(23) Wire basket of 6.5 mm or smaller mesh with wire hanger as specified in
M.S. 30, for determination of specific gravity and water absorption
of aggregates. 1
(24) Airtight container of similar capacity as wire basket above. 1
(25) Gas jar - 1.5 litre. 1
(26) Pyconometer - 1 litre. 1
(27) Warm air blower. 1
(28) Mechanical mixer of 2 kg capacity, for preparation of asphaltic concrete mixtures. 1
(29) Thermostatically controlled water bath for Marshall test specimens as

specified in B.S. 598. 1
(30) Steel Marshall testing head as specified in B.S. 598. 1
(30) Compression testing machine with proving ring, capable of applying loads of
up to at least 22 kN at a constant rate of strain of 50 mm + 3 mm per minute
and recording the maximum load achieved as specified in B.S. 598. 1
(31) Dial gauge and mounting assembly for measuring Marshall test flows of up to
10 mm with accuracy of + 0.1 mm as specified in B.S. 598. 1
Testing which is specifically required in the Contract and any test defined in quoted British
Standard Specifications which are required to ensure compliance with the Contract but cannot be
done in the Site testing laboratory shall be carried out at approved laboratories off the Site. These
tests shall be carried out as directed by the S.O. The cost incurred by the Contractor shall be
deemed to have been included in the tendered rates.

APPENDIX 1E
SURVEY EQUIPMENT
The Contractor shall provide and maintain the following instruments and equipment for the
purpose of measurements and setting out. These shall become the property of the Contractor at the
end of the Contract :-
1 No. Theodolite of direct read out accurate to 1 second.
2 No. Automatic levels - Wild NA2 or Koni 007 or equivalent.
2 No. Levelling staves - 5 m aluminium.
1 No. 50 m x 5 mm steel measuring band divided throughout and numbered at 5 m intervals.

Divided over first 30 m at 1 m intervals. Divided over first 5 m at 50 mm intervals.
1 No. Repair set for the same.
2 No. 30 m steel box tapes, white face.
2 No. 30 m fibreglass box tapes.
10 No. 2.5 m ranging rods.
2 No. 1 m spirit level, steel or aluminium.
2 No. Survey umbrellas.
Templates, straightedges, canvas bags, pegs, hammers, parangs, etc.

Figure 1.1
APPERTURE CARD FOR MICROFILM

SECTION 2
EARTHWORKS

SECTION 2 - EARTHWORKS
Page
2.1 CLEARING, GRUBBING AND STRIPPING TOPSOIL S2-35
2.1.1 Description S2-35

2.1.1.1 Clearing S2-35
2.1.1.2 Grubbing S2-35
2.1.1.3 Stripping Topsoil S2-35
2.1.2 Construction Methods S2-35
2.1.2.1 Areas To Be Cleared S2-35
2.1.2.2 Areas To Be Cleared, Grubbed and Stripped Of Topsoil S2-36
2.1.2.3 Topsoil S2-36
2.1.2.4 Timber S2-36
2.1.2.5 Structures S2-37
2.1.2.6 Disposal Of Material S2-37
2.2 EARTHWORKS S2-38
2.2.1 Definitions S2-38
2.2.2 General Requirements S2-39
2.2.3 Roadway Excavation S2-39

2.2.3.1 Dimensional Tolerances S2-39
2.2.3.2 Separation and Stockpiling of Suitable Material S2-40
2.2.3.3 Removal of Excavated Material From Site S2-40
2.2.3.4 Removal of Unsuitable Material S2-40
2.2.3.5 Replacement of Unsuitable Material Under Standing Water S2-40
2.2.3.6 Widening Cuts S2-40
2.2.3.7 Excavation of Rock S2-41
2.2.3.8 Storage and Handling of Explosives S2-42
2.2.3.9 Blasting S2-42
2.2.3.10 Safety Measures S2-42
2.2.3.11 Insecure Material S2-43
2.2.4 Earth Embankment S2-43

2.2.4.1 Material S2-43
2.2.4.2 Borrow Pits S2-43
2.2.4.3 Placement of Fill Material S2-43
2.2.4.4 Compaction S2-44
2.2.5 Rock fill Embankment S2-45

Page
2.2.6 Embankment Over Soft Ground S2-46

2.2.6.1 Foundation Treatment S2-46
2.2.6.2 Surcharge and Staged Construction S2-46
2.2.6.3 Settlement Markers S2-46
2.2.6.4 Settlement Records S2-47
2.2.7 Subgrade S2-47
2.2.8 Protective Vegetation for Erosion Control S2-48

2.2.8.1 Topsoil S2-48
2.2.8.2 Turfing S2-48
2.2.8.3 Seeding S2-48

SECTION 2 - EARTHWORKS Clearing shall also include the

levelling of obsolete dikes,
terraces, ditches, etc., unless
2.1 CLEARING, GRUBBING AND otherwise directed by the S.O.
STRIPPING TOPSOIL
2.1.1.2 Grubbing
2.1.1 Description
Grubbing shall consist of the
This work shall consist of clearing, removal and disposal of surface
grubbing and stripping topsoil in the vegetation, the bases of stumps,
areas designated hereunder and/or roots, the underground parts of
shown on the Drawings and/or structures, and other obstructions
directed by the S.O., and of clearing to a depth of at least 0.50 metre
only in other areas designated here below ground level, all to the
under and/or shown on the Drawings satisfaction of the S.O.
and/or directed by the S.O., all as
specified herein and as required by 2.1.1.3 Stripping Topsoil
the S.O. The work shall also include
the demolition and disposal of Stripping topsoil shall consist of
structures in said areas, except where the removal of topsoil to an
otherwise provided for in the average depth of at least 100 mm
Contract, as specified herein and as below ground level, and its
required by the S.O. stockpiling for use in the Works,
and/or its disposal, as directed by
2.1.1.1 Clearing the S.O.
Clearing shall consist of the 2.1.2 Construction Methods

cutting and/or taking down,
removal and disposal of 2.1.2.1 Areas To Be Cleared
everything above ground
level, including objects The entire road reserve area shall
overhanging the areas to be be cleared as described above,
cleared such as tree branches, unless otherwise shown on the
except such trees, vegetation, Drawings and/or directed by the
structures or parts of structures, S.O.
and other things which are
designated in the Contract to Clearing shall be carried out to
remain, or be removed by others, the extents deemed necessary and
or which the S.O. directs are to approved or directed by the S.O.
be left undisturbed. The material in areas outside the road reserve
to be cleared shall include but not where channel excavation or
necessarily be limited to trees, other work is required.
stumps (parts above ground),
logs, brush, undergrowth, long In areas which are to be cleared
grasses, crops, loose vegetable only, and in which grubbing and
matter and structures (except stripping topsoil are not required,
those structures whose removal the methods of work shall be
or clearance is otherwise such as will not unduly damage
provided for in the Contract). the surface vegetation and
topsoil, and care shall be taken

not to disturb the topsoil and the This work shall be considered
root systems of grasses and other incidental to the work of clearing,
surface vegetation. No topsoil grubbing and stripping topsoil,
shall be removed from such and shall not be measured for
areas, except as directed by the payment.
S.O., and any topsoil, grasses and
other surface vegetation other 2.1.2.3 Topsoil
wise removed or disturbed shall
be replaced and made good at the Topsoil to be stockpiled for the
Contractor's own expense, all to Works shall be sufficiently fertile
the satisfaction of the S.O. to promote and support the
growth of vegetation, and shall be
2.1.2.2 Areas To Be Cleared,Grubbed taken from such areas where
and Stripped Of Topsoil clearing, grubbing and stripping
topsoil is required as approved or
Except as otherwise shown on directed by the S.O. Before
the Drawings and/or directed by stockpiling, topsoil shall be
the S.O., clearing, grubbing and separated from objectionable
stripping topsoil shall be carried materials, all to the satisfaction of
out in all areas of roadway the S.O. The Contractor shall
excavation and in all areas where arrange for stockpile sites either
embankment is to be constructed, within or outside the road
except that grubbing and reserve, at his own expense, and
stripping topsoil shall not be all to the satisfaction of the S.O.
carried out in those areas where :-
Otherwise, topsoil removed
i) embankment is to be during grubbing and stripping
constructed on earth operations shall be separated
designated as swamp or soft from objectionable materials and
ground; spread within the road reserve or
borrow areas, or otherwise
ii) embankment is to be disposed of, as approved or
constructed to a height at the directed by the S.O.
centre-line of 1.50 metres or
more on ground with a 2.1.2.4 Timber
cross-slope of not more than 1
(vertical) to 30 (horizontal). The ownership of timber is
vested in the Government.
Clearing, grubbing and stripping topsoil shall Saleable timber shall be trimmed
be carried out to the extents deemed necessary and stacked in accordance with
and approved or directed by the S.O. in areas the requirements of the
both inside and outside the road reserve where appropriate Government agency,
channel excavation or other work is required. in accessible places within the
road reserve as approved or
Except where further excavation is required, directed by the S.O.
holes and cavities in the ground surface after
clearing, grubbing and stripping topsoil shall be The Contractor shall have the
filled with materials similar to the adjacent right to use unsaleable timber (or
ground, and such fill shall be compacted to a saleable timber when permission
dry density similar to that of the surrounding is granted in writing by the
material, all to the satisfaction of the S.O.
appropriate Government agency Combustible material

or authority) for his own including all timber (except
purposes in connection with the timber to be salvaged or
Contract, always provided that he used), all brush, stumps,
shall comply with the roots, vegetation and other
requirements of the S.O. agency combustible refuse may be
or authority) for his own piled up within the road
purposes in connection with the reserve and burned, where
Contract, always provided that he burning is allowed.
shall comply with the
requirements of the S.O. All burning shall be subject
to the prior approval of the
2.1.2.5 Structures relevant Government
authorities, and shall be
Major structures are those which carried out in conformance
cannot practicably be cleared by with all pertinent
bulldozer and/or hydraulic regulations. Burning shall
excavator, whose demolition also be carried out at such
requires pneumatic tools, places and at such times and
explosives and/or other in such a manner as to
specialised equipment. A brief prevent fire from damaging
description of each major vegetation and property
structure (if any) and depth to within the road reserve
which extent it shall be designated to be preserved,
demolished is given in the Bill of and from spreading to areas
Quantities. adjoining the road reserve
and damaging vegetation
All fences, buildings, structures, and property therein.
and encumbrances of any
character within the limits of the Should the clearing,
road reserve, except those to be grubbing and stripping of
removed by others or designated topsoil be carried out at a
to remain, shall be demolished time when burning is not
and removed by the Contractor. permitted, the Contractor
may pile up combustible
Materials designated in the materials within the road
Contract or directed by the S.O. reserve outside the limits of
to be salvaged, shall be carefully the road works, and burn it
removed and stored, and shall be at a time when burning is
the property of the Government. permitted.
2.1.2.6 Disposal Of Material Where burning is not

permitted at any time, or the
Unwanted material from clearing, Contractor elects not to burn
grubbing and stripping topsoil unwanted material,
(including the demolition of combustible material shall
structures) shall be disposed of as be disposed of together with
approved or directed by the S.O. incombustible material.

Incombustible material, including ii) any material

where appropriate the remains of
burning, shall be disposed of in a - consisting of highly
safe and tidy manner at solid organic clay and silt;
waste dumps outside the Site,
unless otherwise approved or - which is clay having a
directed by the S.O. The liquid limit exceeding
Contractor shall be solely 80% and/or a plasticity
responsible for making the index exceeding 55%;
necessary agreements, and paying
expenses and claims arising from - which is susceptible to
the use of such solid waste spontaneous combustion;
dumps whether on Government
or private land. - which has a loss of weight
greater than 2.5% on
ignition;
2.2 EARTHWORKS
- containing large amounts
2.2.1 Definitions of roots, grass and other
vegetable matter.
(a) Formation Level
Materials that are soft or unstable
Formation level means the top merely because they are too wet
surface of the subgrade. or too dry for effective
compaction are not to be
(b) Subgrade classified as unsuitable, unless
otherwise classified by the S.O.
Subgrade means that part of the
embankment or existing ground (e) Suitable Materials
in cutting which is immediately
below the subbase or lower Suitable materials shall mean
subbase of the road pavement those materials other than the
and shoulders. unsuitable materials defined in
Sub-Section 2.2.1 (d) above.
(c) Common Excavation
(f) Rock
Common excavation shall mean
excavation in any materials Rock shall mean material found
which are not rock or artificial in ledges or masses in its original
hard materials as defined in position which would normally
Sub-Sections 2.2.1 (f) and (g). have to be loosened either by
blasting or by pneumatic tools or,
(d) Unsuitable Materials if excavated by hand, by wedges
and sledge hammers. It shall not
Unsuitable materials shall include material which can be
include :- loosened with a track-type tractor
with mounted and drawn ripper
i) running silt, peat, logs, of the following descriptions :-
stumps, perishable or toxic
material, slurry or mud, or

i) Tractor Unit : Equipment with a The Contractor shall provide where

minimum weight of 20 tonnes necessary temporary water courses,
and nett horse power rating of ditches, drains, pumping or other means of
200 brake horse power or more. maintaining the earthworks free from
The tractor unit is to be in good water. Such provision shall include
condition and operated by carrying out the work of forming the
experienced personnel skilled in cuttings and embankments in such a
the use of ripping equipment; manner that their surfaces have at all times
a sufficient gradient to enable them to shed
ii) Ripping Unit : The ripper to be water and prevent ponding.
attached to the tractor shall be the
most efficient parallelogram type In pumping out excavations and in the
recommended by the tractor or lowering of water tables the Contractor
ripper manufacturer. The ripper shall pay due regard to the stability of all
shall have a single shank in good structures.
working condition with
sharpened cutting point. Adequate means for trapping silt shall be
provided on all temporary drainage
Boulders or detached pieces shall only be systems. Similar arrangements shall be
regarded as rock if they individually made for all earthworks including
exceed 0.5 cubic metre. excavations whether for pile trenches,
foundations or cuttings.
(g) Artificial Hard Material
Should the surface of completed areas be
This shall mean any hard artificial damaged by erosion or by any other cause
material which would require the use the Contractor shall at his own cost make
of blasting or approved pneumatic good such areas to the satisfaction of the
tools for its removal but shall S.O.
exclude individual masses less than
0.5 cubic metre. The Contractor shall exercise care in
preventing wastage of suitable material
2.2.2 General Requirements needed for embankment or fill
construction.
The work shall include the
excavation of all types of material, 2.2.3 Roadway Excavation
backfilling, compaction, forming
embankments and slopes, etc., as is 2.2.3.1 Dimensional Tolerances
necessary for the completion of the
Works up to the formation levels, in Slopes in cutting shall be
accordance with the lines, grades, trimmed mechanically to neat
dimensions, shapes and typical and even surfaces which shall
cross- sections shown on the have gradients not steeper than
Drawings and to the approval of the that shown on the Drawings.
S.O. Widths of excavations shall not
exceed the dimensions shown on
the Drawings by more than 300
mm, unless otherwise approved
by the S.O.

2.2.3.2 Separation and Stockpiling of 2.2.3.4 Removal of Unsuitable Material

Suitable Material
Unsuitable material shall be
Where excavation reveals a excavated to such depth and over
combination of suitable and such area as directed by the S.O.
unsuitable materials, the and be transported and disposed
Contractor shall, wherever the of in an approved manner. Unless
S.O. considers it practicable, approval of the S.O. to dump and
carry out the excavation in such a spread the unsuitable materials
manner that the suitable materials within the Site is obtained, the
are excavated separately for use Contractor shall be responsible
in the Works without for providing his own dump site
contamination by the unsuitable for such unsuitable materials.
materials. The Contractor shall The Contractor shall comply with
stockpile separately material for statutory requirements such as
subgrade as specified in Sub- payment of royalties,
Section 2.2.7. environmental protection, etc.
Voids created due to removal of
2.2.3.3 Removal of Excavated Material unsuitable material shall be
From Site backfilled with suitable material
compacted to a dry density not
No excavated material shall be less than that of the surrounding
removed from the Site except on material or that specified for the
the direction or with the approval respective part of the earthworks
of the S.O. Should the or as directed by the S.O.
Contractor be permitted to
remove suitable materials from 2.2.3.5 Replacement of Unsuitable
the Site to suit his operational Material Under Standing Water
procedure, then he shall make
good any consequent deficit of Where it is decided by the S.O.
fill material arising there from, at that replacement of unsuitable
his own expense. Unless material shall be done under
designated dump sites have been standing water, voids created due
shown on the Drawings, the to removal of unsuitable material
Contractor shall dispose of shall be backfilled with hard
surplus suitable material at his clean crushed rock, natural gravel
own dump areas outside the Site or sand having grading within the
as approved by the S.O. In doing respective limits specified in
so, the Contractor shall comply Table 2.1.
with statutory requirements such
as payment of royalties, environ 2.2.3.6 Widening Cuts
mental protection, etc.
The S.O. may instruct the
Contractor or the Contractor
himself may elect to obtain
material for the Works by
widening cuts. In the latter case,
the Contractor shall first request
permission in writing from the
S.O.

TABLE 2.1 - GRADING LIMITS OF Where the rock is of satisfactory

MATERIALS FOR quality, the Contractor may elect to
REPLACEMENT OF crush and screen it to produce
UNSUITABLE MATERIAL aggregates required for concrete,
roadbase, subbase, or other purposes.
Excavated rock needed for earth
B.S. Sieve Size % Passing By work construction which the
Weight Contractor elects so to use for
producing select materials shall be
Crushed Rock or
replaced at the Contractor's own
Gravel expense by borrow of satisfactory
100 quality approved by the S.O.
63.0 mm 85 - 100
37.5 mm 0 - 20 Otherwise, excavated rock shall be
20.0 mm 0-5
used in the construction of
10.0 mm
embankment and fill, to the fullest
Sand practical extent, in either of the two
following ways :-
10.0 mm 100
5.0 mm 90 - 100
1.18 mm 45 - 80
300 um 10 - 30 i) excavated rock shall be broken
150 um 2 - 10 down to a maximum particle size
of 400 mm and used as rock fill
as described in Sub-Section 2.2.5;
2.2.3.7 Excavation of Rock ii) excavated rock shall be broken
down to a maximum particle size
Rock excavation shall be carried of 150 mm, blended with suitable
out by methods appropriate to earth fill material in a proportion
Site requirements as approved by not exceeding 1 rock to 1 earth,
the S.O. Where explosives shall and used as common fill.
be used, the relevant security
regulations dealing with The Contractor may only waste
purchase, transport, handling, excavated rock with the approval of the
storage and usage of explosives S.O. Excavated rock needed for
shall be complied with. earthwork construction which the
Contractor elects to waste shall be
All material from rock replaced at the Contractor's own expense
excavations shall be used as far by borrow of satisfactory quality
as is practicable in the Works. approved by the S.O.

2.2.3.8 Storage and Handling of All necessary precautions shall be

Explosives taken to preserve in the soundest
possible condition the materials
Proper buildings or below and beyond the lines of all
magazines, with separate excavations. Delayed blasting to
compartments for detonators, reduce shock waves shall be used
in suitable positions for the to avoid damage to concrete and
storage of explosives in other works already completed.
manner and quantities to be As the excavation approaches its
approved shall be provided. final lines, blasting shall be
The prevention of any carried out by means of parallel
unauthorised issue or drill holes perpendicular to the
improper use of any explosive toe of the excavation and parallel
brought on the Works shall be to the finally required face.
the responsibility of the
Contractor and only 2.2.3.10 Safety Measures
experienced and responsible
men shall be employed to When blasting is carried out close
handle explosives for the to properties or roads, appropriate
purpose of the Works. safety rules shall be strictly
adhered to. Where necessary or
2.2.3.9 Blasting as directed by the S.O., the use of
heavy mesh blasting mats shall
Explosives shall be used in be used to ensure that no damage
the quantities and manner is caused to persons or property
recommended by the on or off Site. Special care shall
manufacturers. Blasting shall be taken in wet ground to ensure
be restricted to such periods that individual explosions are
as the S.O. may prescribe. If, reduced to such size as to
in the opinion of the S.O., preclude damage to any buildings
blasting would be dangerous or structures. Plaster shooting
to persons or property or to will not be permitted within 400
any finished work, or is being metres of any building or
carried on in a reckless structure. If traffic on any road
manner, he may prohibit it, or railway has to be interrupted
and order the rock to be for blasting operations, the
excavated by other means. Contractor shall obtain approval
The use of explosives in large of his schedule for such
blasts, i.e. exceeding 9 kg of interruption from the appropriate
explosive, as in seams, drifts, authorities and shall prove to the
shafts, pits, or large holes, is S.O. that he has obtained it, prior
prohibited unless authorised to the interruption.
in writing by the S.O. Such
authorisation shall not in any
way relieve the Contractor of
his liabilities under the
Conditions of Contract.

2.2.3.11 Insecure Material 2.2.4.2 Borrow Pits
The slopes of cuttings shall be The Contractor shall be

cleared of all rock fragments responsible for locating
which move when prised with borrow pits. Designated
a crow-bar. Where, in the borrow pits shown on the
slopes of cuttings, layers of Drawings only indicate to the
rock and soft material Contractor potential areas for
alternate and the S.O. borrow. Whether the
considers that the slope, Contractor obtains materials
immediately after dressing, from the designated or his
will not permanently own borrow pit, it shall be his
withstand the effect of responsibility to ascertain the
weather, the Contractor shall suitability of the pit with
excavate any insecure respect to the quantity and
material to an approved depth quality of the materials, which
and build up the resulting shall be subject to the
spaces with grade 15P/20 approval of the S.O. The
concrete or masonry using Contractor shall pay all
rock similar to the adjoining necessary fees, taxes or
natural rock so as to ensure a royalties to the appropriate
solid face. authorities and observe all
relevant regulations. The
2.2.4 Earth Embankment Contractor shall keep the
borrow pits free from ponding
2.2.4.1 Material water and the excavation neat
and tidy and shall carry out
Fill materials for use in necessary erosion protection
forming embankments shall measures as instructed by the
be the suitable material S.O.
obtained from excavation in
cuttings. Where the quantity 2.2.4.3 Placement of Fill Material
of such materials is
inadequate, the Contractor All fill materials shall be
shall obtain suitable materials deposited in layers. The loose
from the designated borrow depth for each layer of fill
pits or from his own borrow shall be determined from the
pits which have been trial compaction. Each layer
approved by the S.O. shall extend over the full
width of the fill area and shall
be compacted in accordance
with the requirements of Sub-
Section 2.2.4.4. Each
compacted layer shall be
maintained at all times with a
sufficiently even surface in
order to drain away the
sur face water.

Where embankment is to be Compaction shall be

constructed on ground with a undertaken to the
cross-slope flatter than 1 requirements of this Section
(vertical) to 10 (horizontal) but by plant approved by the S.O.
steeper than 1 (vertical) to 30 All compaction requirements
(horizontal), the foundation shall be controlled by means
material, except where this is of field density measurement.
rock, shall be scarified to a depth
of 100 mm, blended with For compaction of
embankment fill material and embankment slope, the
compacted as described in Sub- Contractor may either extend
Section 2.2.4.4. each compacted layer beyond
the design slope surface by at
Where embankment is to be least 600 mm and then trim
constructed against existing back to the required slope
embankment or on ground with a angle, or he may employ a
cross-slope of 1 or more (vertical) tow type roller to compact the
to 10 (horizontal), the foundation sloping surface.
shall be excavated in all materials
(including hard rock) to form (b) Compaction Trials
benches with horizontal and
vertical faces from which con The B.S. 1377 Compaction
struction of the embankment shall Test (4.5 kg rammer method)
proceed. The benches shall be shall be used in determining
contiguous beneath the full width the moisture versus density
of the embankment, and shall be relation of soil.
of a suitable width to accomodate
construction equipment such as The Contractor shall submit to
motor-graders, trucks, rollers, etc. the S.O. for his approval the
Scarifying of the horizontal and proposed method of
vertical faces of the benches shall compaction for each main
not normally be required, and the type of material to be used in
material excavated in forming the the embankment. This shall
benches may normally be used as include the type of
fill in the embankment as compaction plant for each
approved by the S.O. type of material and the
number of passes in relation
2.2.4.4 Compaction to the loose depth of material
to achieve desired
(a) General compaction. The maximum
compacted thickness for fill
All materials used in shall be limited to 300 mm
embankments and as fill unless otherwise approved by
elsewhere shall be compacted the S.O. The Contractor shall
as soon as practicable after carry out field compaction
being placed and spread. trials, supplemented by any
necessary laboratory
investigations, as required by
the S.O.

This shall be done by using the moisture content at which each

procedures proposed by the soil type shall be compacted.
Contractor for earthworks and Water shall be added, or the
shall satisfy the S.O. that all the material aerated and dried to
specified requirements regarding adjust the soil to the proper
compaction can be achieved. moisture content to obtain the
Compaction trials with the main required density. A satisfactory
types of material likely to be method and sufficient equipment
encountered shall be completed as approved by the S.O. shall be
before the works with the used for the furnishing and
corresponding materials will be handling of water.
allowed to commence. Each trial
area shall be not smaller than If the natural water content of
8 m x 15 m. suitable materials is too high for
the proper compaction to be
(c) Degree of Compaction carried out, the Contractor can
either bring down the moisture
The whole of the embankment content by aeration or drying or
below the top 300 mm of the alternatively replace it with
subgrade shall be compacted to suitable materials of compactable
not less than 90% (for cohesive moisture range at his own cost.
material) or 95% (for
cohesionless material) of the 2.2.5 Rock fill Embankment
maximum dry density determined
in the B.S. 1377 Compaction Test Rock used in rock fill
(4.5 kg rammer method). embankments shall be of maximum
particle size of 400 mm so that it can
(d) Field Density Testing be deposited in horizontal layers,
each not exceeding 500 mm in
Field density tests on each layer compacted depth and extending over
of compacted earth fill shall be the full width of the embankment
carried out using the sand except for any specified external
replacement method in cover to slopes or new formation
accordance with B.S. 1377 or by level. The materials shall be spread
using other means of testing of and levelled by a crawler tractor
comparable accuracy approved weighing not less than 15 tonnes.
by the S.O. Each layer shall consist of
reasonably well graded rock and all
(e) Moisture Control large voids shall be filled with
broken fragments before the next
Each layer of earth fill shall be layer is placed. The top surface and
processed as necessary to bring side slopes of embankments so
its moisture content to a uniform formed shall be thoroughly blinded
level throughout the material, with approved fine graded material
suitable for compaction. The to seal the surface.
optimum moisture content as
determined by the B.S. 1377
Compaction Test (4.5 kg rammer
method) shall be used as a guide
in determining the proper

There shall be a transition layer 2.2.6.2 Surcharge and Staged

between rock fill and earth fill or the Construction
top 300 mm of subgrade of at least
300 mm compacted thickness. This Where indicated in the Contract
shall consist of uniformly graded or directed by the S.O., the
crushed rock between 6 mm and 150 embankment shall be built to
mm as approved by the S.O. different heights in stages with or
without surcharge with allowance
Each layer of rock used as rock fill for consolidation time periods in
in embankments shall be between stages, all in accordance
systematically compacted by at least with the Contract. Where sur
12 passes of a vibrating roller with a charge is specified, the
static load per 25 mm width of roll Contractor shall be responsible
of at least 45 kg or a grid roller with for the provision of surcharge
load per 25 mm width of roll of at material and the removal and
least 200 kg or other approved plant. disposal of excess material on
completion of consolidation or
2.2.6 Embankment Over Soft Ground when directed by the S.O.
2.2.6.1 Foundation Treatment 2.2.6.3 Settlement Markers
Prior to forming embankment Markers shall be provided and

over soft ground, the soil over installed by the Contractor in the
which fill material shall be positions indicated on the
placed shall be given strength Drawings for the purpose of
improvement treatment as measuring settlements taking
specified and to the details as place under the embankments
shown on the Drawings or as during and after the construction
directed or approved by the period. The design of markers
S.O. Treatment by means of shall be as shown on the
replacement of unsuitable Drawings and the Contractor
material shall be as specified shall be responsible for supplying
in Sub-Sections 2.2.3.4 and and installing such markers and
2.2.3.5. for extending the markers as the
work proceeds. Adjustments to
The first layer or layers of fill the height of markers shall be
materials shall be deposited made when required by the S.O.
over the full width of the Each marker shall be identified
embankment and berms in by painting on it the chainage of
thicknesses and compacted as its position.
approved by the S.O. The
Contractor shall provide The Contractor shall take all
compaction plant suitable for necessary measures to protect
working over soft ground. markers from damage by plant
and vehicles at all times and shall
repair any such damage to the
satisfaction of the S.O. Readily
visible barriers shall be installed
around each marker.

2.2.6.4 Settlement Records (for cohesionless material) of the

maximum dry density determined in
Joint measurement of the B.S. 1377 Compaction Test (4.5
settlement shall be taken kg rammer method). If the S.O. is
weekly while fill is being fully satisfied that the subgrade in its
placed in the vicinity of the natural state possesses a density
markers. Thereafter, readings exceeding the requirements, then the
shall be taken fortnightly for a surface of the subgrade shall be
period as directed by the S.O. trimmed and rolled to obtain a
The readings shall be smooth finish.
submitted on an approved
printed form to be supplied by Where the material in cut area is
the Contractor. found to be unsuitable for use in the
top 300 mm of subgrade it shall be
For the measurement of the removed and replaced with suitable
volume that has settled below material which shall be compacted as
the original level of the indicated above.
foundation of the
embankment, the measured The subgrade shall be finished in a
settlement of each marker neat and workmanlike manner, and
shall be used for volume the widths of embankments and cuts
computation following the shall be everywhere at least those
method shown on the specified or shown on the Drawings
Drawings. on both sides of the centreline. The
top surface of the subgrade shall
2.2.7 Subgrade have the required shape,
superelevation, levels and grades and
Material for the top 300 mm of shall be finished everywhere to with
subgrade shall have a minimum in + 10 mm and minus 30 mm of the
California Bearing Ratio (CBR) required level.
as shown on the Drawings when
compacted to 95% of the i) Where rock surface extends over
maximum dry density determined the whole width of the
in the B.S. 1377 Compaction formation :-
Test (4.5 kg rammer method)
under 4 days soaked condition. The rock surface shall be
trimmed to a free draining
Throughout the top 300 mm of profile, at or below formation
subgrade, the material shall be levels. No high spot shall
compacted to not less than 95% protrude above the formation
(for cohesive material) or 100% levels.
(for cohesionless material) of the
maximum dry density determined Any voids or cavities more than
in the B.S. 1377 Compaction Test 0.5 metre below the formation
(4.5 kg rammer method). level shall be filled up with
approved lean concrete having
In cut area, the top 300 mm of 7-day cube strength greater than
the subgrade shall be scarified 7 N/sq.mm. The rock surface
and recompacted to 95% (for shall then be brought up to the
cohesive material) or 100% formation levels with approved

crushed rock or gravel, regulated Turf sods shall be stacked and

and blinded. watered when they cannot be
laid immediately after cutting.
ii) Where rock outcrop occurs over
part of the formation only:- The surfaces to be turfed shall
be trimmed and thoroughly
The rock outcrop shall be cut wetted. The turf shall then be
down to a level not less than 300 carefully laid to form a complete
mm below the formation level. and uniform cover as shown on
The surface shall then be brought the Drawings. Turf laid on slopes
up to level with suitable subgrade steeper than 1 (vertical) and 3
material. (horizontal) shall be pegged
down with bamboo stakes
2.2.8 Protective Vegetation for Erosion approximately 250 mm in length.
Control Approved fertiliser shall be
applied after placing of turf at
2.2.8.1 Topsoil suitable times and at rates of
application approved by the S.O.
Topsoil stockpiled for the Works
in accordance with Sub- Sections All turf shall be regularly
2.1.1.3 and 2.1.2.3 shall be spread watered and fertilised to the
and lightly compacted to an even satisfaction of the S.O. until
thickness of 50 mm as directed the vegetation is satisfactorily
by the S.O. in areas to be turfed established. Any dead turf
and/or seeded, or used as the S.O. shall be replaced with new
shall otherwise direct for tree turf at the Contractor's own
planting and other purposes. expense.
2.2.8.2 Turfing
2.2.8.3 Seeding
Turfing shall be carried out as
soon as practicable on all earth Seeding or hydroseeding shall be
slopes and other areas as shown carried out as soon as practicable
on the Drawings and/or where on slopes and other areas as
directed by the S.O. The type of shown on the Drawings and/or
turf shall be as indicated on the directed by the S.O.
Drawings or other alternative
type as approved by the S.O. and The Contractor shall submit to
shall be free of lallang and the S.O. for his consideration and
essentially free of weeds. approval, at least four (4) weeks
in advance of the proposed work,
Turf shall be obtained in full details of his proposed
unbroken sods with a substantial method of seeding or
amount of topsoil and shall be hydroseeding. The information
approximately 250 mm x 250 submitted shall include, but not
mm in size and 100 mm thick, necessarily be limited to, a full
from an approved source, and description of the following
shall be placed in position as aspects of the work :-
soon as practicable after cutting.

i) the preparation of the areas to be xii) the cultivation and after-care of

seeded or hydroseeded, including the seeded areas, including rates
if appropriate the amount of top and frequencies of watering,
soil to be used and its method of fertilising, grass cutting and
application; general maintenance for at least 1
year after seeding;
ii) the details and results of
investigations to determine which xiii) the time after seeding required for
types of grass and legume are establishing permanent, dense
compatible with the soil in the growth of grasses, which will
areas to be seeded; require minimal maintenance;
iii) the types of grass and legume (if xiv) guarantees of the success of the
any) and strains of seed to be seeding work.
used, and the function, root and
growth characteristics of each All grass shall be regularly watered until
type; the vegetation is satisfactorily
established to the satisfaction of the S.O.
iv) the rates of application of the Any dead grass shall be replaced at the
grass and legume seeds; Contractor's own expense.
v) the composition of fertiliser to be

used at the time of seeding and its
rate of application;
vi) the composition of fertiliser to be

used after seeding, the times of
application after seeding, and the
rates of application;
vii) the type of mulch to be used and

its method and rate of
application;
viii) the amounts of lime or other

chemicals (if any) to be applied
to improve the soil before,
during and/or after seeding;
ix) the type and amounts of binding

agent to be applied with the
seeds, mulch, fertiliser, etc.,
as appropriate.
x) the proportions and methods of

preparation of the seeding mix;
xi) the equipment and methods to be

used in preparing and placing the
seeding mix and other materials;

SECTION 3
DRAINAGE WORKS

SECTION 3 - DRAINAGE WORKS
Page
3.1 GENERAL S3-54
3.2 EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS S3-54
3.2.2 Materials S3-54

3.2.2.1 Excavation S3-54
3.2.2.2 Granular Bedding Material S3-54
3.2.2.3 Concrete Bedding S3-54
3.2.2.4 Ordinary Backfill Material S3-54
3.2.2.5 Granular Backfill Material S3-54
3.2.2.6 Concrete Backfill S3-55
3.2.3 Excavation S3-55
3.2.4 Backfilling with Ordinary or Granular Backfill Material S3-56
3.3 CHANNEL EXCAVATION S3-57
3.4 SURFACE DRAINAGE S3-58
3.4.1 Surface Drainage Types S3-58
3.4.2 Surface Drain Construction S3-58

3.4.2.1 Unlined Drains S3-58
3.4.2.2 Cast In Situ Concrete Drains S3-59
3.4.2.3 Precast Concrete Drain Sections S3-59
3.5 STONE PITCHING S3-60

3.5.2.1 Stone S3-60
3.5.2.2 Cement Mortar S3-60

Page

3.5.3.1 Grouted Stone Pitching S3-60
3.5.3.2 Ungrouted Stone Pitching S3-61
3.6 GABIONS S3-61

3.6.2.1 Wire Mesh Gabions S3-61
3.6.2.2 Polyvinyl Chloride Coating S3-62
3.6.2.3 Stone S3-62
3.7 BRICKWORK S3-63

3.7.2.1 Common Bricks S3-63
3.7.3.1 Brick Laying S3-63
3.7.3.2 Plastering Brickwork S3-64
3.8 SUBSOIL DRAINS S3-64

3.8.2.1 Pipes S3-64
3.8.2.2 Filter Material S3-64
3.8.2.3 Filter Cloth S3-65
3.9 R.C. PIPE CULVERTS S3-66

3.9.2.1 Pipes S3-66
3.9.2.3 Bedding Material S3-66

Page
3.9.3 Excavation and Backfilling for R.C. Pipe Culverts S3-67

3.9.3.2 Backfilling S3-68
3.9.4 Installation of R.C. Pipe Culverts S3-68

3.9.4.1 General S3-68
3.9.4.2 Butt Ended Pipe Culverts with Precast Concrete Collars S3-68
3.9.4.3 Rebated Pipe Culverts S3-69
3.9.4.4 Spigot and Socket Pipe Culverts S3-70
3.10 CORRUGATED METAL PIPE CULVERTS S3-70

3.10.2.1 Pipes S3-70
3.10.2.2 Bitumen Coating S3-71
3.10.2.3 Bolts and Nuts S3-71
3.10.3 Excavation and Backfilling for Corrugated Metal Pipe Culverts S3-72
3.10.4 Installation of Corrugated Metal Pipe Culverts S3-72

3.10.4.1 General S3-72
3.10.4.2 Mortar Lining S3-72
3.11 PRECAST BOX CULVERTS S3-72

3.11.2.1 Precast Box Culverts S3-72
3.11.3 Excavation and Backfilling S3-73

3.11.3.1 Excavation for Precast Box Culverts S3-73
3.11.4 Installation of Precast Box Culverts S3-73
3.12 EXTENSION OF CULVERTS S3-74
3.12.1 Extension of Pipe Culverts S3-74

3.12.2 Extension of Box Culverts S3-74

SECTION 3 - DRAINAGE WORKS 3.2.2 Materials
3.2.2.1 Excavation
3.1 GENERAL Material excavated shall be

classified as common excavation
This work shall consist of the or rock as defined in Section 2 of
construction of surface drains, subsoil this Specification.
drains, pipe culverts, box culverts,
sumps and other drainage structures in 3.2.2.2 Granular Bedding Material
accordance with this Specification or
as directed by the S.O. Drainage works Granular bedding material for the
shall be constructed to the lines, levels, foundations of structures shall be
grades and cross-sections shown on the suitably graded broken rubble,
Drawings or as directed by the S.O. crushed stone, crushed gravel,
sand or other material as
specified on the Drawings or as
3.2 EXCAVATION AND required by the S.O.
BACKFILLING FOR DRAINAGE
WORKS 3.2.2.3 Concrete Bedding
3.2.1 Description Concrete bedding or blinding for

the foundations of structures shall
This work shall consist of excavation conform to the requirements of
for the construction of surface drains, Section 9 of this Specification
subsoil drains, cast in site box for the class of concrete specified
culverts, and other drainage on the Drawings or required by
structures, except pipe culverts, not the S.O.
otherwise provided for in this
Specification, and shall include 3.2.2.4 Ordinary Backfill Material
furnishing, placing, compacting and
shaping foundation bedding Ordinary backfill material shall
materials, backfilling excavations be suitable material as defined in
against completed structures with Section 2 of this Specification.
suitable material or granular backfill The maximum particle size of the
where specified, and the removal and backfill material shall be 50 mm.
disposal of all excess excavated
material, in accordance with this 3.2.2.5 Granular Backfill Material
Specification and as shown on the
Drawings and as required by the Granular backfill material shall
S.O. be sand, crushed stone, crushed
gravel or a mixture of crushed
Excavation and backfill for pipe and natural aggregates, shall be
culverts and precast box culverts essentially free from vegetative
shall be in accordance with the and other organic matter and clay,
provisions of Sub-Section 3.9. and shall not contain lateritic or
concretionary materials.

The material shall conform to the 3.2.2.6 Concrete Backfill

following physical and
mechanical quality requirements:- Concrete backfill where
specified shall be of the
i) the fines shall be non-plastic; grade as shown on the
Drawings and shall con
ii) sand shall have a gradation form to Section 9 of this
conforming to the envelope Specification.
shown in Table 3.1;
TABLE 3.1 - GRADING LIMITS FOR SAND 3.2.3 Excavation
BACKFILL
The Contractor shall notify the S.O.
B.S. Sieve Size % Passing By Weight sufficiently in advance of the
beginning of any excavation so that
cross-section elevations and
10.0 mm 100 measurements may be taken of the
5.0 mm 90 - 100 undisturbed ground. The natural
1.18 mm 45 - 80 ground adjacent to the structure shall
not be disturbed without permission
300 um 10 - 30 of the S.O.
150 um 2 - 10
Trenches and foundation pits for
structures and structure footings and
iii) material other than sand shall underdrains shall be excavated to the
have a gradation conforming lines, grades and elevations shown
to one of the envelopes shown on the Drawings or as directed by
in Table 3.2. the S.O. Excavations must be kept
free from water and temporary
TABLE 3.2 - GRADING LIMITS FOR drains, sumps and pumps shall be
GRANULAR BACKFILL OTHER THAN provided when necessary. The rate of
SAND excavation and backfill shall be
approved by the S.O. The elevations
of the bottoms of footings shown on
B.S. % Passing By Weight the Drawings are approximate only
Sieve A B C and the S.O. may order in writing
Size such changes in the dimensions or
elevations of footings as may be
37.5mm 100 - - deemed necessary to secure a satis
28.0mm 70 –100 100 - factory foundation.
20.0mm 60 – 90 70 - 100 100
10.0mm 45 – 75 45 - 75 - Boulders, logs and other
5.0mm 30 – 60 35 - 65 45 – 75 objectionable materials encountered
2.0mm 20 – 50 25 - 50 30 – 60 in excavation shall be removed.
425um 10 – 30 10 - 30 15 – 35
75um 0–2 0–2 0–2 After each excavation is completed
the Contractor shall notify the S.O.
to that effect and no footing,
bedding material or structure shall be
placed until the S.O.

to that effect and no footing, All excavated material, so far as

bedding material or structure shall be suitable, shall be utilized as backfill
placed until the S.O. has approved or embankment. The surplus
the depth of excavation and the material, whether or not temporarily
character of the foundation material. allowed to be placed within a stream
area, shall be finally disposed of in
Rock and other hard foundation such a manner as not to obstruct the
material shall be cleared of all loose stream nor otherwise impair the
material and cut to a firm surface, efficiency or appearance of the
either level or stepped or serrated, as works, nor is it to endanger the
specified or shown on the Drawings partly finished structure.
or directed by the S.O. All seams
and crevices shall be cleared out and Excavated material suitable for use
grouted with Portland cement grout as backfill may be deposited by the
at the time the footing is placed. Contractor in storage piles at points
convenient for rehandling of the
All loose and disintegrated rock and material during the backfilling
thin strata shall be removed. When operation.
the footing is to rest on material
other than rock, special care shall be Excavated material shall be
taken not to disturb the bottom of the deposited in such places and in such
excavation, and excavation to final a manner as not to cause damage to
grade shall be deferred until just highway, services or property either
before the footing is to be placed. within or outside the road reserve,
When, in the opinion of the S.O., the and so as to cause no impediment to
foundation material is soft or mucky the drainage of the Site or
or otherwise unsuitable, the surrounding area.
Contractor shall remove the
unsuitable material and insert 3.2.4 Backfilling with Ordinary or
foundation fill material or concrete Granular Backfill Material
as specified or shown on the
Drawings or directed by the S.O. If All spaces excavated under this
foundation fill material is required it Specification and not occupied by a
shall be placed and compacted in permanent structure shall be
layers not more than 150 mm thick backfilled. Backfill material shall be
or as directed by the S.O. The free from large lumps, wood and
degree of compaction shall be other extraneous material.
equivalent to that of the surrounding
foundations. Backfill not within the embankment
areas shall be placed in layers not
All excavation surfaces and surfaces more than 250 mm in depth
of backfill material against which (compacted measurement) and shall
concrete is to be placed shall be be compacted to a density
even and firm and true to line and comparable with the adjacent
level. undisturbed material.

Backfill within the embankment Special care shall be taken to prevent

areas shall be made with approved any unduly high pressures against
material placed in uniform layers not the structures.
to exceed 150 mm in depth
(compacted measurement) and each The placing of embankment and the
layer shall be constructed in benching of slopes shall continue in
accordance with Section 2 of this such a manner that at all times there
Specification except that mechanical will be a horizontal berm of
tampers may be used for thoroughly compacted material for a
compaction. Each layer of backfill distance at least equal to the height
shall be wetted uniformly as of the abutment or wall to be back
necessary and compacted to the filled.
same requirements as the adjacent
earthwork as specified in Section 2 3.3 CHANNEL EXCAVATION
of this Specification. Unless
otherwise approved by the S.O., 3.3.1 Description
hand tamping will not be accepted.
This work shall consist of excavation
In placing backfill and embankment, for waterway channels both inside
the material shall be placed insofar and outside the road reserve as
as possible to approximately the shown on the Drawings or directed
same height on both sides of the by the S.O., and shall include all
structure. If conditions require required excavation for widening,
backfilling appreciably higher on one training or permanently diverting
side, the additional material on the rivers, streams and irrigation and
higher side shall not be placed until drainage channels other than drains
permission is given by the S.O. or and ditches appurtenant to the
until the S.O. is satisfied that the roadway, except excavation of top
structure has enough strength to soil for use in the Works and
withstand any pressure created. excavation required for clearing and
grubbing. This work shall also
Backfill for embankment shall not be include the backfilling of old
placed behind the walls of box channels, haulage to their points of
culverts until the top slab is placed utilization in the Works or the
for the required time and not less removal and disposal of all
than three days. Backfill and excavated materials, the construction
embankment behind abutments held of appurtenant bunds, dikes and
at the top by superstructure shall be berms, and the shaping and finishing
carried up simultaneously behind of all earthworks involved in the
opposite abutments and side walls. construction of channels in accor
dance with the required lines, levels,
No backfilling shall be placed grades and cross-sections.
against any structure until permission
shall have been given by the S.O. 3.3.2 Materials
Jetting of fill or other hydraulic
methods involving, or likely to Channel excavation shall be
involve, liquid or semi-liquid classified as common excavation or
pressure shall be prohibited. rock as specified in Section 2 of this
Specification.

3.3.3 Construction Methods Sections of channel abandoned

owing to diversions shall be back
All suitable materials removed from filled as directed by the S.O.
channel excavations shall be used for
backfilling waterways to be
abandoned and constructing bunds, 3.4 SURFACE DRAINAGE
dikes and other earth appurtenances
as required. Surplus suitable 3.4.1 Surface Drainage Types
materials shall be used as far as is
practicable in constructing the Surface drains of the types shown on
roadway. The Contractor shall the Drawings shall be constructed to
provide borrow of satisfactory q the lines, levels, grades and cross-
quality and approved by the S.O. sections as specified or as directed
should this be necessary to complete by the S.O. Surface drains shall
the work. Borrow which is required include interceptor drains, roadside
to replace suitable excavated drains, embankment toe drains,
materials needed for construction shoulder drains, bench drains, berm
which the Contractor elects to waste drains, median drains, outfall drains,
shall not be paid for. cascade drains, etc.
Excavated unsuitable material, Any of the above drains may be

suitable material surplus to that constructed either unlined or lined
needed for construction and suitable using cast in situ concrete, precast or
material that the Contractor elects to porous concrete drain sections, or
waste, shall be disposed of at stone pitching.
designated areas in such a manner as
to present a neat appearance and not 3.4.2 Surface Drain Construction
obstruct flow in any channels,
ditches or drains, nor cause damage 3.4.2.1 Unlined Drains
to highway works or property, all to
the satisfaction of the S.O. Excavation for unlined drains
shall be trimmed to form a
During construction, channel smooth, firm surface to the
excavations shall be kept drained as required lines, levels, grades and
far as is practicable and the work cross-sections as shown on the
shall be carried out in a neat and Drawings or as required by the
workmanlike manner. S.O.
All channels and appurtenances shall Any areas of over excavation

be excavated and constructed to the shall be made good to the
lines, levels, grades and cross- satisfaction of the S.O., all at the
sections shown on the Drawings or Contractor's expense.
as directed by the S.O. Excavation
beyond the limits required shall not
be paid for and shall be backfilled at
the Contractor's expense as directed
by the S.O. should he deem it
necessary.

3.4.2.2 Cast In Situ Concrete Drains Ready made precast concrete

drain sections may be used
Excavation shall be carried subject to the approval of the
out to the lines and levels as S.O. Samples of ready made
specified and as shown on the drain sections shall be submitted
Drawings. Templates which to the S.O. for his approval
may be of timber or steel shall before placing of orders.
then be provided to ensure the Notwithstanding any approval
thickness and shape of the given by the S.O., any defective
concrete drains. The concrete or broken drain section shall be
shall be poured in sections not replaced by the Contractor at his
exceeding 2 m in length and own expense before or after
shall be carried out between laying in position.
end forms in alternate bays.
Construction joints shall not Precast concrete drain sections
be formed in the inverts. shall be laid on concrete bedding
in trenches excavated to the lines
All concrete shall be grade and levels as specified and
20/20 concrete unless otherwise jointed to produce a neat even
specified and shall conform to the alignment and gradient. The joint
requirements of Section 9 of this shall be grouted with 1:3 cement
Specification. Weep holes shall mortar complying with Sub-
be cast in situ as shown on the Section 3.5.2.2 and weep holes
Drawings or as directed by the shall be provided as shown on the
S.O. Drawings or as directed by the
S.O.
3.4.2.3 Precast Concrete Drain
Sections Porous concrete shall comply
with the requirements of porous
Precast concrete block inverts concrete for pipes as described in
shall be of the shapes and M.S. 525. Cement and
dimensions as shown on the aggregates used in the
Drawings and shall be of manufacture of the porous
grade 20/20 concrete conforming concrete drain sections shall con
to the requirements of Section 9 form to the requirements of
of this Specification or of Section 9 of this Specification.
porous concrete unless otherwise
specified. The precast concrete Mass concrete for bases shall be
drain sections shall be of grade 10/25 concrete or as
manufactured using good quality specified and to the dimensions
moulds and the finished product and thicknesses as shown on the
shall be round and have smooth Drawings.
inside surfaces all to the approval
of the S.O. Ready made precast
concrete drain sections may be
used subject to the approval of
the S.O.

3.5 STONE PITCHING 3.5.2.2 Cement Mortar
3.5.1 Description Cement mortar, unless otherwise

specified, shall contain 1 part
This work shall consist of the ordinary Portland cement to 3
construction of all structures or parts parts fine aggregate by volume.
of structures to be composed of stone Water shall be added to the mix
pitching either grouted or ungrouted to produce a suitable consistency
as shown on the Drawings or as for the intended use, all to the
directed by the S.O. including satisfaction of the S.O. The
erosion protection pavements and constituent materials of the
aprons, drain linings, culvert inlets mortar shall comply with the
and outlets, etc. The work shall be appropriate requirements of
carried out all in accordance with Section 9 of this Specification.
this Specification and to the lines,
levels, grades, dimensions and cross- The ingredients for mortar shall
sections shown on the Drawings and be measured in proper gauge
as required by the S.O. boxes and mixed on a clean
boarded platform or in an
3.5.2 Materials approved mechanical batch
mixer.
3.5.2.1 Stone
All mortar shall be used within
Stone shall be clean rough quarry 30 minutes of mixing and no
stone, or pit or river cobbles, or a reworking of mortar shall be
mixture of any of these materials, permitted thereafter.
and shall be essentially free from
dust, clay, vegetative matter and 3.5.3 Construction Methods
other deleterious materials.
Individual pieces of stone shall be 3.5.3.1 Grouted Stone Pitching
approximately cubical or
spherical and shall have least Prior to constructing grouted
dimensions in the range 100 to stone pitching, the surfaces
150 mm and a maximum against which it is to be placed
dimension of 250 mm, shall have been finished in
maximum, unless otherwise accordance with the appropriate
specified. The stone shall be provisions of this Specification.
hard, tough, durable and dense, Notwithstanding any earlier
resistant to the action of air and approval of these finished
water, and suitable in all respects surfaces, any damage to or
for the purpose intended. deterioration of them shall be
made good to the satisfaction of
the S.O. before grouted stone
pitching is placed.

Construction of grouted stone building up the structure to full

pitching shall commence at the thickness is commenced on any
lowest part of each structure or section of the work, as the con
section of a structure and struction advances.
continue progressively upward.
Long structures such as drain The work shall be carried out and
linings and slope protection finished all to the satisfaction of
pavements shall be constructed in the S.O.
sections of practicable length, to
the satisfaction of the S.O. The 3.5.3.2 Ungrouted Stone Pitching
surface against which the work is
to be placed shall be moistened Where shown on the Drawings,
with clean water a little in ungrouted stone pitching shall be
advance of construction, and hand set to provide maximum
covered with a layer of cement interlocking effect. The stones,
mortar about 50 mm thick. the largest of which shall be used
Stones shall then be firmly set by at the bottom, shall be well
hand into the mortar, densely bedded on a 75 mm layer of
packed against adjacent stones gravel or aggregate rammed to an
and built up to form a stone even surface. The whole work
structure of more or less uniform shall be finished to the
thickness which shall nowhere be satisfaction of the S.O
less than 150 mm (measured per
pendicularly to the surface 3.6 GABIONS
covered). All the while that
stones are being placed, all voids 3.6.1 Description
in the structure shall be packed
solidly with mortar and stone This work shall consist of the
spalls; however the surfaces of construction of miscellaneous
stones in the exposed faces and erosion protection and retaining
edges shall not be covered with structures to be composed of stone
mortar. The exposed surfaces filled wire mesh gabions. The work
and edges of the structure shall be shall be carried out all in accordance
constructed such that they have with this Specification and as shown
as large a proportion as on the Drawings and/or as approved
practicable composed of stone by the S.O.
faces. Weep holes shall be
provided as shown on the 3.6.2 Materials
Drawings or as directed by the
S.O. 3.6.2.1 Wire Mesh Gabions
Mortar which has been mixed for Gabions shall be rectangular

more than 30 minutes shall not be baskets of the required
used in the works. Nor shall dimensions as shown on the
mortar be laid against the Drawings or ordered by the S.O.
supporting surface more than 2 Unless otherwise specified, they
minutes before pitching stone and shall be of the following standard
dimensions :-

i) width - 1.00 metre; Gabion mesh shall be triple

twisted and shall have a uniform
ii) length - 1.00, 2.00 or 3.00 hexagonal pattern with openings
metres; of 100 x 120 mm or less. The
mesh shall be securely tied to
iii) height - 0.50 or 1.00 metre. selvage wires to form rectangular
panels which shall be securely
Gabions longer than 1.00 m shall wired together to form the
be divided into compartments of completed gabion baskets. The
equal length not exceeding 1.00 ties and connections for each
m by wire mesh diaphragms gabion basket shall comprise not
securely tied along all edges. less than 8% of its total weight,
Each gabion or compartment of a and the fabrication shall be all to
gabion shall be provided with at the satisfaction of the S.O.
least 4 cross-connecting wires if
its height is 0.50 m or less, and 3.6.2.2 Polyvinyl Chloride Coating
with at least 8 cross-connecting
wires if its height is in the range When specified on the Drawings,
0.50 to 1.00 metre. all wire used in the fabrication of
gabions and in the wiring
Gabions shall be fabricated from operation during construction
steel wire manufactured in shall, after galvanising, have
accordance with B.S. 1052 and extruded on to it a coating of
galvanised in accordance with polyvinyl chloride (PVC). The
M.S. 407, or such similar PVC coating, not inclusive of
standards as the S.O. shall galvanising, shall nowhere be less
approve. The galvanised wire than 0.55 mm in thickness.
sizes used shall be in accordance
with Table 3.3. 3.6.2.3 Stone
TABLE 3.3 - GALVANISED WIRE SIZES Stone fill for gabions shall be
FOR GABIONS clean rough quarry stone, or pit
or river cobbles, or a mixture of
any of these materials, and shall
be essentially free from dust,
Type of Wire Minimum Diameter
clay, vegetative matter and other
deleterious materials. Individual
pieces of stone shall have least
Selvage (perimeter) wire 3.50 mm dimensions not less than 20 mm
larger than the gabion mesh
openings and greatest dimensions
Mesh wire 2.70 mm not more than 250 mm. The stone
shall be hard, tough, durable and
Tying and connecting 2.20 mm dense, resistant to the action of
air and water, and suitable in all
wire aspects for the purpose intended.
The material shall be approved
by the S.O.

3.6.3 Construction Methods 3.7 BRICKWORK
Prior to placing gabions, the surface 3.7.1 Description

on and against which they are to be
constructed shall have been prepared This work shall include the laying of
and finished in accordance with the brickwork to the lines, levels and
relevant provisions of the appropriate grades shown on the Drawings
Sections of this Specification. and/or as directed by the S.O.
Notwithstanding any earlier approval
of these finished surfaces, any 3.7.2 Materials
damage to or deterioration of them
shall be made good to the 3.7.2.1 Common Bricks
satisfaction of the S.O. before
gabions are placed. Common bricks shall be sound,
hard, well burnt, of proper size
Each gabion basket shall be put in and clean and shall give a clear
place in its turn, completely ring when struck. They shall be
fabricated except for the fastening Class 3 standard format
down of the lid, stretched to the complying with the requirements
correct shape and dimensions, and of M.S. 76. Bricks shall be
fastened securely to all contiguous obtained from manufacturers
baskets along each edge with tying approved by the S.O.
wire. The basket shall then be tightly
packed with approved stone by hand 3.7.2.2 Cement Mortar
in such a manner that voids are kept
to a practicable minimum and are Cement mortar for brickwork
uniformly distributed in the stone shall comply with the
mass. Finally, the lid of the basket requirements of Sub-Section
shall be securely fastened down with 3.5.2.2.
tying wire along all hitherto
unfastened edges, all to the 3.7.3 Construction Methods
satisfaction of the S.O. In no case
shall the weight of the finished 3.7.3.1 Brick Laying
gabion be less than 1300 kg
per cubic metre. Brickwork shall be executed with
cement mortar and shall be of the
As a gabion structure is built up, thickness and bonds as shown on
backfilling against finished gabions the Drawings. Bricks shall be
shall be carried out as necessary for kept damp until used and shall be
proper progressive construction, all laid on a full bed of mortar. The
in accordance with the relevant brickwork shall be true to line
provisions of the appropriate and plumb, and courses shall be
Sections of this Specification. Unless kept truly level. The thickness of
otherwise specified, vertical joints mortar joints shall not exceed 10
between gabions shall be staggered mm and shall be such that 4
in gabion structures in a pattern courses of brickwork forms a
similar to the joints in running bond height of 300 mm.
brickwork.

Newly laid brickwork shall be 3.8 SUBSOIL DRAINS

protected from the harmful
effects of sunshine, rain, running 3.8.1 Description
and surface water and shocks.
Any brickwork that is damaged This work shall include the supply
shall be taken down and rebuilt and installation of subsoil drains
and the joints raked out and constructed in accordance with this
pointed as directed by the S.O. Specification at the locations and in
Any such remedial work shall be accordance with the lines, levels and
at the Contractor's own expense. grades as shown on the Drawings
and/or as directed by the S.O.
3.7.3.2 Plastering Brickwork
3.8.2 Materials
All exposed brickwork surfaces
shall be plastered. The plaster 3.8.2.1 Pipes
shall be applied in 2 coats
generally to a total thickness of Porous concrete pipes for subsoil
20 mm and shall be finished with drains shall comply with M.S.
a steel trowel for internal surfaces 525.
and with a wooden float for
external surfaces. Clay pipes for subsoil drains shall
comply with B.S. 1196.
Plain plaster shall consist of 1
part masonry cement complying Polyvinyl Chloride (PVC) pipes
with M.S. 794 to 3 parts of sand for subsoil drains shall comply
by volume. where ordinary with Australian Standard
portland cement is used, Specification 2439 or B.S. 3656.
plasticiser of a type approved by
the S.O. may be added to the mix 3.8.2.2 Filter Material
in accordance with the
manufacturer's instructions. Filter material used in the
construction of subsoil drains
Ordinary Portland cement and shall consist of hard, clean sand
water shall comply with the conforming to the grading limits
appropriate requirements of given in Table 3.4. The material
Section 9 of this Specification. passing the 425 um sieve shall be
non-plastic when tested in
Weep holes shall be provided as accordance with B.S. 1377.
shown on the Drawings or as
directed by the S.O. TABLE 3.4 - GRADING LIMITS FOR
FILTER MATERIAL
B.S. Sieve % Passing By

Size Weight
10.0mm 100
5.0mm 90 - 100
2.36mm 75 - 100
1.18mm 55 - 90
600um 35 - 59
300um 8 - 30
150um 0 - 10

3.8.2.3 Filter Cloth (c) Filtration Requirement
The synthetic filter cloth shall be Equivalent opening size of the

a non-woven type of approved filter cloth determined by sieving
manufacture having the following as described in ASTM D422 shall
properties :- be less than the eighty-five
percentage size of the adjacent
(a) Chemical Composition soil.
Requirements
(d) Permeability Requirement
Fibres used in the manufacture of
the engineering fabric shall The equivalent Darcy
consist of a long chain synthetic Permeability of the filter cloth
polymer, composed of at least shall be greater than 10 times
85% by weight of the Darcy Permeability of the
polypropylene, -ethylene, - soil to be drained.
esteramide or -vinylidene
chloride and shall contain 3.8.2.4 Cement Mortar
stabilisers and/or inhibitors added
to the base plastic (as necessary) 1:3 cement mortar for use in pipe
to make the fabric resistant to joints shall comply with Sub-
deterioration from ultraviolet and Section 3.5.2.2.
heat exposure.
3.8.3 Construction Methods
(b) Physical Property
Requirements Excavation for subsoil drains shall
be carried out all in accordance with
The physical properties of the the appropriate provisions of Sub-
filter cloth shall comply with Section 3.2.
Table 3.5.
Filter material as described in Sub-
TABLE 3.5 - PHYSICAL PROPERTY Section 3.8.2.2 above shall be placed
REQUIREMENTS FOR FILTER CLOTH and uniformly compacted by a
suitable method approved by the
S.O. to form a firm, even bedding for
Grab Strength 0.9 kN the pipe drain as shown on the
Drawings.
(ASTM D1682)
The pipe sections shall be set firmly
Puncture Strength 0.4 kN against the filter material bedding
(ASTM D3787 - 80a) with the flow lines in the design
position. For pipes with mating
joints, the receiving ends shall be
Burst Strength 2100 kN/sq.m upgrade, and the pipe joints shall be
(ASTM D3786 - 80a) fully mated. For butt jointed pipes
with collars, the pipe sections shall
be fully contiguous, and the collars
properly centred over the joints.

Joints shall be spot mortared as 3.9.2 Materials

necessary to hold the pipe sections
correctly centred and aligned, but not 3.9.2.1 Pipes
so as to unduly restrict the infiltration
of water through the joints. Reinforced concrete pipes shall
conform to the requirements of
Slotted or perforated pipes shall be M.S. 881 and shall be supplied
tightly wrapped in filter cloth such by manufacturers approved by
that the entire length of the mortared the S.O.
pipe is covered by at least 2 layers of
cloth. All joints in both layers shall Rebated pipes of diameter 600
have an overlap of at least 100 mm mm and above shall be internally
and joints in the outer layer shall be rebated.
offset by at least 300 mm from joints
in the inner layer, all to the Collars shall be precast with
satisfaction of the S.O. grade 25 concrete and shall be
suitably reinforced all
After pipe laying and, if appropriate, in accordance with Section 9 of
wrapping has been approved by the this Specification. The width of
S.O., the remainder of the filter the collar shall be not less than
material shall be placed and 150 mm and the minimum
uniformly compacted by a suitable thickness shall be 50 mm.
method approved by the S.O. to
form a dense, even surround to the Rubber rings for spigot and
pipe as shown on the Drawings. Care socket pipes shall comply with
shall be taken that the pipe is neither the requirements of Type 2 as
damaged nor displaced. specified in B.S. 2494.
Backfill shall then be placed and 3.9.2.2 Cement Mortar

compacted in accordance with the
appropriate provisions of Sub- 1:3 cement mortar for jointing of
Section 3.2.4. reinforced concrete pipes shall
3.9 R.C. PIPE CULVERTS Sub-Section 3.5.2.2.
3.9.1 Description 3.9.2.3 Bedding Material
This work shall comprise the supply Type A bedding shall consist of
and installation of reinforced grade 20/20 concrete complying
concrete pipe culverts, inclusive of with Section 9 of this
excavation, backfilling, jointing, Specification.
bedding, construction of headwalls,
wingwalls, aprons and sumps and Type B bedding shall consist of
channel protection works, all in clean, natural sand or gravelly
accordance with this Specification sand of suitable gradation and
and the details shown on the quality, approved by the S.O.
Drawings. The material shall have a
maximum particle size of not
more than 12 mm.

3.9.3 Excavation and Backfilling for R.C. Where rock or other hard
Pipe Culverts unyielding foundation
material is encountered in the
3.9.3.1 Excavation trench, it shall be excavated to
a depth below the bottom of
(a) General pipe design levels of at least
300 mm or 12.5 mm per 300
Unless otherwise directed by mm of fill to be placed over
the S.O., prior to construction the top of the pipe, whichever
of a pipe culvert, the earth is greater, up to a maximum
works at the required location of 75% of the internal
shall have been constructed diameter of the pipe. The
to a level at least 600 mm hard material so excavated
above the top of culvert shall be replaced with suitable
design levels or to the top of material uniformly compacted
subgrade levels, whichever is in layers of not more than 150
lower. mm compacted thickness to
provide satisfactory support
Pipe culverts specified to be for the pipe, all to the
constructed in trench satisfaction of the S.O.
conditions shall be excavated
in accordance with Sub- (c) Open Ground Method
Section 3.9.3.1 (b) below.
Where existing ground levels
Where drainage conditions or are above top of bedding
other circumstances so material design levels and
require, the S.O. may direct firm foundation materials are
the Contractor to construct the encountered, excavation and
pipe culvert without first foundation preparation shall
constructing the earthworks to be similar to that described
the level specified above, in in the trench method above.
which case excavation and Otherwise a firm foundation
foundation preparation shall plane shall be prepared, which
be in accordance with Sub- shall be essentially free
Section 3.9.3.1 (c) below. draining along the line of the
culvert, by trimming the
(b) Trench Method existing ground, or such fill as
it is necessary to place and
The trench to receive a culvert compact, over a width
pipe shall be of sufficient sufficient to permit
width and depth to enable the satisfactory construction of
placing of bedding material the pipe bedding, all to the
and construction of pipe joints satisfaction of the S.O. Hard
in accordance with this materials shall be excavated
Specification, and the bottom from the pipe foundation over
of the trench shall be trimmed a width equal to the outside
to a suitably smooth plane diameter of the pipe to the
surface which shall be kept same depth as specified in the
free from water, all to the trench method, and shall be
satisfaction of the S.O. replaced with suitable

material uniformly compacted Heavy plant and equipment shall

in layers of not more than 150 not operate within 1.5 m of any
mm compacted thickness to pipe culvert until backfilling and,
provide satisfactory support where appropriate, pavement
for the pipe, all to the construction has advanced to a
satisfaction of the S.O. stage which provides at least 600
mm of cover to the culvert.
Where soft or unstable soil is Subject to the approval of the
encountered in the foundation, S.O., light compaction equipment
it shall be excavated over a may be operated above pipe
width of at least 1.5 times the culverts after a minimum of 300
outside diameter of the pipe mm of cover has been placed and
on each side of the culvert compacted.
centre-line to the depth
directed by the S.O., and 3.9.4 Installation of R.C. Pipe Culverts
replaced with suitable
material uniformly 3.9.4.1 General
compacted in layers of not
more than 150 mm The type, size and class of pipe to
compacted thickness to be installed at each location shall
provide satisfactory support be as shown on the Drawings or
for the pipe, all to the as directed by the S.O. Culverts
satisfaction of the S.O. shall not be installed at any
location until the type of pipe, the
3.9.3.2 Backfilling exact location, the lines, levels
and grades, the length of pipe and
Backfilling against reinforced details of inlet and outlet
concrete pipe culverts and their structures have been confirmed
appurtenant structures shall be by the S.O. In addition, special
carried out in accordance with the requirements recommended by
construction methods described the manufacturer with respect to
in Sub-Section 3.2.4, using assembly and installation shall be
material conforming to the complied with.
requirements of Sub-Section
3.2.2.5. Special care shall be Especially where elliptically
taken to properly compact reinforced pipe sections are used,
backfill against the undersides of care shall be taken to ensure that
culvert pipes without disturbing the loading axes are positioned
or damaging the pipes and joints. exactly vertically.
Backfill shall be built up evenly
on both sides of each pipe culvert 3.9.4.2 Butt Ended Pipe Culverts with
along its entire length. Precast Concrete Collars
The pipes shall be laid on Type A

bedding in conformity with the
dimensions shown on the
Drawings. Before placing any
concrete bedding, the pipes shall
be assembled complete with
precast concrete collars to the

correct levels and grades on precast Following pipe assembly and

concrete spacing blocks of the same mortaring up as above, the
class of concrete as the bedding remainder of the cradle shall be
material and of sufficient size to cast monolithically, all to the
eliminate any risk of settlement of satisfaction of the S.O.
the pipes before or during
concreting. Where vertical construction joints
in the concrete cradle are
All joints shall be fully mortared unavoidable due to circumstances
with 1:3 cement mortar before on Site, transfer bars shall be
concreting of the cradle, all to the provided to the satisfaction of the
satisfaction of the S.O. The concrete S.O.
cradle shall be cast as one monolithic
unit. Alternatively, part of the Special care shall be taken when
concrete cradle below the underside placing the concrete cradle to
of the pipe may be constructed avoid the entrapment of air
monolithically at least 24 hours underneath the pipe. To
before the assembly and mortaring eliminate this possibility,
up of the pipe sections and collars, concrete shall be placed to one
on condition that shear connectors side of the pipe only until such
are provided across horizontal time as the level of the concrete
construction joints to the satisfaction surface rises above the underside
of the S.O. of the pipe on the side remote
from that on which concrete is
During installation, the ends of the being placed. The concrete shall
pipes shall be butted and the collar then be brought up at the same
centred about the joint using wedges level on both sides of the pipe.
or other approved means. The
annular shall be completely filled 3.9.4.3 Rebated Pipe Culverts
with 1:3 cement mortar with only
sufficient water added to ensure The pipes shall be laid on Type A
adequate workability and the wedges bedding in conformity with the
removed before finally fairing the dimensions shown on the
joint. Special care shall be taken to Drawings.
ensure that excess cement mortar is
neatly cleaned off. For pipes over The method of construction shall
900 mm in diameter the jointing follow that described in Sub-
space shall be filled from inside the Section 3.9.4.2 for butt ended
pipe after completion of pipe culverts except for the
embankment construction using 1:3 exclusion of precast concrete
cement mortar. When installed, the collars.
clearance between the outer
diameter of pipe and the inner The rebated joint shall be
diameter of collar shall be at least internally flush and fully
20 mm. mortared with 1:3 cement mortar,
all to the satisfaction of the S.O.

3.9.4.4 Spigot and Socket Pipe Culverts Care shall be taken to see that the
rubber ring is adequately
The pipes shall be laid on Type compressed to seal the joint. All
B bedding in conformity with the pipes shall be laid to the
dimensions shown on the satisfaction of the S.O.
Drawings. The bedding material
shall be accurately shaped by a 3.10 CORRUGATED METAL PIPE
template to fit the lower part of CULVERTS
the pipe exterior for a height of at
least 10% of the outside diameter 3.10.1 Description
of the pipe. Gaps shall be left in
the bedding material and recesses This work shall comprise the supply
dug in the earth foundation of and installation of bolted, corrugated
sufficient width and depth to metal pipe culverts inclusive of
accomodate the socket without it excavation, backfilling, jointing,
resting on the bottom of the bedding, construction of headwalls,
recess. The widths of the wingwalls, aprons and sumps and
recesses in the foundation and the channel protection works, all in
bedding shall both exceed the accordance with this Specification
width of the socket by more than and the details shown on the
50 mm. Drawings.
Jointing of the pipes shall be 3.10.2 Materials

carried out strictly in accordance
with the manufacturer's recom 3.10.2.1 Pipes
mendations, all to the satisfaction
of the S.O. The pipe sections shall be
fabricated from zinc-coated
Concrete pipes as specified above (galvanised) steel sheets
shall be laid true to line and level, conforming to AASHTO M218
each pipe being separately boned or from structural plates
between sight rails. Pipes shall conforming to AASHTO M167
be laid in an upstream direction depending on the pipe size
with the sockets towards the inlet requirements.
and shall rest on even
foundations for the full length of The dimensions of the pipes shall
the barrel. Rubber ring joints conform to AASHTO M36. All
shall be installed strictly in pipes shall be clearly identified
accordance with the by marking on each section the
manufacturer's instructions. Prior following information :-
to jointing, rubber rings and
jointing surfaces shall be cleaned i) name of manufacturer;
of all contaminants except for ii) diameter of pipe;
specified lubricants. The spigot iii) gauge number;
of each pipe shall be inserted iv) date of manufacture.
concentrically in the socket of the
one previously laid, and the pipe The above markings shall have
then adjusted and fixed in its been marked by the
correct position with the spigot manufacturer.
correctly entered in the socket.

The Contractor shall submit to For pipe material conforming to

the S.O. the material test AASHTO M218 (corrugation 68
certificates from the manufacturer mm pitch x 13 mm depth) with
showing the chemical diameters of 1500 mm or smaller,
composition and mechanical 12 mm diameter bolts shall be
properties of the base metal and used. Bolt holes along
the amount of zinc coating for circumferential seams shall have
every lot of pipes supplied. The spacings of not more than 314
S.O. may order further tests in the mm.
sections supplied to Site at the
rate of not more than 1 in 100. For pipe material conforming to
AASHTO M167 (corrugation
All costs on such tests shall be 150 mm pitch x 50 mm depth)
borne by the Contractor. with diameters of 1500 mm or
larger, 19 mm diameter bolts
3.10.2.2 Bitumen Coating shall be used. Four bolt holes per
300 mm of longitudinal seam
Where specified, the pipe shall be provided and these shall
sections or plates shall be coated be staggered in rows 51 mm a
with an approved bitumen apart with holes in one row in the
coating at the factory by the hot- trough and holes in the other row
dip process for Type A as in the crest of the corrugation.
specified in AASHTO M190. Bolt holes in the circumferential
Before coating, any damage to seams shall have spacings of not
the galvanising shall be made more than 254 mm.
good in a manner approved by
the S.O. Notwithstanding the above, the
Contractor shall satisfy the S.O.
3.10.2.3 Bolts and Nuts as to the adequacy of all bolted
connections.
All bolts and nuts shall be of high
strength carbonated steel meeting 3.10.2.4 Cement Mortar
the provisions of ASTM A449
and ASTM A563 Grade `C' 1:3 cement mortar shall comply
respectively. The galvanising on with the requirements of Sub-
bolts and nuts must meet the Section 3.5.2.2.
requirements of ASTM A153.
3.10.2.5 Bedding Material
Diameters of bolt holes in the
longitudinal seams, except those Corrugated metal pipe culverts
at the plate corners, shall not shall be bedded on Type B
exceed the bolt diameter by more bedding as specified in Sub-
than 3 mm. The bolt holes in the Section 3.9.2.3.
circumferential seams, including
those at the plate corners, shall
not exceed the bolt diameter by
more than 6 mm. The minimum
distance from the centre of a hole
to the edge of a plate shall be
1.75 times the diameter of the
bolt.
3.10.3 Excavation and Backfilling for placed along the entire length
Corrugated Metal Pipe Culverts of the culvert. The lining
shall be constructed after
Unless otherwise directed and/or completion of earthworks and
approved by the S.O., the pipe wingwalls.
culvert shall be laid in a trench
excavated in accordance with 3.11 PRECAST BOX CULVERTS
Sub-Section 3.9.3.1 (b).
3.11.1 Description
Where the open ground method
is approved, the work shall This work shall comprise the supply
comply with Sub-Section and installation of precast box
3.9.3.1 (c). culverts inclusive of excavation,
backfilling, jointing, bedding,
3.10.4 Installation of Corrugated Metal construction of headwalls,
Pipe Culverts wingwalls, aprons and sumps and
channel protection works, all in
3.10.4.1 General accordance with this Specification
and the details shown on the
The culvert sections shall be Drawings.
assembled, strutted, and
protected during construction 3.11.2 Materials
in accordance with the
manufacturer's instructions. 3.11.2.1 Precast Box Culverts
Special attention shall be
given to the sequence of Precast box culverts shall be of
tightening bolts and the approved manufacture complying
specified torque to be applied with Australian Standard
during assembly. After Specification 1597 Part 1, or any
assembly the bitumen coating equivalent alternative standard
shall, where damaged, be acceptable and approved by the
repaired and made good with S.O.
further application of the
bitumen coating. 3.11.2.2 Cement Mortar
1:3 cement mortar for jointing of

3.10.4.2 Mortar Lining precast box culvert sections shall
For corrugated metal pipe Sub-Section 3.5.2.2.
culverts of 1800 mm diameter
or more, or where directed by 3.11.2.3 Bedding Material
the S.O. for pipes of smaller
diameters, a 1:3 cement Precast box culverts shall be
mortar lining shall cover the bedded on Type B bedding as
inverts of the pipes to a specified in Sub-Section 3.9.2.3.
thickness of 25 mm above the
crest of the corrugations over
a minimum of one third of the
circumference centrally

3.11.3 Excavation and Backfilling Backfill shall be built up

evenly on both sides of each
3.11.3.1 Excavation for Precast Box box culvert along its entire
Culverts length.
Unless otherwise directed by Unless otherwise approved by

the S.O., prior to construction the S.O., heavy plant and
of a precast box culvert, the equipment shall not operate
earthworks at the required within 2.0 m of any precast
location shall have been box culvert until backfilling
first constructed to a level at and, where appropriate,
least 600 mm above the top pavement construction has
of the culvert design levels or advanced to a stage which
to the top of subgrade levels, provides at least 300 mm of
whichever is lower, and the cover to the culvert.
precast box culvert shall then
be constructed in a trench 3.11.4 Installation of Precast Box
excavated in accordance with Culverts
Sub-Section 3.9.3.1 (b).
The type and size of precast box
Where drainage conditions or culvert to be installed at each
other circumstances so location shall be as shown on the
require, the S.O. may direct Drawings or as directed by the
the Contractor to construct S.O. Precast box culverts shall
the precast box culvert not be installed at any location
without first constructing the until the exact location, the lines,
earthworks to the level levels and grades, the length of
specified above, in which culvert and details of inlet and
case excavation and outlet structures have been con
foundation preparation shall firmed by the S.O. In addition,
be in accordance with Sub- special requirements
Section 3.9.3.1 (c). recommended by the
manufacturer shall be complied
3.11.3.2 Backfilling with.
Backfilling against precast Precast box culverts shall be

box culverts and their laid on Type B bedding as
appurtenant structures shall specified in Sub-Section 3.9.4 in
be carried out in accordance conformity with the dimensions
with the construction shown on the Drawings. Where
methods described in Sub- specified on the Drawings or
Section 3.2.4, using material directed by the S.O., Type B
conforming to the bedding shall be laid on a layer of
requirements of Sub-Section crushed aggregate of maximum
3.2.2.5. Special care shall be particle size not exceeding 50
taken to properly compact mm.
backfill without disturbing or
damaging the precast box
culvert sections.

All joints shall be fully mortared 3.12.2 Extension of Box Culverts

with 1:3 cement mortar, all to the
satisfaction of the S.O. In The existing wingwalls, aprons
addition, a 3 mm layer of 1:3 and concrete bedding shall be
cement mortar shall be spread on demolished wherever indicated
top of the legs of the invert in on the Drawings to expose the
order to ensure uniform bearing existing box culvert on the side(s)
between the invert and lid. to be extended. The end of the
existing box culvert to be
Lifting holes shall be filled with extended shall then be wire-
1:3 cement mortar. brushed or some other means
employed to give a clean sur
face.Extension joints shall be
3.12 EXTENSION OF CULVERTS formed as shown on the
Drawings by injecting Thioflex
600 - Gun Grade (manufactured
3.12.1 Extension of Pipe Culverts by Expandite) or its equivalent to
a thickness of not less than 25
The existing wingwalls, aprons and mm in the 15 mm wide gap
concrete bedding shall be between the existing box culvert
demolished wherever indicated on and the new box culvert section.
the Drawings to expose the existing The remaining space in the gap
pipe culvert on the side(s) to be shall then be filled with Flexcell
extended. The end of the existing Expansion Filler.
pipe culvert to be extended shall then
be wire-brushed or some other Bakau piles shall be installed as
means employed to give a clean pipe shown on the Drawings, unless
end. otherwise directed by the S.O.
Extension joints shall be formed as

shown on the Drawings by injecting
Thioflex 600 - Gun Grade
(manufactured by Expandite) or its
equivalent to a thickness of not less
than 25 mm in the 15 mm wide gap
between the existing pipe and the
new pipe. The remaining space in
the gap shall then be filled with
Flexcell Expansion Filler.
Bakau piles shall be installed as

shown on the Drawings, unless
otherwise directed by the S.O.

SECTION 4
FLEXIBLE PAVEMENT

SECTION 4 - FLEXIBLE PAVEMENT
Page
4.1 UNBOUND PAVEMENT COURSES S4-78
4.1.1 Lower Subbase S4-78

4.1.1.1 Description S4-78
4.1.1.2 Materials S4-78
4.1.1.3 Construction Methods S4-78
4.1.2 Subbase S4-79

4.1.3 Gravel Surfacing S4-81

4.1.4 Crushed Aggregate Roadbase S4-83

4.2 BITUMINOUS PAVEMENT COURSES S4-85
4.2.1 Bitumen Prime Coat S4-85

4.2.1.3 Equipment S4-85
4.2.2 Bituminous Tack Coat S4-88

4.2.3 Bituminous Surface Dressing S4-90


Page
4.2.4 Asphaltic Concrete S4-99

4.2.4.3 Asphaltic Concrete Mix Design S4-102
4.2.5 Bituminous Macadam S4-116

4.3 SHOULDERS S4-119

4.3.2.1 Earth Shoulders S4-119
4.3.2.2 Gravel Shoulders S4-119
4.4 HORIZONTAL ALIGNMENT, SURFACE LEVELS AND

SURFACE REGULARITY OF PAVEMENT COURSES S4-120
4.4.1 Horizontal Alignment S4-120
4.4.2 Surface Levels of Pavement Courses S4-120
4.4.3 Surface Regularity S4-121

SECTION 4 - accordance with the provisions of

FLEXIBLE PAVEMENT Sub-Section 2.2.7.
Notwithstanding any earlier
approval of finished subgrade,
4.1 UNBOUND PAVEMENT any damage to or deterioration of
COURSES the subgrade shall be made good
to the satisfaction of the S.O.
before lower subbase is
4.1.1 Lower Subbase constructed.
4.1.1.1 Description Lower subbase shall be placed

over the full width of the
This work shall consist of formation to the required
furnishing, placing, compacting thickness as shown on the
and shaping lower subbase Drawings or directed by the S.O.
material on a prepared and in one layer or more, each layer
accepted subgrade in accordance not exceeding 200 mm
with this Specification and the compacted thickness. Where two
lines, levels, grades, dimensions or more layers are required they
and cross-sections shown on the shall be of approximately equal
Drawings and/or as required by thickness and none shall be less
the S.O. than 100 mm compacted
thickness.
4.1.1.2 Materials
Each layer of lower subbase shall
Lower subbase material shall be be processed as necessary to
inorganic soil, sand, gravel, bring its moisture content to a
weathered or fragmented rock, or uniform level throughout the
a mixture of any of these material suitable for compaction,
materials, essentially free from and shall then be compacted
vegetative and other organic using suitable compaction
matter and expansive clay equipment approved by the S.O.
minerals. It shall have a to not less than 95% of the
maximum particle size of 75 mm maximum dry density determined
or less, and shall have a CBR in the B.S. 1377 Compaction Test
value not less than that shown on (4.5 kg rammer method).
the Drawings when compacted to Compaction shall be carried out
95% of the maximum dry density in a longitudinal direction along
determined in the B.S. 1377 the roadbed, and shall generally
Compaction Test (4.5 kg rammer begin at the outer edge and
method) and soaked for 4 days progress uniformly towards the
under a surcharge of 4.5 kg. crown on each side in such a
manner that each section receives
4.1.1.3 Construction Methods equal compactive effort, all to the
satisfaction of the S.O.
Prior to placing any lower
subbase material, the underlying
subgrade (particularly the top 300
mm of the subgrade) shall have
been shaped and compacted in

The lower subbase shall be i) the liquid limit shall be not

finished in a neat and workman more than 25%;
like manner, and shall have an
average thickness over any 100 ii) the plasticity index shall be
metre length not less than the not more than 6;
required thickness. The top
surface of the lower subbase shall iii) the aggregate crushing value
have the required shape, when tested in accordance
superelevation, levels and grades, with M.S. 30 shall be not
and shall be everywhere within more than 35;
the tolerances specified in Sub-
Section 4.4. iv) unless otherwise specified on
the Drawings or directed by
4.1.2 Subbase the S.O., the material shall
have a CBR value of 30 or
4.1.2.1 Description more when compacted to
95% of the maximum dry
This work shall consist of density determined in the B.S.
furnishing, placing, compacting 1377 Compaction Test (4.5 kg
and shaping subbase material on rammer method) and soaked
a prepared and accepted subgrade for 4 days under a surcharge
or lower subbase in accordance of 4.5 kg;
with this Specification and the
lines, levels, grades, dimensions v) the gradation shall conform
and cross-sections shown on the to one of the envelopes
Drawings and/or as required by shown in Table 4.1 with the
the S.O. fraction passing the B.S. 75
um sieve not greater than 2/3
4.1.2.2 Materials of the fraction passing the
B.S. 425 um sieve.
Subbase material shall be a
natural or prepared aggregate
comprising crushed rock,
weathered or fragmented rock,
gravel or crushed gravel, sand, or
a mixture of any of these
materials. It shall have a small
proportion of plastic or
non-plastic fines and shall be
essentially free from vegetative
and other organic matter,
expansive clay minerals and
lumps of clay. The material
shall conform to the following
physical and mechanical quality
requirements :-

TABLE 4.1 - GRADATION LIMITS FOR SUBBASE MATERIAL
B.S. % Passing By Weight

Sieve
Size A B C D E F
50.0 mm 100 100 - - - -

25.0 mm - 79-95 100 100 100 100
9.5 mm 30-65 40-75 50-85 60-100 - -
4.75 mm 25-55 30-60 35-65 50-85 55-100 70-100
2.00 mm 15-40 20-45 25-50 40-70 40-100 55-100
425 um 8-20 15-30 15-30 25-45 20-50 30-70
75 um 2-8 5-20 5-20 5-20 6-20 8-25
4.1.2.3 Construction Methods suitable for compaction, and shall

then be compacted using suitable
Prior to placing any subbase compaction equipment approved
material, the underlying subgrade by the S.O. to not less than 95%
(particularly the top 300 mm of the of the maximum dry density
subgrade) or lower subbase shall determined in the B.S. 1377
have been shaped and compacted in Compaction Test (4.5 kg rammer
accordance with the provisions of method). Compaction shall be
Sub-Section 2.2.7 or Sub-Section carried out in a longitudinal
4.1.1.3 as appropriate. direction along the carriageway,
Notwithstanding any earlier and shall generally begin at the
approval of finished subgrade or outer edge and progress
lower subbase, any damage to or uniformly towards the centre on
deterioration of the subgrade or each side, except on
lower subbase shall be made good superelevated curves where
to the satisfaction of the S.O. before rolling shall begin at the lower
subbase is constructed. edge and progress uniformly
towards the higher edge. In all
Subbase shall be placed with cases compaction shall be carried
equipment approved by the S.O. out in such a manner that each
over the full width of the formation section receives equal compactive
to the required thickness as shown effort, all to the satisfaction of the
on the Drawings or directed by the S.O.
S.O. in one layer or more, each
layer not exceeding 200 mm Throughout the placing,
compacted thickness. Where two adjustment of moisture content
or more layers are required they and compaction of subbase
shall be of approximately equal material, care shall be taken to
thickness and none shall be less maintain a uniform gradation of
than 100 mm compacted thickness. the material and prevent its
separation into coarse and fine
Each layer of subbase shall be parts, all to the satisfaction of the
processed as necessary to bring S.O.
its moisture content to a uniform
level throughout the material

The subbase shall be finished in a 4.1.3.2 Materials

neat and workmanlike manner;
its width shall be everywhere at Gravel surfacing material shall be
least that specified or shown on a natural or prepared soil-
the Drawings on both sides of the aggregate mixture comprising
centre-line; and its average gravel and sand size particles
thickness over any 100 metre together with a small proportion
length shall be not less than the of plastic fines, and shall be
required thickness. The top essentially free from vegetative
surface of the subbase shall have and other organic matter,
the required shape, expansive clay minerals and
superelevation, levels and grades, lumps of clay. The material shall
and shall be everywhere within conform to the following physical
the tolerances specified in Sub- and mechanical quality
Section 4.4. requirements :-
4.1.3 Gravel Surfacing i) the liquid limit shall be not

more than 35%;
4.1.3.1 Description
ii) the plasticity index shall be in
This work shall consist of the range 4 to 10;
furnishing, placing, compacting
and shaping gravel surfacing iii) the aggregate crushing value
material on a prepared and when tested in accordance
accepted subgrade or lower with M.S. 30 shall be not
subbase in accordance with this more than 35;
Specification and the lines, levels,
grades, dimensions and iv) the gradation shall conform
cross-sections shown on the to one of the envelopes
Drawings and/or as required by shown in Table 4.2 with the
the S.O. fraction passing the B.S. 75
um sieve not greater than 2/3
of the fraction passing the
B.S. 425 um sieve.
TABLE 4.2 - GRADATION LIMITS FOR GRAVEL SURFACING
% Passing By Weight
B.S. Sieve
Size
A B C D
37.5 mm 100 100 100 100

12.5 mm 45 - 75 55 - 85 60 - 100 -
4.75 mm 30 - 60 35 - 65 50 - 85 55 - 90
2.00 mm 20 - 45 25 - 50 40 - 70 40 - 70
425 um 15 - 30 15 - 30 25 - 45 20 - 50
75 um 8 - 20 8 - 20 8 - 20 8 - 25

Material with a maximum uniform level throughout the

particle size of 37.5 mm, while material suitable for compaction,
otherwise not conforming to the and shall then be compacted
gradation specification but using suitable compaction
satisfying the other requirements, equipment approved by the S.O.
shall be acceptable provided that to not less than 95% of the
it shall have a CBR value of 30 maximum dry density determined
or more when compacted to 95% in the B.S. 1377 Compaction Test
of the maximum dry density (4.5 kg rammer method).
determined in the B.S. 1377 Compaction shall be carried out
Compaction Test (4.5 kg rammer in a longitudinal direction along
method) and soaked for 4 days the carriageway, and shall
under a surcharge of 4.5 kg. generally begin at the outer edge
and progress uniformly towards
4.1.3.3 Construction Methods the centre on each side, except on
superelevated curves where
Prior to placing any gravel rolling shall begin at the lower
surfacing material, the underlying edge and progress uniformly
subgrade (particularly the top 300 towards the higher edge. In all
mm of the subgrade) or lower cases compaction shall be carried
subbase shall have been shaped out in such a manner that each
and compacted in accordance section receives equal compactive
with the provisions of Sub- effort, all to the satisfaction of the
Section 2.2.7 or Sub-Section S.O.
4.1.1.3 as appropriate.
Notwithstanding any earlier Throughout the placing,
approval of finished subgrade or adjustment of moisture content
lower subbase, any damage to or and compaction of gravel
deterioration of the subgrade or surfacing material, care shall be
lower subbase shall be made taken to maintain a uniform
good to the satisfaction of the gradation of the material and
S.O. before gravel surfacing is prevent its separation into coarse
constructed. and fine parts, all to the
Gravel surfacing shall be placed
to the required width and The gravel surfacing shall be
thickness as shown on the finished in a neat and
Drawings or directed by the S.O. workmanlike manner; its width
in one layer or more, each layer shall be everywhere at least that
not exceeding 200 mm specified or shown on the
compacted thickness. Where two Drawings on both sides of the
or more layers are required they centre-line; and its average
shall be of approximately equal thickness over any 100 metre
thickness and none shall be less length shall be not less than the
than 100 mm compacted required thickness and its
thickness. minimum thickness at any point
shall be not less than the required
Each layer of gravel surfacing thickness minus 20 mm.
shall be processed as necessary to
bring its moisture content to a

The top surface of the gravel iv) not less than 80% of particles
surfacing shall have the required retained on the B.S. 4.75 mm
shape, superelevation, levels and sieve shall have at least one
grades, and shall be everywhere fractured face;
within 10 mm of the required
plane or such higher, v) the weighted average loss of
approximately parallel plane, as weight in the sodium sulphate
the S.O. shall approve. soundness test (5 cycles)
when tested in accordance
4.1.4 Crushed Aggregate Roadbase with AASHTO Test Method
T 104 shall be not more than
4.1.4.1 Description 12%;
This work shall consist of vi) the material shall have a CBR
furnishing, placing, compacting value of not less than 80 when
and shaping crushed aggregate compacted to 95% of the
roadbase material on a prepared maximum dry density
and accepted subgrade or lower determined in the B.S. 1377
subbase or subbase in accordance Compaction Test (4.5 kg
with this Specification and the rammer method) and soaked
lines, levels, grades, dimensions for 4 days under a surcharge
and cross-sections shown on the of 4.5 kg;
Drawings and/or as required by
the S.O. vii)the gradation shall comply
with the envelope shown in
4.1.4.2 Materials Table 4.3 for the type
specified.
Crushed aggregate roadbase
material shall be crushed rock, or
crushed gravel, or a mixture of TABLE 4.3 - GRADATION LIMITS FOR
crushed and natural aggregates, CRUSHED AGGREGATE ROADBASE
which is hard, durable, clean and
essentially free from clay and
other deleterious materials. B.S. Sieve % Passing By Weight
Size
The material shall conform to the
Type I Type II
following physical and
mechanical quality requirements:-
50.0 mm 100 100
37.5 mm 95 - 100 85 - 100
i) the plasticity index shall be not - 70 - 100
28.0 mm
more than 6; 20.0 mm 60 - 80 60 - 90
10.0 mm 40 - 60 40 - 65
ii) the aggregate crushing value 5.0 mm 25 - 40 30 - 55
when tested in accordance with 2.36 mm 15 - 30 -
M.S. 30 shall be not more than 2.00 mm - 20 - 40
30; 600 um 8 – 22 -
425 um - 10 - 25
iii) the flakiness index when tested in 75 um 0–8 2 - 10
accordance with M.S. 30 shall be
not more than 30;

4.1.4.3 Construction Methods of the maximum dry density

determined in the B.S. 1377
Prior to placing any crushed Compaction Test (4.5 kg rammer
aggregate roadbase material, the method).
underlying subgrade or lower
subbase or subbase shall have Compaction shall be carried out
been shaped and compacted in in a longitudinal direction along
accordance with the provisions of the carriageway, and shall
the appropriate Section of this generally begin at the outer edge
Specification. Notwithstanding and progress uniformly towards
any earlier approval of finished the centre on each side, except on
subgrade or lower subbase or superelevated curves where
subbase, any damage to or rolling shall begin at the lower
deterioration of the subgrade or edge and progress uniformly
lower subbase or subbase shall be towards the higher edge. In all
made good to the satisfaction of cases compaction shall be carried
the S.O. before crushed aggregate out in such a manner that each
roadbase is constructed. section receives equal compactive
effort, all to the satisfaction of the
Crushed aggregate roadbase shall S.O.
be placed to the required width
and thickness as shown on the Throughout the placing,
Drawings or directed by the S.O. adjustment of moisture content
in one layer or more, each layer and compaction of crushed
not exceeding 200 mm aggregate roadbase material, care
compacted thickness. Where two shall be taken to maintain a uni
or more layers are required they form gradation of the material
shall be of approximately equal and prevent its separation into
thickness and none shall be less coarse and fine parts, all to the
than 100 mm compacted satisfaction of the S.O.
thickness. Spreading shall be
done by a mechanical spreader The crushed aggregate roadbase
approved by the S.O. or, if shall be finished in a neat and
approved by the S.O., by motor workmanlike manner; its width
grader. shall be everywhere at least that
specified or shown on the
Prior to spreading, crushed Drawings on both sides of the
aggregate roadbase shall be centre-line; and its average
processed as necessary to bring thickness over any 100 metre
its moisture content to a uniform length shall be not less than the
level throughout the material required thickness. The top
suitable for compaction. Spread surface of the crushed aggregate
material shall be maintained at roadbase shall have the required
the correct moisture content for shape, superelevation, levels and
proper compaction by sprinkling grades, and shall be everywhere
with water or drying as may be within the tolerances specified in
necessary, and shall be Sub-Section 4.4.2.
compacted using suitable
compaction equipment approved
by the S.O. to not less than 95%

4.2 BITUMINOUS PAVEMENT (a) Power Broom

COURSES
The power broom shall be a
4.2.1 Bitumen Prime Coat rotary type specifically
designed for sweeping road
4.2.1.1 Description surfaces, and shall be
This work shall consist of the
careful and thorough cleaning of (b) Compressed Air Blower
the surface of a prepared and
accepted crushed aggregate The compressed air blower
roadbase, and the furnishing and shall comprise a portable air
application to the cleaned compressor of 3 cu.m/min. in
roadbase surface of a bituminous capacity at 0.7 N/sq.mm
priming material, all in delivery pressure with a
accordance with this suitable hose and nozzle for
Specification and the lines, blowing clean a road surface
dimensions and cross-sections after power brooming, and
shown on the Drawings and/or as shall be approved by the S.O.
required by the S.O.
(c) Pressure Distributor for
4.2.1.2 Materials Bituminous Material
The bituminous priming material The distributor shall be a

shall be either cut-back bitumen purpose built model of
or bitumen emulsion as stated in recognised manufacture and
the Bill of Quantities. shall be approved by the S.O.
It shall conform to the
Cut-back bitumen shall be grade requirements described
RC-70 or MC-70 conforming to hereunder.
the requirements of M.S. 159.
The distributor shall have a
Bitumen emulsion shall be slow suitable capacity and shall be
setting, grade SS-1 or SS-1K, equipped with a gas or oil
conforming to the requirements fired heating system capable
of M.S. 161, as appropriate to the of heating a full charge of
type of roadbase material to be bituminous material to
primed and approved by the S.O. l80°C. The heating system
shall be such that overheating
4.2.1.3 Equipment of the bituminous material
will not occur and shall be of
The equipment used by the a type in which flames from
Contractor shall include a power the burner do not come into
broom, a compressed air blower, direct contact with the casing
a self-propelled pressure of the tank containing the
distributor for bituminous bituminous material. The
material, and as necessary, tank shall be insulated in such
equipment for storing and heating a manner that when filled
bituminous material. with bituminous material at
l80°C and not heated,

the drop in temperature shall be 0.25 to 8.0 litres/sq.m at normal

less than 3°C per hour. A distributor operating speeds, such
thermometer shall be provided to that deviation from the prescribed
measure continuously the rate of application shall not
temperature of the bituminous exceed 10%.
material in the tank and shall be
so arranged that the highest The distributor shall be equipped
temperature in the tank is with a hand spraying system.
measured. The tank shall be
fitted with an accurately The meters for the `fifth wheel'
calibrated dipstick or contents tachometer system and the
gauge, and the pipe for filling the bituminous material pumping
tank shall be fitted with an easily flow rate, pumping pressure and
replaceable filter. temperature shall be located in
such a manner that the vehicle
The distributor shall run on driver can easily read them while
pneumatic tyred wheels of such operating the distributor. The
width and number that the load spray bar shall be controlled by a
produced on the road surface second operator riding at the rear
when the vehicle is fully charged of the vehicle in such a position
shall not exceed l2 kg/mm of tyre that all the discharge sprays are in
width. The vehicle shall be his good view.
equipped with a `fifth wheel'
tacheometer system to accurately All measuring equipment on the
measure its forward speed during distributor shall have been
spraying operations. recently calibrated, and accurate
and satisfactory records of the
The distributor shall be equipped calibrations shall be submitted to
with a full circulation type spray the S.O. If in the course of the
bar with nozzles from which the work the rates of application of
bituminous material is sprayed on bituminous material are found to
to the road surface uniformly be inaccurate, the distributor shall
over the full spraying width. The be withdrawn from the Works
spraying width shall be variable and recalibrated to the
in increments of not more than satisfaction of the S.O. before
100 mm up to a maximum of 5.0 being returned to service.
metres. The spraying pump shall
be driven by a separate power The S.O. may require such
unit and shall be equipped with performance tests as he considers
an accurate pressure gauge and necessary to check that the
an accurate flow rate gauge or distributor is operating
meter. On the suction side the satisfactorily. As directed by the
pump shall be fitted with an S.O., the Contractor shall make
easily replaceable filter. The the distributor and its equipment
spray bar and pump shall be so available for such tests and shall
designed that bituminous material supply all necessary assistance,
at even temperature and uniform materials, tools, testing apparatus,
pressure may be sprayed uni etc., all at the Contractor's own
formly over the spraying width at expense.
controlled rates in the range

(d) Storage and Heating Facilities Notwithstanding any earlier

for Bituminous Material approval of finished crushed
aggregate roadbase, any
Tanks for storage of damage to or deterioration of
bituminous material shall the roadbase shall be made
have a capacity suited to the good to the satisfaction of the
proposed rate of utilisation of S.O. before prime coat is
the material and the method applied.
and frequency of its delivery
to the Works, all to the satis Immediately prior to applying
faction of the S.O. The tanks the bituminous material, the
and, where necessary, barrel full width of the surface to be
decanters shall be equipped treated shall be swept using a
with heating systems which power broom followed by a
provide for effective and compressed air blower and, if
positive control of the necessary, scraped using hand
temperature of the bituminous tools to remove all dirt, dust
material at all times up to the and other objectionable
temperature required for material, all to the satisfaction
utilisation. The method of of the S.O.
heating shall be such that
neither flames nor the (c) Application of Bituminous
products of combustion shall Material
come into direct contact with
the bituminous material or the The bituminous priming
casing of its immediate material shall be sprayed on
container, and such that no to the cleaned roadbase
portion of the bituminous surface by means of a
material shall be subject to pressure distributor. Any
overheating. areas inaccessible to the
distributor spray bar shall be
4.2.1.4 Construction Methods treated using the distributor's
hand spraying system. The
(a) General Conditions rate or rates of application
shall be as directed by the
Bitumen prime coat work S.O. based on the results of
shall only be carried out in test applications, but shall
dry, warm weather when the usually be in the range 0.5 to
surface to be treated is 1.0 litre/sq.m. The
essentially dry. temperature of cut-back
bitumen shall be maintained
(b) Surface Preparation and in the range 50°C to 70°C
Cleaning during spraying operations.
For bitumen emulsions, the
Prior to applying the prime spraying temperature shall be
coat, the crushed aggregate in the range 25°C to 45°C.
roadbase shall have been
shaped and compacted in
accordance with the
provisions of Sub-Section
4.1.4.3.
If necessary, in order to The Contractor shall maintain

prevent the bituminous the prime coat, all to the
material from flowing on the satisfaction of the S.O., until
sprayed surface, the pre the overlying pavement
scribed prime coat shall be course is constructed, which
applied in two separate shall not be within 24 hours
spraying operations. Where after the application of the
the condition of the treated bituminous priming material
surface indicates that it is nor within such longer period
necessary, bituminous as is required, in the opinion
material additional to that of the S.O., for the prime coat
prescribed shall be applied as to achieve maximum
the S.O. shall direct. penetration of the roadbase
and become fully cured.
Prime coat shall be distributed
uniformly over the surface to 4.2.2 Bituminous Tack Coat
be treated without streaking;
the quantities applied shall not 4.2.2.1 Description
deviate by more than 10%
from those prescribed. Areas This work shall consist of the
with insufficient bituminous careful and thorough cleaning of
material shall be resprayed as the surface of a prepared and
necessary to make up the accepted bituminous or bitumen
deficiency, all to the primed pavement course, and the
satisfaction of the S.O. furnishing and application to the
cleaned surface of a bituminous
The surfaces of structures, tack coat prior to the construction
road furniture and trees of an overlying bituminous
adjacent to the areas being pavement course, all in
sprayed shall be protected in accordance with this
such a manner as to prevent Specification and the lines,
their being spattered or dimensions and cross-sections
marred by bituminous shown on the Drawings and/or as
material. Bituminous material required by the S.O.
shall not be discharged into
road drains, gutters, etc. 4.2.2.2 Materials
(d) Curing and Opening to Traffic Bituminous tack coat material

shall be rapid setting bitumen
Prime coat shall normally be emulsion of grade RS-1 or RS-
left undisturbed for at least 24 1K conforming to the
hours after application and requirements of M.S. 161.
shall not be opened to traffic
until, in the opinion of the 4.2.2.3 Equipment
S.O., it has penetrated the
roadbase and cured The equipment shall be as
sufficiently so that it will not specified in Sub-Section 4.2.1.3.
be picked up by the wheels of
vehicles.

4.2.2.4 Construction Methods (c) Application of Bituminous

Material
(a) General Conditions
The bituminous tack coat
Bituminous tack coat shall shall be sprayed on to the
only be applied to a clean, cleaned bituminous or
dry, bituminous or bitumen bitumen primed surface by
primed surface. means of a pressure
distributor. Any areas
Bituminous tack coat shall inaccessible to the distributor
only be applied as far in spray bar shall be treated
advance of the construction of using the distributor's hand
the overlying bituminous spraying system. The rate or
pavement course as is rates of application shall be as
necessary to achieve a satis directed by the S.O. based on
factory degree of tackiness the results of test applications,
before the overlying material but shall usually be in the
is placed, all to the range 0.25 to 0.55 litres/sq.m.
satisfaction of the S.O. The temperature of the
bituminous material shall be
(b) Surface Preparation and maintained in the range 25°C
Cleaning to 45°C during spraying
operations.
Prior to applying bituminous
tack coat, the surface to be Tack coat shall be distributed
treated shall have been uniformly over the surface to
prepared in accordance with be treated without streaking;
the appropriate Sections of the quantities applied shall not
this Specification. deviate by more than 10%
Notwithstanding any earlier from those prescribed. Areas
approval of this surface, any with bituminous material in
damage to it or deterioration excess of these limits shall
of it shall be made good have the excess removed at
before tack coat is applied. the Contractor's expense, and
areas with insufficient
Immediately prior to applying bituminous material shall be
bituminous tack coat, the full resprayed as necessary to
width of the surface to be make up the deficiency, all to
treated shall be swept using a the satisfaction of the S.O.
power broom followed by a
compressed air blower, and if The surfaces of structures,
necessary, scraped using hand road furniture and trees
tools, to remove all dirt, dust adjacent to the areas being
and other objectionable sprayed shall be protected in
material, all to the satisfaction such a manner as to prevent
of the S.O. their being spattered or
marred by bituminous
material. Bituminous material
road drains, gutters, etc.

Traffic shall be kept off the Penetration graded bitumen

tack coat at all times, and the shall be 80-100 grade con
Contractor shall maintain the forming to M.S. 124.
tack coat, all to the
satisfaction of the S.O., until Cut-back bitumen shall be
the overlying pavement grade RC-70 or MC-70
course is constructed. conforming to M.S. 159.
4.2.3 Bituminous Surface Dressing Bitumen emulsion shall be

rapid setting of grade RS-
4.2.3.1 Description 1, RS-1K, RS-2, RS-2K or
RS-3K conforming to M.S.
This work shall consist of the 161. The grade of emulsion
careful and thorough cleaning of selected shall be anionic or
the surface of a prepared and cationic as appropriate to the
accepted bituminous or bitumen type of rock from which the
primed pavement course, and the cover aggregate is derived,
furnishing and placing on the and shall be approved by the
cleaned surface of one or two S.O.
applications of bituminous
material and cover aggregate, all (b) Additives for Bituminous
in accordance with this Material
Specification and the lines,
dimensions and cross-sections An adhesion and anti-
shown on the Drawings and/or as stripping agent shall be added
required by the S.O. When one to the bituminous material if
application of bituminous the S.O. shall so direct or
material and cover aggregate is approve. The additive shall be
placed the term `single of a type approved by the
bituminous surface dressing' S.O. and the required quantity
(SBSD) shall apply, and when of additive shall be
two applications of bituminous thoroughly mixed with the
material and cover aggregate are bituminous material in
placed, the term `double accordance with the
bituminous surface dressing' manufacturer's instructions or
(DBSD) shall apply. as directed by the S.O. for
such time as is necessary to
4.2.3.2 Materials produce a homogenous
mixture.
(a) Bituminous Material
(c) Aggregates for Bituminous
Bituminous binder for Surface Dressing
bituminous surface dressing
shall be penetration graded For single bituminous surface
bitumen, or cut-back bitumen, dressing the cover aggregate
or bitumen emulsion as shall be nominal 20 mm, 14
shown on the Drawings or mm, 10 mm or 6 mm size
otherwise specified. chippings as shown on the
Drawings and/or directed by
the S.O.

For double bituminous iii) the weighted average loss

surface dressing the cover of weight in the sodium
aggregate for the first sulphate soundness test (5
application of bituminous cycles) when tested in
material and cover aggregate accordance with AASHTO
shall be nominal 20 mm size Test Method T 104 shall
chippings, and the cover be not more than 12%;
aggregate for the second
application of bituminous iv) the flakiness index when
material and cover aggregate tested in accordance with
shall be nominal 10 mm size M.S. 30 shall be not more
chippings. than 25;
Cover aggregates shall be v) the polished stone value

screened, crushed stone and when tested in accordance
shall comprise clean, dry, with M.S. 30 shall be not
hard, tough, sound, angular less than 40;
and cubical chippings free
from vegetative and other vi) the gradation shall con
organic matter, clay and other form to the appropriate
deleterious substances, and envelope shown in Table
containing few, if any, flaky 4.4.
or elongated particles. Dusty
chippings shall be washed 4.2.3.3 Equipment
clean, all to the satisfaction of
the S.O. Cover agregates The Contractor shall provide all
shall conform to the following the plant and equipment
physical and mechanical necessary for executing the work
requirements :- in accordance with this
Specification, and shall furnish
i) using the type of the S.O. with such details of
bituminous material to be particular items of equipment,
used in the Works, treated e.g. manufacturer, model type,
with additive if so capacity, weight, etc., as the S.O.
required, the coated area in shall require.
the coating and stripping
test for bitumen aggregate The equipment shall include a
mixtures, AASHTO Test power broom, a compressed air
Method T 182, shall not blower, a self-propelled pressure
be less than 95%; distributor for bituminous
material, all necessary equipment
ii) the aggregate crushing for storing and heating
value when tested in bituminous material, aggregate
accordance with M.S. 30 spreading equipment, a suitable
shall be not more than 30; number of tip-trucks and a self-
propelled pneumatic tyred roller.

TABLE 4.4 - GRADATION LIMITS FOR BITUMINOUS SURFACE DRESSING
% Passing By Weight
B.S.
Sieve
Size Nominal Nominal Nominal Nominal
20 mm 14 mm 10 mm 6 mm
Chippings Chippings Chippings Chippings
25.0 mm 100 - - -
20.0 mm 85 - 100 100 - -
14.0 mm 0 - 20 85 - 100 100 -
10.0 mm - 0 - 20 85 - 100 100
6.3 mm - - 0 - 20 85 - 100
4.75 mm 0-5 0-5 0 - 10 0 - 25
2.36 mm 0-2 0-2 0-2 0 - 10
(a) Power Broom (e) Aggregate Spreading

Equipment
The power broom shall be
as specified in Sub-Section Aggregates shall be placed
4.2.1.3(a). using mechanical
spreaders of a type
(b) Compressed Air Blower approved by the S.O. The
The compressed air spreaders shall be capable
blower shall be as of applying aggregate
specified in Sub-Section uniformly over the full
4.2.1.3 (b). width of the area being
treated and shall have
(c) Pressure Distributor for controls to regulate the
Bituminous Material rate of spread as required
by this Specification, all to
The distributor shall be as the satisfaction of the S.O.
specified in Sub-Section
4.2.1.3(c). (f) Tip-Trucks
(d) Storage and Heating The Contractor shall

Facilities for Bituminous provide a suitable number
Material of tip-trucks of a type
approved by the S.O.,
Storage and heating capable of spreading
facilities for bituminous aggregate in accordance
material shall be as with this Specification.
specified in Sub-Section
4.2.1.3 (d).

(g) Pneumatic Tyred Roller In operation, the ballasted

weight and the tyre
The pneumatic tyred roller inflation pressure shall be
shall be of recognised adjusted to meet the
manufcature and shall be requirements of each
approved by the S.O. It particular operation. Each
shall conform to the tyre shall be kept inflated
requirements described at the specified pressure
hereunder. such that the pressure
difference between any
The pneumatic tyred roller two tyres shall not exceed
shall be self-propelled and 0.04 N/sq.mm. Means
capable of being reversed shall be provided for
without backlash; it shall checking and adjusting
be equipped with power tyre pressures at all times
steering and dual controls at the place of the works.
allowing operation from
either the left or right side. The Contractor shall
provide the S.O. with a
The roller shall have nine calibration chart for the
wheels equipped with roller showing the
smooth treaded tyres all of relationship between the
the same size and quantity or depth of ballast
construction, and capable and total weight, and also
of operating at inflation a chart showing the
pressures of up to 0.9 relationship between
N/sq.mm. Five wheels wheel load, tyre inflation
shall be on the driven axle pressure and contact
and four on the steering pressure.
axle, all equally spaced on
both axles and arranged so 4.2.3.4 Construction Methods
that the tyres on the
steering axle track midway (a) General Conditions
between those on the
driven axle with a small Bituminous surface dressing
overlap. The roller shall be shall only be carried out in
equipped with water tanks, dry, warm weather when the
sprinkler systems and pads surface to be treated is dry.
of coconut matting to keep Work shall be discontinued
all tyres evenly wetted when rain appears imminent
during operation. and during periods of strong
wind.
The roller shall be
equipped with means of The S.O. may order the
adjusting its total weight discontinuation of work on
by ballasting so that the account of adverse weather,
load per wheel can be unsatisfactory condition of
varied in the range 1.0 to materials, equipment or
2.0 tonnes.

surface to be treated, or such (c) Application of Bituminous

other conditions as he shall Material
consider detrimental to the
work. The bituminous material for a
single bituminous surface
(b) Surface Preparation and dressing or for each
Cleaning application of bituminous
material and cover aggregate
Prior to constructing a of a double bituminous
bituminous surface dressing, surface dressing, shall be
the surface to be treated shall sprayed on to the cleaned
have been prepared in surface to be treated by means
accordance with the of a pressure distributor. Any
appropriate Sections of this areas inaccessible to the
Specification.Notwithstanding distributor spray bar shall be
any earlier approval of this treated using the distributor's
surface, any damage to or hand spraying system.
deterioration of it shall be
made good before surface The rate or rates of
dressing is commenced. application shall be as
directed by the S.O. based on
Immediately prior to the results of laboratory tests
commencing surface dressing, and/or test applications but for
the full width of the surface to penetration graded bitumen
be treated, together with an shall usually be in the
additional 300 mm width on appropriate range given in
each side, shall be swept Table 4.5.
using a power broom
followed by a compressed air
blower and, if necessary,
scraped using hand tools to TABLE 4.5 - RATES OF APPLICATION
remove all loose particles, OF PENETRATION GRADED BITUMEN
dirt, dust and other
objectionable material, all to
the satisfaction of the S.O. Nominal Size Rate of Application of
of Aggregate Penetration Graded
In double bituminous surface Bitumen
dressing construction, the
surface of the first application
of bituminous material and 20 mm 2.0 - 3.0 litre/sq.m
cover aggregate shall be
similarly made good and 14 mm 1.5 - 2.2 litre/sq.m
cleaned, immediately prior to
commencing the second 10 mm 1.0 - 1.5 litre/sq.m
application.
6 mm 0.7 - 1.0 litre/sq.m

The rates of application The spraying of bituminous

for cut-back bitumens and material over any portion of
bitumen emulsions shall the surface to be treated shall
be commensurately higher not be carried out more than
depending on their residual two minutes in advance of
bitumen contents. placing the cover aggregate
on that portion at the specified
The temperature of the rate; an the progress of
bituminous material shall spraying the bituminous
be maintained during material shall be restricted as
spraying operations within necessary to comply with
the appropriate range this requirement.
given in Table 4.6.
TABLE 4.6 - SPRAYING TEMPERATURE
The bituminous material FOR BITUMINOUS
shall be distributed
uniformly over the surface
to be treated without
streaking; the quantities
applied shall not deviate
Bituminous Material Spraying Temperature
by more than 10% from
those prescribed. The rate
of application shall be 80-100 penetration 150 oC to 165 oC
checked for each spraying grade bitumen
run by measuring the
volume of bituminous Cut-back bitumen 50 oC to 65 oC
material in the distributor grade
before and after spraying RC-70 or MC-70
and the area treated. 25oC to 45 oC
Adjustments shall be made Bitumen emulsions
as necessary to ensure that
the prescribed rate of
application is maintained
in subsequent runs. Bituminous materials
Spraying shall be Bituminous materials shall
discontinued immediately not be heated to spraying
if any defect develops in temperatures too soon in
the distributor, and it shall advance of requirements.
not be resumed until the Any bituminous material
fault has been rectified to which has been heated to
the satisfaction of the S.O. spraying temperature for
more than ten hours or
which has been overheated
shall be rejected.

In cases where the Provision shall be made

bituminous material is for a volume of
applied in lanes there shall bituminous material of at
be a small overlap of least 10% of the capacity
bituminous material at the of the distributor, or such
joints between lanes equal other quantity as the S.O.
in width to the edge strip shall direct, to remain in
of the sprayed area which the distributor tank at the
does not receive the full completion of each spraying
rate of application of run, in order to avoid air
bituminous material. For entrapment within the
double bituminous surface bitumen spraying system.
dressing, joints in the
second application of The surfaces of structures,
bituminous material shall road furniture and trees
be offset from those in the adjacent to the areas being
first application by 150 - sprayed shall be protected
300 mm for longitudinal in such a manner as to prevent
joints and by at least 1.0 their being spattered or
metre, where possible, for marred by bituminous
transverse joints. material. Bituminous material
Each spraying run shall road drains, gutters, etc.
commence and terminate
on lengths of building (d) Application of Cover
paper placed across the Aggregate
full spraying width
immediately before and Before each spraying run
after the section to be of bituminous material
sprayed. Sufficient building commences, sufficient
paper shall be aggregate to provide full
placed so that the distributor cover at the prescribed rate
may be started and stopped of application over the
with the spray bar over paper, entire area to be sprayed
and so that the correct shall have been loaded in
distributor road speed and rate trucks at the Site of the
of spraying can be maintained Works in readiness for
over the entire length of the spreading.
section to be sprayed, all to
the satisfaction of the S.O. Immediately following
Immediately after use and the application of the
before application of cover bituminous material, the
aggregate, the building clean, dry cover aggregate
paper shall be removed shall be uniformly spread over
and disposed of in a manner the bituminous material using
approved by the S.O. mechanical spreaders

The aggregate shall be placed The rate of application shall

as quickly as practicable after be checked for each spraying
the application of bituminous run from measurements of the
material on all parts of the quantities of aggregate in the
area to be covered, and for no trucks and the area treated, or
portion of the surface to be by sampling and measuring
treated shall there be a delay the aggregate spread on the
of more than two minutes road. Any bare or
between the application of the insufficiently covered areas
bituminous material shall be made good by hand
and the spreading of spreading as quickly as
the aggregate. possible. Aggregate in excess
of the rate prescribed shall be
The trucks feeding the evenly distributed over the
aggregate to the mechanical surface or removed as quickly
spreaders shall operate as possible, all to the
backward during aggregate satisfaction of the S.O.
spreading in order that the
wheels of the spreaders and In cases where the surface
trucks shall not run on dressing is constructed in
uncovered bituminous lanes, the edge of the
material. aggregate spread adjacent to
an untreated lane shall
The rate of application of coincide with the edge of the
cover aggregate shall be as sprayed area which receives
directed by the S.O. based on the full rate of application of
the results of laboratory tests the bituminous material. This
and/or tests applications, but will leave a narrow strip of
shall usually be in the bituminous material of partial
appropriate range given in thickness which shall be
Table 4.7 overlapped by the bituminous
material spray and aggregate
TABLE 4.7 - RATES OF APPLICATION OF spread of the adjacent lane.
COVER AGGREGATE
Immediately following the
spreading of the aggregate to
Nominal Rate of Application
the satisfaction of the S.O.,
Size of Aggregate
the aggregate shall be rolled
with a pneumatic tyred roller
approved by the S.O. to
embed the aggregate in the
20 mm 17 – 27 kg/sq.m bituminous material. Rolling
shall commence as quickly as
14 mm 12 – 18 kg/sq.m practicable after the
application of the bituminous
10 mm 8 – 12 kg/sq.m material and aggregate on all
parts of the area to be
6 mm 5 – 8 kg/sq.m covered, and for no portion
of the surface to be treated
shall there be a delay of more

than 3 minutes between the shall then proceed as soon as

application of the bituminous is practicable.
material and the
commencement of rolling. (e) Opening to Traffic
The pneumatic tyred roller Bituminous surface dressing

shall be ballasted to an shall normally not be opened
operating weight of 9 - 10 to traffic until such time as,
tonnes and its tyre inflation in the opinion of the S.O., the
pressure shall be 0.53 surfacing shall have
N/sq.mm for surface dressing developed sufficient strength
work. Rolling shall be to withstand normal traffic
continued for as long as is forces without dislodgement
necessary to thoroughly of the aggregate. This will
embed the aggregate in the usually be not less than 24
bituminous material, all to the hours after the completion of
satisfaction of the S.O. rolling. Where it is necessary
to allow earlier use of the
Rolling shall generally begin finished surface to facilitate
at the outer edge of surface the movement of traffic,
dressing and progress vehicles may be allowed to
uniformly towards the centre run on the work after rolling
on each side, except on super has been completed, provided
elevated curves where rolling that speeds are restricted to 30
shall begin at the lower edge km per hour or less and sharp
and progress uniformly turning movements are
towards the higher edge. prohibited. The finished
Consecutive roller passes surface shall subsequently
shall generally overlap by have to be closed
about one half of the roller's temporarily to enable the
width. loose aggregate to be swept
off and disposed of as
When, in the opinion of the described in Sub-Section
S.O., the bituminous material 4.2.3.4 (d).
has hardened sufficiently to
prevent the dislodgement of Ideally, the first application of
embedded aggregate by the bituminous material and cover
action of the power broom, all aggregate of a double
loose aggregate shall be swept bituminous surface dressing
from the treated surface using should not be opened to
the power broom and traffic before construction of
compressed air blower and the second application.
disposed of to the satisfaction However, where it is
of the S.O. Where the necessary to facilitate the
dressing so prepared is the movement of traffic, the first
first application of a double application may be opened to
bituminous surface dressing, traffic prior to construction of
construction of the second the second application.
application of bituminous Nevertheless, traffic
material and cover aggregate movement on the completed

first application shall be kept organic matter, and other

to a practicable minimum and deleterious substances. They
the second application shall shall conform to the following
be constructed as soon as is physical and mechanical quality
practicable after the requirements :-
completion of the first.
i) the aggregate crushing value
when tested in accordance
4.2.4 Asphaltic Concrete with M.S. 30 shall be not
more than 30;
4.2.4.1 Description
ii) the weighted average loss of
This work shall consist of weight in the sodium sulphate
furnishing, placing, shaping and soundness test (5 cycles)
compacting asphaltic concrete when tested in accordance
binder course and/or wearing with AASHTO Test Method T
course on a prepared and 104 shall be not more than
accepted bituminous or bitumen 12%;
primed pavement course, and
shall include the careful and iii) the flakiness index when
thorough cleaning of surfaces tested in accordance with
which are to be covered without M.S. 30 shall be not more
receiving a bituminous tack coat. than 30;
The work shall be carried out all
in accordance with this iv) the water absorption when
Specification and the lines, tested in accordance with
levels, grades, dimensions and M.S. 30 shall be not more
cross-sections shown on the than 2%;
Drawings and/or as required by
the S.O. v) the polished stone value when
tested in accordance with
4.2.4.2 Materials M.S. 30 shall be not less than
40 (only applicable to
(a) Aggregates aggregates for wearing
course).
Aggregate for asphaltic
concrete shall be a mixture of Fine aggregates shall be clean
coarse and fine aggregates natural sands, screened quarry
and, if necessary, mineral fines, or mining sand. Mining
filler. The individual aggregates sand shall be thoroughly washed
shall be of sizes suitable for before use. Other types of fine
blending to produce the required aggregate may be used subject to
gradation of the combined the approval of the S.O.
aggregate, all to the satisfaction
of the S.O. Fine aggregates shall be non-
plastic and free from clay, loam,
Coarse aggregates shall be aggregations of material,
screened crushed hard rock, vegetative and other organic
angular in shape and free from matter, and other deleterious
dust, clay, vegetative and other substances.

They shall conform to the Notwithstanding compliance with

following physical and the requirements of this
mechanical quality requirements:- Specification, limestone
aggregates shall not be permitted
i) the weighted average loss of for use in wearing course.
weight in the sodium sulphate
soundness test (5 cycles) The gradation of the combined
when tested in accordance coarse and fine aggregates,
with AASHTO Test Method T together with ordinary Portland
104 shall be not more than cement added as an adhesion and
12%; anti-stripping agent and, if
necessary, any other mineral
ii) the water absorption when filler, shall conform to the
tested in accordance with appropriate envelope shown in
M.S. 30 shall be not more Table 4.8
than 2%.
TABLE 4.8 - GRADATION LIMITS FOR ASPHALTIC CONCRETE
Mix Type Wearing Course Binder Course

Mix ACW 20 ACB 28
Designation
B.S. Sieve % Passing by weight
37.5 mm 100
28.0 mm 100 80 - 100
20.0 mm 76 - 100 72 - 93
14.0 mm 64 - 89 58 - 82
10.0 mm 56 - 81 50 - 75
5.0 mm 46 - 71 36 - 58
3.35 mm 32 - 58 30 - 52
1.18 mm 20 - 42 18 - 38
425 um 12 - 28 11 - 25
150 um 6 - 16 5 - 14
75 um 4-8 3-8

The gradation envelopes in the adhesion and anti-stripping agent. The

above Table are purposely wider amount of cement added for this
than the tolerances for good purpose shall be 2% by weight of the
works control of asphaltic combined aggregate. (Additional
concrete mixes. For each type of cement may also be added, if necessary,
mix required in the Works, the to serve as filler.)
Contractor shall establish a job
mix formula gradation which Ordinary Portland cement for this
shall consist of a single definite purpose shall conform to the
percentage passing for each sieve requirements of M.S. 522 and shall be
size in the above Table and shall dry, free flowing and free from
produce a smooth curve within agglomerations at the time of use.
and essentially parallel to the
appropriate gradation envelope. Notwithstanding the use of ordinary
This job mix formula gradation, Portland cement as an anti-stripping
with the allowable tolerances for agent as specified above, the Contractor
a single test as specified in Sub- shall be responsible for ensuring that the
Section 4.2.4.3 (c), then becomes bitumen binder adheres satisfactorily to
the job control envelope and this the aggregate and does not strip from it
job control envelope must be during the service life of the asphaltic
totally within the limits of the concrete.
appropriate gradation envelope in
the above Table. Accordingly, the Contractor shall
carry out bitumen stripping tests with
(b) Mineral Filler the proposed aggregates to demonstrate
to the complete satisfaction of the S.O.
Mineral filler shall be finely that the aggregates will perform
divided mineral matter such as satisfactorily in service with the
rock dust, limestone dust, hydrated specified bitumen binder. Such tests
lime, hydraulic cement, or such other shall be carried out in accordance with
suitable material as the S.O. shall AASHTO Test Method T 182, or such
approve. At the time of mixing with other test methods as the S.O. shall
bitumen it shall be sufficiently dry to direct or approve. When AASHTO Test
flow freely and shall be essentially Method T 182 is used, the coated area at
free from agglomerations. Not less the end of the mixture's period of
than 70% by weight shall pass the immersion in water shall be not less
B.S. 75 um sieve. than 95%.
(c) Bituminous Material Where, in the opinion of the S.O.,

ordinary Portland cement does not per
Bituminous binder for asphaltic form satisfactorily as an anti-stripping
concrete shall be penetration graded agent, the Contractor may propose to
bitumen of 80-100 grade conforming use another adhesion and anti-stripping
to M.S. 124. agent in addition to, or wholly or
partially instead of, the ordinary
(d) Anti-Stripping Agent Portland cement specified above. Such
agent shall be of a type approved
Ordinary Portland cement shall be by the S.O. and shall be thoroughly
added to the combined aggregate for mixed with the bituminous binder,
asphaltic concrete to serve as an

all in accordance with the A sample of each trial mix (i.e. each
manufacturer's instructions. In such a combination of trial gradation and
case, the agent shall be added to the bitumen content) shall be subject to a
bitumen binder used in the bitumen comprehensive Marshall method test
stripping tests in the appropriate amount and analysis as follows :-
and manner.
i) preparation of specimens for the
Aggregate which does not perform standard stability and flow test in
satisfactorily in the bitumen stripping accordance with AASHTO Test
tests, using the approved adhesion and Method T 245 using the 75
anti-stripping agent when appropriate, blows/face compaction standard;
shall not be used in asphaltic concrete.
ii) determination of the bulk
4.2.4.3 Asphaltic Concrete Mix Design specific gravity of the specimens
in accordance with AASHTO
(a) Job Mix Formulae Test Method T 166;
After obtaining supplies or iii) determination of the stability and

production (as applicable) of all flow values in accordance with
aggregates consistent as to gradation AASHTO Test Method T 245;
and other qualities, the Contractor
shall propose a job mix formula for iv) analysis of the density and
each class of mix required in the voids parameters to determine
Works. In order to attain optimum the percentage of voids in the
quality of the mixtures, the job mix compacted aggregate, the
formula for each class shall be percentage of voids in the
prepared on the basis of testing compacted aggregate filled with
several trial gradations within the bitumen, and hence the
limits set in Table 4.8 at an percentage of air voids in the
appropriate range of bitumen compacted mix.
contents. As a guide to the testing
range of bitumen contents, the design For each trial mix conforming to a
bitumen content will usually be in proposed job mix formula, the
the appropriate range given in Table parameters of the above tests and
4.9. analyses shall conform to the
requirements of the appropriate type
of mix as given in Table 4.10.
TABLE 4.9 - DESIGN BITUMEN
CONTENTS
ACW14 - Wearing Course 5.0 – 7.0 %

ACW14 - Binder Course 4.5 - 6.5 %
ACB 28 - Binder Course 4.0 - 6.0%

TABLE 4.10 - TEST AND ANALYSIS PARAMETERS

FOR ASPHALTIC CONCRETE
Parameter Wearing Course Binder Course
Stability S > 500 kg > 450kg
Flow F > 2.0 mm > 2.0mm
Stiffness S/F > 250 kg/mm > 225 kg/mm
Air voids in mix 3.0% - 5.0% 3.0% - 7.0%
Voids in aggregate
filled with bitumen 75% - 85% 65% - 80%
Air voids shall be defined as the The Marshall density of an asphaltic

small pockets of air between the concrete mix is defined as the
coated aggregate particles in a average density of a set of three (3)
compacted asphaltic concrete mix. test specimens moulded for the
The portion of the bitumen absorbed standard stability and flow test in
into the aggregate particles must accordance with AASHTO Test
therefore be allowed for when Method T 245 using the 75 blows
calculating the air voids. For per face compaction standard.
combined aggregate with a water
absorption of not more than 2.0%, The Contractor shall submit to the
the absorbed bitumen may be S.O. full details of his proposed job
estimated on the basis that the mix formula for each class of mix
absorption of bitumen will be required in the Works including :-
approximately 20% of the water
absorption. i) the gradation analysis of each
aggregate to be used in the mix;
Voids in the aggregate of a mix shall
be calculated on the basis of the ii) the proportions for cold batching
weighted average bulk specific the aggregates;
gravity on an oven dried basis of the
coarse and fine aggregate fractions iii) the mixing plant screen sizes, the
(separated by the ASTM # 10 sieve smallest of which shall generally
or B.S. 2.0 mm sieve) as determined be not more than 3.2 mm;
in accordance with AASHTO Test
Method T 84 and T 85 as applicable. iv) the gradation analysis of the
aggregate in each of the mixing
plants' hot bins and of the mineral
filler (including any ordinary
Portland cement added as
anti-stripping agent);

v) the job mix formula gradation of As directed by the S.O., comprehensive

the combined aggregate and sampling and testing of each class of
filler; mix shall be carried out to check for
satisfactory compliance with its job mix
vi) the proportions for combining the formula, and for a satisfactory degree of
hot bin aggregates and filler; compaction.
vii)the bitumen content (by weight of As a result of the plant trials, the S.O.
total mix); may require amendments to the job mix
formulae, further tests and analyses,
viii)the dry and wet mixing times if a and possibly additional plant trials
batch plant is to be used, or the before finally approving the mixes for
mixing time if a continuous mix full scale production and use in the
plant is to be used; Works.
ix) the full results of the (c) Compliance with the Job Mix Formulae
comprehensive Marshall method
tests and analyses as described The S.O.'s final approval of the job mix
above for each trial mix used in formulae shall bind the Contractor to
determining the job mix formula. furnish asphaltic concrete mixes
meeting the precise gradations and
The S.O. may require changes of any bitumen contents specified in these
of the factors in each proposed job formulae within the tolerances set
mix formula and further tests and forth in Table 4.11.
analyses in order to attain optimum
quality of the asphaltic concrete Modifications to a job mix formula may
mixes. only be made with the approval of the
S.O. Should the S.O. at any time have
(b) Plant Trials reason to believe that the materials and
methods of mixing and laying are
After having received the S.O.'s different from those approved, he shall
preliminary approval of his proposed so advise the Contractor, and may order
job mix formulae, the Contractor that asphaltic concrete works be
shall arrange to mix, lay and compact discontinued pending further trials and
asphaltic concrete conforming to the testing.
proposed formula for each class of mix
required in the Works. A minimum of
10 tonnes of each mix shall be placed
in trial areas to demonstrate to the
satisfaction of the S.O. that the mixing,
laying and compacting equipment
conforms to the requirements of this
Specification, and that the proposed
mixes are satisfactory. The trial areas
shall not be part of the Contract Works
but shall be provided by the Contractor
at his own expense. They shall be

TABLE 4.11 - TOLERANCES FOR ASPHALTIC CONCRETE MIXES
ParameterPermissible Variation % By Weight of Total

Mix
Bitumen. + 0.2%
Fractions of combined
aggregate passing 5.0 mm
and larger sieves. + 5.0%
aggregate passing 3.35 mm + 4.0%
and 1.18 mm sieves.
aggregate passing 425 um + 3.0%
and 150 um sieves.
Fraction of combined
aggregate passing 75 um + 2.0%
sieve.
4.2.4.4 Equipment
The Contractor shall provide all the blower as specified in Sub-Sections

plant and equipment necessary for 4.2.1.3 (a) and 4.2.1.3 (b) respectively.
executing the work in accordance
with this Specification and shall (b) Asphalt Mixing Plant
furnish the S.O. with such details of
particular items of equipment, e.g. The asphalt plant shall be either a
manufacturer, model type, capacity, batch plant or a drum mix plant or a
weight, operating features, etc., as continuous mix plant of recognized
the S.O. shall require. manufacture and shall be approved by
the S.O. It shall conform to the
(a) Road Cleaning Equipment requirements described hereunder.
Road cleaning equipment will be The mixing plant shall have a capacity
required where asphaltic concrete is suited to the Works and sufficient to
to be laid on a surface which is not enable the paver to operate more or less
to receive a tack coat. The continuously when paving at normal
equipment shall be the same as that speeds at the required thicknesses. The
required for preparing a surface for plant shall be so designed as to enable
a tack coat, and shall include a consistent production of asphaltic
power broom and compressed air

concrete mixes within the tolerances The plant shall be provided with
prescribed in this Specification, all to accurate mechanical means for
the satisfaction of the S.O. uniformly feeding the aggregates into
the dryer so that uniform production and
Scales for all weigh boxes or hoppers temperature of the heated aggregates
shall be of the springless dial type, will be obtained. A separate feed bin
accurate to within 0.5% of the with an adjustable gate opening shall be
maximum load that may be required. provided for each aggregate to be
Scale dials and pointers shall be easily included in the combined aggregate for
read from their operator's normal the mix; normally four bins will be
position without significant parallax required. The feed bins and gates shall
errors. Scales shall be substantially be so constructed and equipped that they
constructed so that they shall maintain shall be readily accessible for calibrating
their accuracy after initial adjustment. at all times, and shall provide for a
The Contractor shall furnish not less continuous and uniform flow of each
than ten 25 kg test weights at the plant aggregate required in the mix.
for checking, adjusting and calibrating
scales. The plant shall have a rotary drum dryer
of satisfactory design for drying and
Tanks for storage of bitumen shall have heating the combined aggregate so that
a capacity suited to the proposed rate of its temperature will be at the required
utilization of the material and the level at the time it is mixed with the
method and frequency of its delivery to bitumen. The burner shall be so
the Works, all to the satisfaction of the designed that complete combustion of
S.O. The tanks shall be provided with the fuel will be obtained, and the
means of measuring the volume of their aggregate will remain clean and not
contents at all times and of drawing off become coated with soot or oil.
samples of the contents. The bitumen
feeding system shall provide for The plant shall be equipped with four
continuous circulation of hot binder (or more) screens, the smallest of which
through the system and back into the shall generally be not more than 3.2
feed tank. The end of the return line mm. The screens shall have a normal
discharging into the feed tank shall capacity slightly in excess of the
always be kept submerged in the maximum output of the mixing plant.
bitumen in the tank in order to prevent The screens shall be readily accessible
oxidation of the returning hot binder. for inspection.
The storage tanks, and where necessary
barrel decanters, and all elements of the The plant shall include four (or more)
bitumen feeding system shall be storage bins for screened aggregates,
equipped with heating systems or each with a capacity of not less than
insulating jackets as necessary to twice the pugmill dead load capacity.
provide for effective and positive control The bins shall be arranged so as to
of the temperature of the bitumen at all provide separate dry storage for each
times up to the temperature required for screened fraction of the aggregate. Each
utilisation. . The method of heating bin shall be provided with an overflow
shall be such that neither flames nor the pipe of such size and location as to
products of combustion shall come into prevent any backing up of material into
direct contact contact with the bitumen other bins. Each bin shall be so
or the casing of its immediate container, constructed that representative aggregate
and such that no portion of the bitumen samples can be readily obtained, and
shall be subject to overheating.
shall have means for observing the the truck loading area, which shall be
aggregate level. Separate dry storage kept free from drippings from the mixer.
shall be provided for mineral filler, and
the plant shall be satisfactorily equipped Special Requirements for Batch Plants
to feed filler into the mixer.
Each storage bin for screened aggregate
Satisfactory means by either weighing shall be provided with a bottom outlet
or metering shall be provided to obtain gate so constructed as to prevent leakage
the prescribed amount of bitumen in the when closed. These gates shall have a
mix within the specified tolerance. quick and complete closing action.
Means shall be provided for checking
the quantity or flow rate of binder The plant shall be equipped with a
entering the mixer. Suitable means shall weigh box or hopper for accurately
be provided for maintaining the weighing out aggregate from each of the
prescribed temperature of the bitumen in screened aggregate storage bins. The
the pipelines, weigh bucket or flow weigh box or hopper shall be
meter, and spray bars. suspended from its scale's lever
mechanism and shall be sufficiently
An armoured thermometer with a large to hold a full batch equal to the
range of 30 oC to 200 oC shall be fitted pugmill capacity without hand raking or
in the bitumen feed line at a suitable spilling of the aggregate. The discharge
location near the discharge valve at the gate shall be so constructed as to allow
mixer unit. Suitable dial-scale mercury rapid and complete emptying of the
actuated thermometers, electric weigh box or hopper into the mixer, and
pyrometers or other thermometric prevent leakage when closed.
instruments shall be fitted at the
discharge chute of the dryer and in each The plant shall be equipped with a
hot aggregate storage bin to indicate the binder weigh bucket which shall be
temperatures of the heated aggregates. charged through a fast acting non-drip
valve in the binder feed pipe located
The plant shall be equipped with a dust directly over the bucket. The bucket
collector so constructed as to waste the shall be suspended from its scale's lever
material collected or feed it uniformly to mechanism and shall have a capacity
the heated aggregate. sufficient to weigh out binder up to 20%
of the weight of the pugmill dead load
The plant shall be equipped with capacity. The bucket shall have a
adequate and safe stairways to the discharge mechanism which shall
mixing platform and sampling locations, provide for rapid and complete
and guarded ladders and cat-walks shall emptying of the bucket in a thin uniform
provide access to all other positions as sheet or multiple sprays over the full
necessary for proper operation, length and width of the mixer. The
inspection and maintenance of the plant, dicharge mechanism shall not leak or
all to the satisfaction of the S.O. All drip when closed.
gears, pulleys, chains, sprockets and
other dangerous moving parts shall be The batch mixer shall be a suitable
properly guarded and protected. Ample twinshaft pugmill, with a capacity of at
and unobstructed space shall be least 500 kg of asphaltic concrete,
provided on the mixing platform, and capable of producing a thoroughly
clear and unobstructed passage shall be homogeneous mixture. The clearance of
maintained at all times in and around the paddle blades from all fixed and

moving parts of the mixer shall be not producing an accurate and continuous
more than 20 mm. If the pugmill is not blend of the individual aggregate sizes
enclosed it shall be equipped with a dust from the cold feed compartment.
hood to prevent loss of fines from the
mixture. The discharge gate shall be so The drum mixer shall be of an inclined,
constructed as to allow rapid and oil-fired and parallel flow type in which
complete emptying of the mixer, and the aggregates and exhaust gases flow in
prevent leakage of any mix constituent the same direction. The drum mixer
when closed. length to diameter ratio shall be such as
to ensure efficient drying and intimate
The mixer shall be equipped with an mixing of aggregate, filler and binder
accurate time lock system for over the full range of rated operating
controlling the operations of a complete efficiencies. A bypass chute shall be
mixing cycle. It shall lock the aggregate incorporated for sampling of cold
weigh box or hopper gate after charging aggregate.
the mixer with aggregate, until the
closing of the mixer gate at the Freshly mixed material shall be
completion of the mixing cycle; it shall delivered and stored in a surge silo
lock the binder weigh bucket discharge through a proper conveyor system.
mechanism during the dry mixing and
wet mixing periods. (The dry mixing Special Requirements for Continuous
period is defined as the interval of time Mix Plants
between the opening of the aggregate
weigh box or hopper gate and the start Each storage bin for screened aggregate
of discharging the binder weigh bucket. shall be provided with an accurately
The wet mixing period is defined as the controlled variable orifice gate
interval of time between the start of discharging on to an aggregate feed
discharging the binder weigh bucket and mechanism. The discharge orifice shall
the opening of the mixer gate.) The dry be rectangular with one dimension
and wet mixing periods shall both be variable by means of an adjustable and
adjustable in increments of not more lockable gate, which shall have an
than 5 seconds from zero to not less than indicator showing the distance it is open.
120 seconds total for dry and wet These gates shall be used for accurately
mixing. proportioning the screened aggregates
for the mix.
Special Requirements for Drum Mix
Plants The plant shall have means of
calibrating the aggregate bin discharge
The cold material feeder unit shall gate openings by weighing test samples
consist of not less than 5 compartments obtained by diverting the aggregate fed
with suitable heaped capacity out of each bin into a suitable test box.
appropriate for the plant. Each bin shall Test boxes shall have a capacity of not
be provided with a control gate and less than 100 kg each.
measuring feeder suitable for accurate
blending of the aggregates on to the cold The plant shall have satisfactory means
feed collecting conveyor. The cold feed of effecting positive interlocking control
system shall incorporate a device for between the flow of screened aggregates
moisture compensation capable of from the storage bins and the flow of
binder from the meter or other
proportioning device. This control shall

be accomplished by interlocking (c) Tip-Trucks

mechanical means or another positive
method satisfactory to the S.O. The Contractor shall provide a suitable
number of tip-trucks of a type approved
The continuous mixer shall be a suitable by the S.O. for transporting asphaltic
twin-shaft pugmill with an adjustable concrete from the mixing plant to the
dam and paddles with reversible blade paving works. The trucks shall have
pitch for adjusting the volume of trays with smooth, flat beds and sides,
mixture held in the pugmill. The and shall have load capacities of not less
clearance of the paddle blades from all than 5 tonnes. Prior to loading, the
fixed parts of the mixer shall be not inside of each truck tray shall be lightly
more than 20 mm. The binder shall be and evenly coated with a soap or
fed into the mixer through a spray bar detergent solution, or such other liquid
directed on to the aggregate across the as the S.O. shall approve, to prevent
full width of the pugmill at the feed end. adhesion of the asphaltic concrete. The
The discharging mixture shall pass over trucks shall be equipped with covers of
the dam into a hopper with a discharge canvas or other suitable material to
gate so constructed as to allow rapid and protect the asphaltic concrete.
complete emptying of the hopper, and
prevent leakage of the mix when closed. (d) Asphalt Paver
The mixer shall be equipped with a
permanent gauge for measuring the The asphalt paver shall be of recognized
depth of mixture in the pugmill and a manufacture and shall be approved by
manufacturer's calibration plate showing the S.O. It shall conform to the
the volume of mixture in the pugmill at requirements described hereunder.
each increment of depth.
The paver shall be self-propelled and
The mixing time shall be determined capable of reverse as well as forward
using the formula :- travel. It shall be equipped with a
hopper at the front designed to receive
Mixing time (seconds) = the paving mixture from tip-trucks, and
Dead weight of mix in pugmill (kg) shall have a mechanical distribution
Pugmill output (kg per second) system for spreading the mixture evenly
and without segregation over the surface
and for a given output it may be varied to be paved in front of a screeding and
slightly by adjusting the depth (and compacting unit which shall be
hence weight) of the mixture held in the equipped with a suitable heating device.
pugmill by varying the dam height, the The screeding and compacting
configuration of the paddle blades, or mechanism shall be capable of
both. However for substantial confining the edges of the material
adjustments of the mixing time, in order being laid without the use of stationary
to maintain the depth at a level side forms, shall be adjustable to strike
compatible with efficient mixing, i.e. so off the mixture to the thickness and
that the paddle tips just break out of the cross-section shape required, and shall
mixture at the height of their action, the be controlled by an automatic levelling
rate of feed of materials to the mixer device to produce an even carpet of
(and hence output) should be changed. bituminous mixture with a uniform sur
face texture free from indentations,
ridges, tear marks or other irregularities.

The paver shall be capable of laying the 4.2.4.5 Construction Methods

bituminous mixture in paving widths in
the range 2.5 to 3.75 m and of finishing (a) General Conditions
the pavement layer true to the required
lines, grades, levels, dimensions and Asphaltic concrete paving work
cross-sections, subject to compaction by shall only be carried out in dry
rolling, all to the satisfaction of the S.O. weather when the surface to be
covered is dry, or if so specified,
has received a bituminous tack
(e) Rollers coat which shall have achieved a
satisfactory degree of tackiness,
A pneumatic tyred roller and two steel all to the satisfaction of the S.O.
wheeled tandem rollers shall be All laying, rolling and finishing
provided. However, a three wheeled work shall be carried out during
steel roller may be substituted for one of daylight hours, unless the Contractor
the tandem rollers if the S.O. shall so shall have provided suitable flood-
approve. All rollers shall be of lighting for the job site, to the
recognized manufacture and shall be satisfaction of the S.O.
The S.O. may order the
The pneumatic tyred roller shall be as discontinuation of work on account
specified in Sub-Section 4.2.3.3 (g). of adverse weather, unsatisfactory
Steel wheeled rollers shall conform to condition of materials, equipment or
the requirements described hereunder. surface to be paved, or such other
conditions as he shall consider detri
Steel wheeled rollers shall be self- mental to the work.
propelled and capable of being reversed
without backlash; they shall be equipped (b) Surface Preparation and Cleaning
with power steering and dual controls
allowing operation from either the left or Prior to constructing an asphaltic
right side. They shall be equipped with concrete pavement layer, the surface
water tanks, sprinkler systems and to be covered shall have been
scraper blades to keep all wheels evenly prepared in accordance with the
wetted and clean during operation. appropriate Sections of this
Specification. Notwithstanding any
Each steel wheeled roller shall be earlier approval of this surface, any
ballasted so that its total operating damage to or deterioration of it shall
weight is in the range 8 to 10 tonnes and be made good before asphaltic
its driven roll (or rolls) shall exert a concrete paving work is commenced.
rolling force of not less than 3.5
tonnes/metre of roll width. The If the surface to be covered is not to
Contractor shall provide the S.O. with a be provided with a bituminous tack
calibration chart for each roller showing coat, then immediately prior to
the relationships between the quantity or commencing asphaltic concrete
depth of ballast and total weight and paving, it shall be swept using a
rolling force. power broom followed by a
compressed air blower and, if
necessary, scraped using hand tools
to remove all loose particles, dirt,
dust and other objectionable

material, all to the satisfaction of the Ordinary Portland cement and/or

S.O. other mineral filler to be used in the
mix shall be stored separately and
If the surface to be covered is to be kept completely dry. Its rate of feed
provided with a bituminous tack coat, into the plant shall be accurately
then this shall be applied all in controlled by weight or volumetric
accordance with the provisions of Sub- measurement, all to the satisfaction
Section 4.2.2. of the S.O.
(c) Aggregate Handling and Heating (d) Heating of Bitumen
Each aggregate to be used in the The binder shall be heated so that

asphaltic concrete mixes shall be stored when delivered to the mixer it shall
in a separate stockpile near the mixing be at a temperature in the range
plant. Stockpiles of sand and other fine 140ºC to 160ºC.
aggregates shall be kept dry using
waterproof covers and other means as (e) Mixing Asphaltic Concrete
necessary. In placing the aggregates in
the stockpiles and loading them into the The mixing plant shall be so
mixing plant's cold aggregate feed bins, coordinated and operated as to
care shall be taken to prevent consistently produce asphaltic
segregation or uncontrolled combination concrete mixes within the tolerances
of materials of different gradation. prescribed in this Specification, all
Segregated or contaminated materials to the satisfaction of the S.O.
shall be rescreened or rejected for use in
the Works and removed from the mixing
plant site. Mixing in Batch Plants
The aggregates shall be fed into the For each batch the screened hot
dryer at a uniform rate proportioned in aggregates shall be weighed out into
accordance with the appropriate job mix the aggregate weigh hopper in
formula. The rate of feed for each accordance with the proportions
aggregate shall be maintained within prescribed in the appropriate job mix
10% of the rate prescribed, and the formula; the sequence of weighing
total rate of feed shall be such that out shall commence with the largest
the plant's screens shall never be sized aggregate and progress down
overloaded. to the fines, unless the S.O. shall
otherwise approve. Mineral filler
The aggregates shall be dried and heated shall be weighed out into the filler
so that when delivered to the mixer they weigh hopper, where this is
shall be at a temperature in the range provided, or added last to the
150ºC to 170ºC. aggregate weigh hopper, in
accordance with the job mix formula
Immediately after heating, the proportions.
aggregates shall be screened into four
(or more) fractions which shall be The hot binder shall be weighed out
separately stored in the hot aggregate into the binder weigh bucket in
storage bins in readiness for mixing. ccordance with the proportions
prescribed in the job mix formula.

The hot aggregates and filler shall be shall be as prescribed in the job mix
discharged into the pugmill and formula; this shall be sufficient so
mixed dry for the dry mixing time that all particles of aggregate are
prescribed in the job mix formula, uniformly coated with bitumen, and
which shall usually be in the range 5 shall usually be 45 seconds or more
to 10 seconds. The hot binder shall for dense graded mixtures.
then be added and wet mixing per
formed for the wet mixing time The plant shall be so adjusted as to
prescribed in the job mix formula; maintain the level of mixture in the
this shall be sufficient so that all pugmill such that the tips of the
particles of aggregate are uniformly paddle blades just break out of the
coated with bitumen, and shall mixture at the height of their action.
usually be 45 seconds or more for
dense graded mixtures. (f) Transportation of Asphaltic
Concrete
The volume of each batch shall be
such that the tips of the pugmill Asphaltic concrete shall be
paddle blades just break out of the transported from the mixing plant to
mixture at the height of their action. the site of the paving works in loads
of not less than 5 tonnes using
After the completion of wet mixing, tip-trucks as specified in
each batch of asphaltic concrete shall
be discharged from the pugmill Sub-Section 4.2.4.4 (c). Except
either into a storage hopper or where asphaltic concrete is to be
directly into a truck for hauling to hand laid, it shall be discharged
the paving site. Care shall be taken directly into the paver hopper, as
that no segregation of the mix required, from the tip-trucks. Care
occurs. shall be taken in the truck loading,
hauling and unloading operations to
Mixing in Continuous Mix Plants prevent segregation of the mix.
During transportation, the asphaltic
The screened hot aggregates and concrete shall be protected from
filler shall be fed continuously from contamination by water, dust, dirt
their storage bins in accordance with and other deleterious materials.
the proportions prescribed in the
appropriate job mix formula, The temperature of asphaltic
combined in the plant, and fed concrete immediately before
continuously into the mixer. The hot unloading from the truck either into
binder shall be sprayed on to the the paver hopper or on to the road
combined aggregate as it enters the for hand spreading shall be not less
pugmill at the rate required to than 125ºC. Any load which has
achieve the bitumen content pre cooled below the specified
scribed in the job mix formula. The temperature in the truck shall be
materials shall then be carried rejected for use in the Works and
through the pugmill and in the removed from the Site of the Works.
process be thoroughly mixed by
the action of the paddles and dis (g) Laying Asphaltic Concrete
charged over the dam into the stor
age hopper. The mixing time (as The sequence of laying operations
defined in Sub-Section 4.2.4.4 (b) shall be planned in advance by the
Contractor and approved by the S.O.
Generally each paving layer shall and before laying restarts after each
have a compacted thickness of not interruption of the paving operation.
less than twice the nominal
maximum aggregate size of the As far as is practicable, the paver
mixture, and not more than 100 mm. shall be operated continuously and
Where applicable, e.g. on the supply of bituminous mix shall
superelevated sections and on be regulated so as to enable
carriageways with cross-slope in one continuous paving. Transverse joints
direction only, laying shall in a paving lane shall be kept to a
commence along the lower side of practicable minimum, and
the carriageway and progress to the intermittent stopping and restarting
higher side. Laying shall not be of the paver shall be avoided as far
carried out in a downhill direction as is practicable.
along any section of road.
Care shall be taken that no
As far as is practicable, laying shall bituminous mix is placed on
be carried out using a paver expansion joints at bridges,
approved by the S.O. Hand-casting inspection covers for utilities ducts,
of bituminous mix on to the machine drainage and sewerage manholes and
finished surface shall be kept to the the like, and that catchpits, drainage
practicable minimum necessary for openings through kerbs, etc., remain
correcting blemishes and properly open and serviceable.
irregularities. In any areas During laying operations, such areas
inaccessible to the paver, laying shall and openings shall be protected by
be carried out by hand methods suitably shaped and secured boards
using rakes, lutes and other hand or other materials approved by the
tools, all to the satisfaction of the S.O., and compaction of mix in the
S.O. All laying of bituminous mix immediately surrounding or adjacent
shall be such that after compaction areas shall be completed by hand
by rolling the specified course or methods, all to the satisfaction of
layer thickness and surface profile the S.O. Alternatively, bituminous
shall be achieved. Care shall be mix shall be laid and compacted by
taken to achieve a uniform surface hand methods as necessary around
texture free from indentations, surfacing discontinuities of these
ridges, tear marks or other types, all to the satisfaction of the
irregularities, and to prevent S.O.
segregation of the mix.
(h) Construction Joints
At the commencement of initial
rolling the temperature of asphaltic Existing bituminous surfacing which
concrete shall be not less than new bituminous mix is to adjoin
110ºC. Material which has cooled shall be cut back to present a
below the specified temperature straight, vertical edge not less than
before laying shall not be used and 25 mm deep and a smooth transition
shall be removed from the Site of the section not less than 0.5 metre long
Works. The Contractor shall provide against which to lay the new
accurate thermometers at the paving material. The specified thickness of
site at all times, and shall check the the new surfacing shall be built up
temperature of asphaltic concrete in gradually from the vertical joint to
the paver hopper at regular intervals avoid any bumps or ridges across the
carriageway.
Where longitudinal or transverse Initial (or breakdown) rolling shall

joints are required in a layer of be carried out with an approved steel
bituminous mix under construction, wheeled tandem roller or three
the material first laid and compacted wheeled steel roller. The principal
shall be cut back to a vertical face for heavy rolling shall be carried out
the full thickness of the layer on a with an approved pneumatic tyred
line satisfactory to the S.O. before roller immediately following the
the adjacent area is paved. initial rolling; the pneumatic tyred
roller shall be ballasted to an
At all construction joints, a thin operating weight of not less than 15
uniform coating of bitumen emulsion tonnes and its tyre inflation pressure
of grade RS-1 or RS-1K shall be shall be not less than 0.7 N/sq.mm.
brushed on to the vertically cut joint The final rolling shall be carried out
faces some 10 to 15 minutes before with an approved steel wheeled
laying the next section of bituminous tandem roller and shall serve to
mix commences to ensure good eliminate minor surface irregularities
bonding. Also, all contact surfaces left by the pneumatic tyred roller.
of kerbs, gutters, manholes,
catchpits, etc., shall be similarly All rollers shall operate in a
treated with a coating of bitumen longitudinal direction along the
emulsion before bituminous mix is carriageway with their driven wheels
placed against them. towards the paver. Rolling shall
generally commence at the lower
Construction joints in a layer of edge of the paved width and progress
bituminous mix shall be offset from uniformly to the higher edge, except
those in any immediately underlying that where there is a longitudinal
bituminous layer by at least 100 mm construction joint at the higher edge,
for longitudinal joints and at least 0.5 this shall be rolled first ahead of the
metre, where possible, for transverse normal pattern of rolling. Generally,
joints. successive roller passes shall overlap
by half the width of the roller, and
(i) Compaction of Asphaltic the points at which the roller is
Concrete reversed shall be staggered.
However, when operating on
For each layer of asphaltic concrete, gradients in excess of 4%, the
compaction by rolling shall breakdown roller shall not pass over
commence as soon after laying as the any previously unrolled mix when
material will support the rollers operating in the downhill direction.
without undue displacement;
nevertheless the temperature of In all cases, compaction shall be
asphaltic concrete at the carried out in such a manner that
commencement of rolling shall be each section receives equal
not less than 110ºC. compactive effort, all to the
In any areas inaccessible to the
rollers, proper compaction shall be The steel wheeled rollers shall
carried out using vibrating plate operate at speeds of not more than 5
compactors, hand tampers or other km/hr and the pneumatic tyred
suitable means, all to the satisfaction rollers shall operate at speeds of
of the S.O. not more than 8 km/hr. No roller or

heavy vehicle shall be allowed to the average thickness over any 100
stand on newly laid bituminous mix metre length shall be not less than
before compaction has been the required thickness, and the
completed and the material has minimum thickness at any point
thoroughly cooled and set. Rolling shall be not less than the required
shall continue as long as is necessary thickness minus 5 mm.
to achieve the appropriate
requirement as follows :- The top surface of a wearing or
binder course shall have the required
Type of Pavement Required Compacted
shape, superelevation, levels and
Layer Density
grades, and shall be everywhere
Wearing course 98 - 100% Marshall within the tolerances specified in
density Sub-Section 4.4.
Binder course 95 - 100% Marshall
density (k) Opening to Traffic
Asphaltic concrete shall not be

Care shall be taken to prevent over- opened to traffic until compaction
compaction of asphaltic concrete. has been completed and the material
has thoroughly cooled and set in the
Within 24 hours of laying and opinion of the S.O. This will usually
compacting the bituminous mix, the be not less than 4 hours after the
Contractor shall cut core samples of commencement of rolling. Where it
not less than 100 mm nominal is necessary to allow earlier use of
diameter at locations selected by the the finished surface to facilitate the
S.O. The rate of sampling shall be 1 movement of traffic, vehicles may
sample per 500 sq.m of mix laid, but be allowed to run on the work after
not less than 2 samples for the work rolling has been completed,
completed in each paving session. provided that speeds are restricted
These core samples shall be used by to 30 km/hr or less and sharp turning
the S.O. to determine the thickness movements are prohibited.
of the compacted layer of mix and
the compacted density of the
material in accordance with either
ASTM Test Method D 1188 or
ASTM Test Method D 2726,
whichever is applicable.
(j) Finished Asphaltic Concrete
Asphaltic concrete binder and

wearing courses shall be finished in a
neat and workmanlike manner; their
widths shall be everywhere at least
those specified or shown on the
Drawings on both sides of the
centre-line; ;

4.2.5 Bituminous Macadam 4.2.5.3 Equipment
4.2.5.1 Description The equipment shall be all as

specified in Sub-Section 4.2.4.4.
This work shall consist of furnishing,
placing, shaping and compacting 4.2.5.4 Construction Methods
bituminous macadam roadbase
and/or levelling course and/or binder All the provisions of Sub-Section
course and/or wearing course on a 4.2.4.5 for the construction of
prepared and accepted bituminous or asphaltic concrete pavement courses
bitumen primed pavement course, shall apply as appropriate to the
and shall include the careful and construction of bituminous macadam
thorough cleaning of surfaces which pavement courses with the
are to be covered without receiving a following variations and additions.
bituminous tack coat. The work shall
be carried out all in accordance with (a) Aggregate Heating
this Specification and the lines,
levels, grades, dimensions and cross- The aggregates shall be dried and
sections shown on the Drawings heated so that when delivered to the
and/or as required by the S.O. mixer they shall be at a temperature
in the range 140 oC to 160 oC.
4.2.5.2 Materials
(b) Rolling Temperature
The materials for bituminous
macadam (aggregates, mineral filler, The temperature of bituminous
bituminous binder and anti-stripping macadam at the commencement of
agent) shall comply with all the rolling shall be not less than 100 oC.
requirements of Sub-Section 4.2.4.2,
except for the combined gradation (c) Compacted Density
requirements.
The compacted density of
For each bituminous macadam mix, bituminous macadam shall be as
the gradation of the combined coarse follows :-
and fine aggregates, together with
ordinary Portland cement added as
an adhesion and anti-stripping agent Type of Pavement Required Compacted
Layer Density
and, if necessary, any other mineral
filler, shall conform to the Bound roadbase 90 - 100% Marshall
appropriate envelope given in Table density
4.12. The binder content shall also be Levelling course 90 - 100% Marshall
density
in accordance with Table 4.12.
Binder course 95 - 100% Marshall
Where the characteristics of the density
aggregates require a binder content Wearing course 98 - 100% Marshall
density
other than that given in the above
Table, the revised target binder
content shall be agreed between the
Contractor and the S.O. and the same
tolerances shall apply.

The Marshall density of a Bituminous macadam levelling

bituminous macadam mix is defined course shall be finished in a neat and
as the average density of a set of workmanlike manner; its dimensions
three test specimens moulded in the shall be as specified or shown on the
same way as asphaltic concrete Drawings or as directed by the S.O.,
specimens are prepared for the all to the satisfaction of the S.O. The
standard stability and flow test in top surface of bituminous macadam
accordance with AASHTO Test levelling course shall have the
Method T 245 using the 75 blows
per face compaction standard. The required shape,, superelevation,
bulk specific gravity of the levels and grades, and shall be every
specimens shall be determined in where within the tolerances for
accordance with AASHTO Test binder course specified in Sub-
Method T 166. Section 4.4.
The Marshall density of each mix Bituminous macadam binder and

shall be determined using a sample wearing courses shall be finished in a
(or samples) taken from the mixing neat and workmanlike manner; their
plant soon after the commencement widths shall be everywhere at least
of preparing each mix for the Works. those specified or shown on the
(Note : Stability and flow tests are Drawings on both sides of the
not normally required for bituminous centre-line; the average thickness
macadam mixes.) over any 100 metre length shall be
not less than the required thickness,
(d) Finished Bituminous Macadam and the minimum thickness at any
point shall be not less than the
Bituminous macadam roadbase shall required thickness minus 5 mm. The
be finished in a neat and top surface of a wearing or binder
workmanlike manner; its width shall course shall have the required shape,
be everywhere at least that specified superelevation, levels and grades,
or shown on the Drawings on both and shall be everywhere within the
sides of the centre-line; and its tolerances specified in Sub-Section
average thickness over any 100 4.4.
metre length shall be not less than
the required thickness. The top
surface of bituminous macadam
roadbase shall have the required
shape, superelevation, levels and
grades, and shall be everywhere
within the tolerances specified in
Sub-Section 4.4.2.

TABLE 4.12 - GRADATION LIMITS AND BINDER CONTENTS

FOR BITUMINOUS MACADAM
Mix Type Bound Bound Levelling Binder Binder Wearing Wearing

Roadbas Roadbase Course Course Course Course Coursex
e
Mix BMR40 BMR28 BML10 BMB28 BMB20 BMW14 BMW20
Designatio
n
B.S. Test % by Weight
Sieve Passing
50.0 mm 100 - - - - - -
37.5 mm 95 - 100 100 - 100 - - -
28.0 mm 70 - 94 90 - 100 - 90 - 100 100 - 100
20.0 mm - 71 - 95 - 71 - 95 95 - 100 100 95 - 100
14.0 mm 56 - 76 56 - 80 100 58 - 82 65 - 85 95 - 100 65 - 85
10.0 mm - - 85 - 100 - 52 - 72 70 - 90 52 - 72
6.3 mm 44 - 60 44 - 60 30 - 60 44 - 60 39 - 55 45 - 65 39 - 55
3.35 mm 32 - 46 31 - 45 15 - 25 32 - 46 32 - 46 30 - 45 32 - 46
1.18 mm - - - - - 15 - 30 -
300 mm 7 - 21 7 - 21 - 7 - 21 7 - 21 - 7 - 21
75 mm 2-9 2-8 2-6 2-8 2-8 3-7 2-8
Binder 3.5 " 4.0 " 5.1 " 4.7 " 4.7 " 5.0 " 4.9 "
Content
± ± ± ± ± ± ±
0.5% 0.5% 0.5% 0.6% 0.6% 0.5% 0.5%

4.3 SHOULDERS Sub-Section 4.1.2.3, and the abutting

carriageway structure course or
4.3.1 Description courses shall likewise have been
shaped and compacted in accordance
This work shall consist of furnishing, with the provisions of the
compacting and shaping earth or appropriate Sub-Section or Sub-
gravel shoulder material on a Sections of this Specification.
prepared and accepted subbase or Notwithstanding any earlier approval
lower subbase or subgrade, all in of the underlying and abutting
accordance with this Specification pavement courses, any damage to or
and the lines, levels, grades, deterioration of these underlying
dimensions and cross-sections shown and abutting pavement courses shall
on the Drawings and/or as required be made good to the satisfaction of
by the S.O. the S.O. before shoulder construction
proceeds.
For paved shoulders, the bituminous
surfacing and underlying pavement Shoulders shall be placed to the
courses shall be constructed as required width and thickness as
described in the appropriate Sections shown on the Drawings or directed
of this Specification. by the S.O. in one layer or more,
each layer not exceeding 200 mm
4.3.2 Materials compacted thickness at the point of
maximum thickness. Where two or
4.3.2.1 Earth Shoulders more layers are required they shall
be of approximately equal shape and
Earth shoulder material shall thickness, and none shall be less than
be suitable material as 100 mm compacted thickness at the
described in Sub-Section 2.2.1. point of maximum thickness.
4.3.2.2 Gravel Shoulders Each layer of shoulder material shall

be processed as necessary to bring its
Gravel shoulder material shall moisture content to a uniform level
conform to the requirements for throughout the material suitable for
gravel surfacing material set forth compaction, and shall then be
in Sub-Section 4.1.3.2. compacted using suitable
compaction equipment approved by
4.3.3 Construction Methods the S.O. to not less than 95% of the
maximum dry density determined in
Shoulders shall be constructed in the B.S. 1377 Compaction Test (4.5
stages or in one operation as directed kg rammer method). Compaction
or approved by the S.O., but in no shall be carried out in a longitudinal
instance shall a shoulder be built up direction along the shoulder and
to a level higher than that part of the shall generally begin at the outer
abutting carriageway structure which edge and progress uniformly towards
has been completed and accepted. the carriageway, except on
superelevated curves where rolling
Prior to placing any shoulder shall begin at lower edge and
material, the underlying subbase or progress uniformly towards the
lower subbase or subgrade shall have higher edge.
been shaped and compacted in
accordance with the provisions of
In all cases, compaction shall be be correct within a tolerance of + 50

carried out in such a manner that mm and minus 0 mm from the
each section receives compactive centre-line, except for kerbs, channel
effort appropriate to its thickness, all blocks and edge lines which shall be
to the satisfaction of the S.O. laid with a smooth alignment within
a tolerance of + 25 mm and minus
Throughout the placing, adjustment 0 mm from the centre-line.
of moisture content and compaction
of shoulder material, care shall be 4.4.2 Surface Levels of Pavement Courses
taken to maintain a uniform
gradation of the material and prevent The design levels of pavement
its seperation into coarse and courses shall be calculated from the
seperate parts, all to the satisfaction vertical profile, crossfall and
of the S.O. pavement course thicknesses shown
on the Drawings. The level of any
Where shown on the Drawings or point on the constructed surface of a
directed by the S.O., earth shoulders pavement course shall be the design
shall be turfed in accordance with level subject to the appropriate
Sub-Section 2.2.8.2. tolerances given in Table 4.13.
Shoulders shall be finished in a neat TABLE 4.13 - TOLERANCES IN SURFACE

and workmanlike manner. The total LEVELS OF PAVEMENT COURSES
width of carriageway and shoulder
shall be everywhere at least that
specified or shown on the Drawings Pavement Course Tolerance
on both sides of the centre-line. The
top surface of each shoulder shall + 5 mm
Wearing Course
have the required shape,
superelevation, levels and grades,
Binder Course + 5 mm
shall be everywhere within 10 mm
of the required plane, and shall
provide a flush joint with the Roadbase + 0 mm
carriageway surface and shall be - 20 mm
uniformly free draining away from
the carriageway, all to the Subbase and Lower + 10 mm
satisfaction of the S.O. Subbase - 20 mm
4.4 HORIZONTAL ALIGNMENT,

SURFACE LEVELS AND The combination of permitted
SURFACE REGULARITY OF tolerances in the levels of different
PAVEMENT COURSES pavement courses shall not result in a
pavement thickness less than that
4.4.1 Horizontal Alignment shown on the Drawings. Each
pavement course shall have an
The horizontal alignment shall be average thickness not less than that
determined from the centre-line of shown on the Drawings.
the pavement surface shown on the
Drawings. The edges of the
pavement as constructed and all
other parallel construction lines shall

4.4.3 Surface Regularity The traverse length of 300 m and its

associated maximum permissible
The regularity of surfaces shall be number of irregularities shall apply
within the relevant limits given in wherever the continuous length of
Table 4.14. the completed carriageway is 300 m
or more, whether or not it is
A longitudinal irregularity is a constructed in shorter lengths.
variation in profile of the road
surface as measured by the rolling Where the total length of pavement
straight-edge or wedge and is less than 300 m the measurements
straight-edge device. The shall be taken on 75 m lengths.
permissible number of such
longitudinal irregularities is indicated The transverse regularity of a newly
in Table 4.14. laid surface shall be measured with a
3 m straight-edge and shall have no
greater depression under the
straight-edge than that shown in
Table 4.14
TABLE 4.14 - TOLERANCES FOR SURFACE IRREGULARITIES
Longitudinal Direction Transverse

Direction
Maximum Permissible Number Maximum

Class of of Surface Irregularities Permissible
Surface Depth of
Regularity Transverse
Depth Exceeding 4 Depth Exceeding 7 mm Irregularities
mm
over over over over
traverse traverse traverse traverse
length length length length
of 300 m of 75 m of 30 m of 75 m
Class SR1 20 9 2 1 4 mm
Class SR2 40 18 4 2 8 mm
Class SR3 60 27 4 3 12 mm
No longitudinal irregularity exceeding 10 mm shall be permitted for Class SR1

Surface Regularity and no longitudinal irregularity exceeding 15 mm shall be
permitted for Class SR2 and Class SR3 Surface Regularities.
The class of Surface Regularity for each portion of the Works shall be as stated on
the Drawings or in the Bills of Quantities.

SECTION 5
PORTLAND CEMENT
CONCRETE PAVEMENT

SECTION 5 - PORTLAND CEMENT CONCRETE PAVEMENT
Page
5.1 DESCRIPTION S5-125
5.2 MATERIALS S5-125
5.2.1 Cement S5-125
5.2 2 Aggregate S5-125
5.2.3 Joint Filler S5-125
5.2.4 Joint Sealants and Seals S5-125
5.2.5 Waterproof Membrane S5-126
5.2.6 Curing Materials S5-126
5.3 PRODUCTION OF CONCRETE S5-128
5.3.1 Concrete S5-128
5.3.2 Equipment S5-128
5.4 CONSTRUCTION S5-128
5.4.1 Preparation of Subgrade or Subbase S5-128
5.4.2 Construction by Machine S5-128

5.4.2.1 Fixed Forms, Rails and Guide Wires For Machine Construction S5-128
5.4.2.2 Construction by Fixed Form Paving Machine S5-129
5.4.2.3 Construction by Slip Form Paving Machine S5-131
5.4.3 Construction by Hand-Guided Method S5-132
5.4.4 Manual Construction S5-132

5.4.4.1 Side Forms for Manual Construction S5-133

Page
5.5 JOINTS S5-133
5.5.1 Transverse Expansion Joints S5-133
5.5.2 Transverse Contraction Joints S5-134

5.5.2.1 Planes of Weakness S5-134
5.5.2.2 Load Transfer Assemblies S5-135
5.5.3 Longitudinal Joints S5-135
5.5.4 Transverse Construction Joints S5-135
5.5.5 Sealing Joints S5-135
5.5.6 Concrete Saw S5-136
5.6 SURFACE TEXTURE S5-136
5.6.1 Texture of Running Surfaces S5-136
5.6.2 Measurement of Texture Depth : Sand Patch Method S5-137

5.6.2.1 Apparatus S5-137
5.6.2.2 Method S5-137
5.7 ROUNDING OF EDGES S5-137
5.8 CURING S5-137
5.9 REMOVING FORMS S5-138
5.10 OPENING TO TRAFFIC S5-139
5.11 TREATMENT OF MANHOLES AND GULLIES S5-139
5.12 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND

SURFACE REGULARITY S5-139

SECTION 5 - PORTLAND CEMENT 5.2.4 Joint Sealants and Seals

CONCRETE PAVEMENT
Joint sealants shall consist of hot or
cold-poured compounds or pre
5.1 DESCRIPTION formed seals as indicated on the
Drawings and shall comply with the
This work shall consist of constructing a following requirements :-
Portland cement concrete pavement with
or without reinforcement in accordance (a) Hot-Poured Sealants
with this Specification, including all
relevant requirements of Section 9, Hot-poured sealants shall comply
and in conformity with the lines, with the requirements of B.S. 2499
levels, grades, dimensions and for Type A2 sealants.
crosssections shown on the Drawings.
Portland cement concrete shall consist
of a mixture of Portland cement, fine
aggregate, coarse aggregate and water, (b) Cold-Poured Sealants
with or without admixture.
Cold-poured sealants shall comply
with the performance requirements
5.2 MATERIALS for the Normal type of sealant given
in B.S. 5212.
All materials shall conform to the
relevant requirements in Section 9 of The sealant shall be composed of a
this Specification. In addition the curing agent and a base resin, which
following requirements shall also be shall be in such proportions as
complied with. recommended by the manufacturer
to provide a fast cure if the material
5.2.1 Cement is mixed and applied by special
machines, or a retarded cure if mixed
Cement shall be ordinary Portland by hand. It shall cure within 1 hour
cement unless otherwise shown on and remain active for not less than 4
the Drawings or directed by the S.O. hours. The sealant shall be applied
after the curing period of the primer
5.2 2 Aggregate and within the period that the primer
remains active.
Coarse aggregate to be used for at
least the top 50 mm of the slab shall Materials to be mixed and applied by
have a polished stone value of not hand shall be supplied in separate
less than 40. containers and shall be mixed in the
correct proportions using a powered
5.2.3 Joint Filler stirrer or mixer or any other method
The expansion joint filler shall
AASHTO M153 or M213.

(c) Gunning Grade Sealants It shall have test certificates from an

approved testing laboratory to show
Gunning grade sealants consisting of that the compound has a curing
two-part poly-sulphide-based sealing efficiency of 90%.
compounds shall comply with B.S.
4254. Alternatively, poly-urethane- The curing compound shall contain
based sealing compounds may be sufficient flaked aluminium in finely
used provided their performance is divided dispersion to produce
not inferior to B.S. 4254 material. complete coverage of the sprayed
surface with a metallic finish. The
(d) Preformed Compression Seals curing compound shall not react
chemically with the concrete to be
Preformed compression seals shall cured and shall not crack, peel or
be made from natural rubber and disintegrate within 2 weeks after
shall conform to the requirements application.
contained in Table 5.1.
5.2.5 Waterproof Membrane
Plastic sheeting shall have a

minimum thickness of 125 um and
shall be of a quality as approved by
the S.O.
5.2.6 Curing Materials
The exposed surface of concrete

pavements shall be cured
immediately after the surface
treatment by the application of one
of the following curing materials :-
(a) White Pigmented Liquid

Membrane-Forming Compound
White pigmented liquid membrane-

forming compound shall conform to
the requirements of AASHTO
M148, Type 2.
(b) Aluminised Curing Compound
Aluminised curing compound

shall be stable and impervious to
evaporation of water from the
concrete surface within 60
minutes after application.

TABLE 5.1 - SPECIFICATION FOR PREFORMED NATURAL RUBBER COMPRESSION

SEALS
Property. Units Requirement
Hardness. IRHD 55 + 5
Tensile Strength, minimum. MPa 15
Elongation at break, minimum. % 400
Compression Set, 24 hours at

100 oC, maximum. % 40
Ageing Resistance, maximum

change from unaged values after
72 hrs + 0 hrs at 100 oC :-
- 2 hrs
- hardness IRHD 0 to + 10
- tensile strength % - 20
- elongation at break. % - 25
Ozone Resistance, 20%

elongation, 96 hours at - No cracking
140 oC, 50 pphm.
Change in Volume after

immersion in water for 7 days at % 0 to + 5
laboratory temperature,
maximum.
Recovery of Finished Seals,

under 50% deflection, after % 85
72 hrs + 0 hrs at 100 oC.
- 2 hrs
Note : All tests are in accordance with ISO Standards.

5.3 PRODUCTION OF CONCRETE Prior to the placing of concrete, all

of the required joint assemblies such
5.3.1 Concrete as dowel bars, tie bars, etc., shall be
installed in accordance with the
Concrete shall be of the grade shown requirements of Sub-Section 5.5. In
on the Drawings and shall comply one-layer construction, the slab
with the relevant requirements of reinforcement shall also be installed
Section 9 of this Specification. and fixed in accordance with the
relevant requirements of Section 9.
5.3.2 Equipment
In two-layer construction, the
All equipment used such as batching thickness of the top layer shall be not
plant and mixers shall comply with less than 50 mm or twice the
the relevant requirements of Section maximum size of the coarse
9 of this Specification. aggregate, whichever is the greater,
and shall be at least 15 mm thicker
than the depth of the groove former,
5.4 CONSTRUCTION if used. Placement of reinforcement
and concreting of the top layer shall
5.4.1 Preparation of Subgrade or Subbase be done immediately, and in any
case not more than 30 minutes, after
Prior to placing concrete pavement, the completion of the bottom layer.
the underlying subgrade or subbase
shall have been shaped and 5.4.2.1 Fixed Forms, Rails and Guide
compacted in accordance with the Wires For Machine Construction
provisions of Sub-Sections 2.2.7 or
4.1.2 as appropriate and the (a) Fixed Forms and Rails
waterproof membrane laid as
required in the Drawings. All forms and rails shall be made
Notwithstanding any earlier approval of steel and be sufficiently robust
of finished subgrade or subbase, any and rigid to support the weight
damage to or deterioration of the and pressure caused by the
subgrade or subbase shall be made paving equipment. Side forms
good to the satisfaction of the S.O. for use with wheeled paving
before the waterproof membrane is machines shall incorporate metal
laid and the concrete pavement rails firmly fixed at a constant
constructed. height below the top of the forms.
5.4.2 Construction by Machine The forms shall be secured by

using not less than three pins for
The concrete slab shall be each 3 m length, having one pin
constructed either by fixed form or fixed at each side of every joint.
by slip form paving plant in a Forms shall be tightly joined
continuous process in either one or together by a locked joint, free
two layers, as approved by the S.O. from play or movement in any
direction.

Forms shall be cleaned and oiled form paving plant. (Each guide
immediately before each use. wire shall be at a constant height
The rails or running surfaces shall above and parallel to the required
be kept clean in front of the edges of the slab within a vertical
wheels of any paving machines. tolerance of ±3 mm. In addition,
The forms shall be straight within one of the wires shall be at a con
a tolerance of 3 mm in 3 m. stant horizontal distance from the
required edge of the pavement
The forms shall be bedded on within a lateral tolerance of ±10
low moisture content cement mm.
mortar and set to the pavement
surface level as described in the The guide wires shall be
Contract within a tolerance of ±3 supported from stakes not more
mm. The bedding shall not than 8 m apart by connectors
extend under the slab. There capable of fine horizontal and
shall be no vertical step between vertical adjustment. The guide
the ends of adjacent forms greater wire shall be tensioned on the
than 3 mm. The horizontal stakes so that a 500 gramme
alignment for forms shall be to weight shall produce a deflection
the required alignment of the of not more than 20 mm when
pavement edge as described in suspended at the mid-point
the Contract within a tolerance of between any pair of stakes. The
±10 mm. The mortar or ends of the guide wires shall be
concrete bedding shall be broken anchored to fixing points which
out after use. shall be not closer to the edge of
the slab than the row of stakes
Prior to concreting, the forms and in no circumstances shall a
shall be approved by the S.O. guide wire be anchored to a
stake.
Forms shall not be removed
earlier than 6 hours after the The stakes and guide wires shall
completion of the construction of be checked and approved by the
the slab. Care shall be taken to S.O. prior to concreting.
prevent damage to the concrete
and any projecting tie bars during 5.4.2.2 Construction by Fixed Form
the removal of the forms. If the Paving Machine
removal of forms results in any
damage to the concrete the period A fixed form paving train shall
of 6 hours shall be increased to consist of separate powered
that which is necessary to avoid machines which spread, compact
further damage and the and finish the concrete in a
Contractor shall make good the continuous operation.
damaged areas.
Concrete shall be discharged
b) Guide Wires without segregation into a hopper
spreader which is equipped with
Unless otherwise agreed by the the means to control its rate of
S.O., a guide wire shall be deposition on to the subbase or
provided along each side of the on to the lower layer. . The con
slab to be constructed by slip crete shall be spread in each layer

without segregation and to a The regulation and finishing of

uniform uncompacted density the surface of the slab shall be
over the whole area of the slab. carried out by a machine which
The deposited concrete shall be incorporates twin oblique
struck off to the necessary level oscillating finishing beams which
by the underside of the hopper as shall be readily adjustable for
it is traversed across the both height and tilt. The beams
spreading machine. The machine shall weigh not less than 170 kg
shall be capable of being rapidly per linear metre, be of rectangular
adjusted for changes in average section and span the full width of
and differential surcharge the slab. The leading beam shall
necessitated by changes in slab be vibrated. The beams shall be
thickness or crossfall. supported on a carriage, the level
of which shall be controlled by
Prior to being compacted, the the average level of not less than
surface level of each loose spread four points evenly spaced over at
layer shall be adjusted to the least 3.5 m of the supporting rail,
correct surcharge by means of beam, or slab, on each side of the
rotating strike off blades or a slab that is being constructed.
screw device. The final regulation and surface
finishing of the slab shall be
The concrete shall be compacted carried out after any wet forming
by vibration or by a combination of joint grooves. After the final
of vibration and mechanical regulation and before texture is
tamping so as to comply with applied, any excess concrete on
Sub-Section 5.3.1 throughout the top of the groove former shall be
full depth of the slab. Poker removed.
vibrators shall be used adjacent to
the side forms and the edge of When a concrete slab is
previously constructed slabs. constructed in more than one
width, flanged wheels on the
The initial regulation and finish paving machines shall not be run
to the surface of the slab shall be directly on the surface of any
effected by means of a beam completed part of the slab. The
oscillating transversely or second or subsequent slabs shall
obliquely to the longitudinal axis be constructed either by
of the pavement. This beam shall supporting machines with flanged
be readily adjustable for both wheels on flat- bottom section
height and tilt. rails weighing not less than 15
kg/m laid on the surface of the
Joint grooves shall be constructed completed slab, or by replacing
in compliance with Sub-Section the flanged wheels on that side of
5.5. The concrete shall be the machine by smooth flangeless
recompacted around the former wheels. Before flangeless wheels
by a hand held vibrating plate or rails are used, the surface
compactor drawn along or on regularity of the slab over which
each side of the joint, prior to they are to pass shall comply
regulation of the surface by the with Sub-Section 5.4.1 and its
diagonal finishing beam. surface shall be thoroughly
cleaned and brushed to remove

all extraneous matter. Flangeless guide wires by at least one sensor

wheels or rails shall be positioned attached to the paver. The
sufficiently far from the edge of alignment and level of ancillary
the slab to avoid damage to that machines for finishing, texturing
edge. and curing of the concrete shall
be automatically controlled
5.4.2.3 Construction by Slip Form relative to the guide wires or to
Paving Machine the surface and edge of the slab.
A slip form paving train shall Slip form paving machines shall
consist of powered machines have vibration of variable output,
which spread, compact and finish with a maximum energy output
the concrete in a continuous of not less than 2.5 kW per metre
operation. of slab per 300 mm depth of slab
for a laying speed of up to 1.5 m
A slip form paving machine shall per minute or pro rata for higher
compact the concrete by internal speeds. The machines shall be of
vibration and shape it between sufficient mass to provide
sliding side forms or over fixed adequate reaction on the traction
side forms by means of either a units to maintain forward
conforming plate or by vibrating movements during the placing of
and oscillating finishing beams. concrete in all situations.
The concrete shall be deposited Joint grooves shall be constructed

without segregation in front of in compliance with Sub-Section
the slip form paver across its 5.5. The concrete shall be
whole width and to a height compacted around the former by
which at all times is in excess of a separate vibrating plate
the required surcharge. The compactor with twin plates. The
deposited concrete shall be struck groove former shall be
off to the necessary average and compacted to the correct level by
differential surcharge by means another vibrating float which may
of a strike-off plate or a screw be included with the transverse
auger device extending across joint finishing beam. In addition
the whole width of the slab. The a hand held vibrating float, at
equipment for striking off the least 1 m wide, shall be drawn
concrete shall be capable of being over the surface along the joint.
rapidly adjusted for changes in Any excess concrete on top of the
the average and differential sur groove former shall be removed
charge necessitated by changes in before the surface is textured.
slab thickness or crossfall. Where a concrete surface slab is
constructed in more than one
The level of the conforming plate width or where the edge needs to
and finishing beams shall be be matched for level to another
controlled automatically from the section of surface slab, and the
guide wires by sensors attached surface levels at the edges are not
at the four corners of the slip achieved, paving shall be carried
form paving machine. The out over separate fixed side forms
alignment of the paver shall be supporting the edge to the
controlled automatically from the required levels.

5.4.3 Construction by Hand-Guided Details of joints shall be as shown on

Method the Drawings. Joint grooves shall be
constructed in compliance with Sub-
Areas to be constructed by hand- Section 5.5. Any irregularities at wet
guided method shall be agreed with formed joint grooves shall be
the S.O. The slabs shall be rectified by means of a vibrating
constructed in one layer. Dowel float at least 1.0 m wide drawn
bars, tie bars and reinforcement, if along the line of the joint. The
specified, shall be fitted in position whole area of the slab shall be
as shown on the Drawings. regulated by two passes of a
scraping straight edge not less than
The concrete shall be spread 1.8 m wide or by a further
uniformly without segregation or application of a twin vibrating
varying degrees of precompaction, finishing beam. Any excess concrete
by conveyor, chute or by other on top of the groove former shall be
means approved by the S.O. The removed before the surface is
concrete shall be struck off by a textured.
screed so that the average and
differential surcharge is sufficient to The surface shall be brush-textured
ensure that after compaction the as described in Sub-Section 5.6.
surface is to the required level.
The concrete shall be cured in
The concrete shall be compacted by compliance with Sub-Section 5.8.
vibrating finishing beams. In
addition, internal poker vibration 5.4.4 Manual Construction
shall be used for slabs thicker than
200 mm and may be used for lesser Areas to be constructed by manual
thicknesses. When used, the pokers method shall be agreed with the S.O.
shall be at points not more than 500 The slabs shall be constructed in one
mm apart over the whole area of the layer. Dowel bars, tie bars and
slab, and adjacent to the side forms reinforcement, if specified, shall be
or the edge of a previously fixed in position as shown on the
constructed slab. Drawings.
The surface shall be regulated and The concrete shall be spread

finished to the level of the top of the uniformly without segregation or
forms or adjacent slab or pavement varying degrees of pre-compaction,
layer by using twin vibrating by conveyor, chute or by other
finishing beams. The beams shall be means approved by the S.O. The
metal with a contact face at least 50 concrete shall be struck off by a
mm wide and a vibrating unit having screed so that the average and
a minimum centrifugal force of 4 kN differential surcharge is sufficient to
with a frequency recommended by ensure that after compaction the
the manufacturer or an equivalent surface is to the required level.
compactive effort. The vibrating
beams shall be moved forward at a The concrete shall be compacted by
steady speed of 0.5 m to 1 m per internal poker vibrator or other
minute whilst vibrating over the means approved by the S.O. The
compacted surface to produce a vibrations shall be at points not more
smooth finish. than 500 mm apart over the whole

area of the slab, and adjacent to the As soon as surplus water has risen to
side forms or the edge of a the surface, the pavement shall be
previously constructed slab. given a broomed finish.
The surface shall be regulated and 5.4.4.1 Side Forms for Manual
finished to the level of the top of the Construction
forms or adjacent slab or pavement
layer by using an approved portable All side forms shall be made of
hand screed. The screed shall be at steel and be sufficiently robust
least 600 mm longer than the width and rigid to withstand
of the slab to be struck off and construction forces. Timber
compacted. It shall be of approved forms shall only be used for work
shape, sufficiently rigid to retain its which is less than 200 m in
shape and constructed either of metal length.
or of other material shod with metal.
The forms shall comply with
Compaction shall be attained by other requirements of Sub-
raising and dropping the screed in Section 5.4.2.1 as appropriate.
successive positions until the
required compaction and reduction 5.5 JOINTS
of surface voids is secured.
Joints shall be constructed as specified
The screed shall then be placed on herein and/or as directed or approved by
the forms and slid along them, with the S.O. Before any joint materials are
out lifting, in a combined set in place, the underlying pavement
longitudinal and transverse shearing course at those locations shall have been
motion moving always in the approved by the S.O.
direction in which the work is
progressing. If necessary, this shall Preformed expansion joint filler shall be
be repeated until the surface is of placed around each structure which
uniform texture, true to grade and extends into or through the pavement
contour, and free from porous areas. over the full interface with the concrete
pavement slab before concrete is placed.
After the concrete has been struck
off and compacted, it shall be further 5.5.1 Transverse Expansion Joints
smoothed, screeded and compacted
by means of a longitudinal hand float The components for each transverse
or other equipment as approved by expansion joint shall be assembled in
the S.O. advance and placed in position as a
unit.
Details of joints shall be as shown on
the Drawings. Joint grooves shall be Each assembly shall consist of an
constructed in compliance with Sub- installing template, preformed joint
Section 5.5. Any irregularities at wet filler of the required dimensions in a
formed joint grooves shall be single piece, dowel bars and sleeves
rectified by suitable means approved of the required sizes and lengths at
by the S.O. the required locations, and spacing
and supporting elements for the
The concrete shall be cured in dowel bars, as shown on the
compliance with Sub-Section 5.8. Drawings.

The installing template shall be Stakes for supporting the installing

metal plate of adequate rigidity template shall be of a cross-section
approved by the S.O., cut to the and length satisfactory to the S.O.
required depth and crown of the slab
and having a length 10 mm less than 5.5.2 Transverse Contraction Joints
the required length of the joint. It
shall be slotted from the bottom as Transverse contraction joints shall
necessary to permit removal. consist of planes of weakness created
Suitable means shall be provided on by forming or cutting grooves in the
the template for facilitating its surface of the pavement and, when
removal. shown on the Drawings, shall
include load transfer dowel bar
One half length of each dowel bar assemblies.
shall be thoroughly coated with a
200 pen bitumen blended with 5.5.2.1 Planes of Weakness
creosote oil or other material as
approved by the S.O. A dowel (a) Sawn Grooves
sleeve shall be fitted on to the coated
end of each dowel. When sawn grooves are specified
they shall be sawn in the con
The dowel supports shall be crete after its initial set.
constructed so as to hold dowels in
correct alignment, both vertically and Grooves shall be at right angles
horizontally, subject to a tolerance of to the centre line of the
not more than 1 in 100. pavement, shall be true to line
and shall have the width and
When assembled, the top of the depth shown on the Drawings.
installing template shall be about 5
mm above the top of the preformed All joints shall be sawn before
filler. The filler shall be vertical and uncontrolled shrinkage cracking
shall be in a plane at right angles to takes place but not until the
the centre line of the road, subject to concrete has hardened to the
a tolerance of not more than 1 in extent that tearing and ravelling is
500. not excessive, usually 4 to 24
hours after placing. If extreme
The joint assembly shall be placed so conditions exist which make it
that the installing template is on the impracticable to prevent erratic
side of the filler remote from pouring cracking by early sawing, formed
operations. The top of the filler shall grooves shall be used.
be 10 mm below the required con
crete surface, and the bottom shall Any procedure for sawing joints
rest on or extend slightly into the that results in premature and
underlying pavement course. The uncontrolled cracking shall be
assembly and its installation shall revised immediately by adjusting
have been approved by the S.O. the sequence of cutting the joints
before any concrete is placed against or the time interval involved
it. between the placing of the con
crete or the removal of the curing
medium and cutting of the joints.

(b) Formed Grooves When adjacent lanes of pavement

are constructed separately, steel side
When formed grooves are forms shall be used which will form
specified, they shall be made a key along the longitudinal joint as
by depressing an approved shown on the Drawings.
tool or device into the soft,
freshly laid concrete. The 5.5.4 Transverse Construction Joints
tool or device shall remain in
place until the concrete has Concreting operations shall be
attained its initial set and then planned such that transverse
be removed without construction joints shall be
disturbing the adjacent constructed at designed transverse
concrete. The line, width and expansion or contraction joints.
depth shall be as shown on
the Drawings. Transverse construction joints shall
be keyed or butt joints formed by
5.5.2.2 Load Transfer Assemblies placing suitable bulkheads approved
by the S.O.
Load transfer assemblies for
transverse contraction joints When there is an interruption of
shall be as shown on the more than 30 minutes in the
Drawings. They shall be of concreting operations, a transverse
similar construction to the construction joint shall be
assemblies for transverse constructed. As far as is practicable,
expansion joints except that this construction joint shall be
no joint filler shall be formed at a designed transverse
required and, consequently, no expansion or contraction joint.
installing template shall be
used. When this is not possible, transverse
construction joints shall be
5.5.3 Longitudinal Joints constructed at least 3 metres from all
transverse expansion or contraction
Longitudinal joints shall be joints. In such cases, tie bars 12 mm
constructed as shown on the in diameter and 1 metre long at 600
Drawings. mm centres shall be placed at the
transverse construction joints. Wire
Planes of weakness shall be created fabric or bar mat reinforcement shall
by forming or cutting grooves as extend across all such transverse
previously specified. construction joints.
Tie bars across a longitudinal joint 5.5.5 Sealing Joints

shall be placed perpendicular to the
joint and shall be rigidly supported Joints shall be sealed as soon after
as shown on the Drawings. The bars completion of the curing period as
shall not be painted or coated with feasible and before the pavement is
bitumen or other material. opened to traffic, including
construction traffic. Immediately
prior to sealing, each joint shall be
thoroughly cleaned of all foreign
material, including membrane curing

compound, and the joint faces shall units and power to complete the
be clean and surface dry when the sawing with a water-cooled diamond
seal is applied. edge saw blade, or an abrasive
wheel, to the required dimensions
The sealing material shall be applied and at the required rate. The
in accordance with the dimensions Contractor shall provide at least one
shown on the Drawings or as stand-by saw in good working order.
directed by the S.O. An ample supply of saw blades shall
be maintained at the site of the work
Sealing material to be applied hot at all times during sawing operations.
shall be stirred during heating so that The Contractor shall provide
localized overheating does not occur. adequate artificial lighting facilities
The pouring shall be done in such a for night sawing. All of this
manner that the material will not be equipment shall be on the job before
spilled on to the exposed surfaces of and continuously during concrete
the concrete. Any excess material on placement.
the surface of the concrete pavement
shall be removed immediately and 5.6 SURFACE TEXTURE
the pavement surface cleaned. The
use of sand or similar material as a 5.6.1 Texture of Running Surfaces
cover for the seal will not be
permitted. After the final regulation and before
the application of the curing
Preformed compression seals for membrane, the surfaces of concrete
sealing joints shall be of the cross- slabs to be used as running surfaces
sectional dimensions shown on the shall be brush-textured in a direction
Drawings. Seals shall be installed at right angles to the centre line of
using suitable tools, without the carriageway.
elongation, and secured in place with
an approved adhesive which shall The type of brush and method of
cover both sides of the concrete application for surface texturing shall
joints. The seals shall be installed in be approved by the S.O. based on
a compressed condition and shall at trial brushing to be conducted by the
time of placement be below the level Contractor.
of the pavement surface by
approximately 5 mm. The seals The texture depth shall be
shall be in one piece for the full determined by the sand patch test as
width of each transverse joint. described herein.
Notwithstanding the above, all The average texture depth for each
sealants shall be applied or installed set of 10 tests shall not be less than
in accordance with the 0.75 mm and not more than one test
manufacturer's instructions or of each set shall show a texture depth
recommendations. of less than 0.65 mm. In no case
shall the maximum texture depth
5.5.6 Concrete Saw exceed 2 mm.
When sawing of joints is specified,

the Contractor shall provide sawing
equipment adequate in number of

5.6.2 Measurement of Texture Depth : 31000 where D is the diameter of the of the
Sand Patch Method D x D patch in mm.
5.6.2.1 Apparatus 5.7 ROUNDING OF EDGES
i) A cylindrical container - 25 Where shown on the Drawings or

ml capacity. directed by the S.O., edges of concrete
slabs shall be rounded as follows.
ii) A flat wooden disc 64 mm in
diameter with a hard rubber After brush texturing but before the
disc, 1.5 mm thick, stuck to concrete has attained its initial set, top
one face, the reverse face edges of concrete slabs shall be worked
being provided with a handle. with an approved tool and rounded to
a radius of 5 mm. A well defined and
iii) Dry natural sand passing a continuous rounded edge shall be
300 um B.S. sieve and produced and a smooth, dense mortar
retained on a 150 um B.S. finish obtained.
sieve.
At all transverse joints, any tool marks a
5.6.2.2 Method ppearing on the slab adjacent to the
joints shall be eliminated by brooming
The surface to be measured shall the surface. In doing this, the rounding
be dried, any extraneous mortar of the edge of the slab shall not be
and/or loose material removed, disturbed. All concrete on top of joints
and the surface swept clean using shall be removed completely.
a wire brush both at right angles
and parallel to the centre line of 5.8 CURING
the carriageway. The cylinder
shall be filled with the sand, The exposed surfaces of concrete
tapping the base three times on a pavement shall be cured immediately
hard surface to ensure after surface texturing and rounding of
compaction, and striking off the edges by treating with a curing
sand, level with the top of the compound fulfilling the requirements of
cylinder. The sand shall be Sub-Section 5.2.6. It shall be
poured into a heap on the surface mechanically sprayed on to the surface
to be tested. The sand shall be at a rate of 0.22 to 0.27 litre per square
spread over the surface, working metre using a fine spray. The
the disc with its face kept flat, in mechanical sprayer shall incorporate an
a circular motion so that the sand efficient mechanical device for
is spread into a circular patch continuous agitation and mixing of the
with the surface depressions compound in its container during
filled with sand to the level of the spraying. For the sides of slip formed
peaks. slabs or when the side forms are
removed within the curing period, and
The diameter of the patch shall for small areas where a mechanical
be measured to the nearest 5 mm. distributor cannot be used, the
The texture depth in mm of compound shall be sprayed by hand
concrete surfaces shall be lance at a rate of 0.27 to 0.36 litre per
calculated as:- square metre.

The compound shall form a uniform, In addition, the entire surface shall be
continuous, coherent film that shall not protected from the effects of solar
crack or peel and shall be free from pin radiation by the use of frames
holes or other imperfections. If covered with material with heat and
discontinuities, pin holes or abrasions rain deflecting properties for not less
exist, an additional coat shall be applied than 4 hours after application of the
within 30 minutes to the affected areas. curing compound.
Necessary precautions shall be taken to
ensure proper curing at the joints and Notwithstanding the foregoing, concrete
that none of the curing compound enters surfaces which are subjected to heavy
joints which are to be sealed with joint rainfall within 3 hours after the curing
sealing compounds. Rope of moistened compound has been applied shall be
paper, fibre or other suitable material resprayed, all as specified above at no
shall be used to seal the top of the joint additional cost.
opening, and the concrete in the region
of the joint shall be sprayed with curing Concrete liable to be affected by running
compound immediately after the rope water shall be adequately protected from
seal has been installed. damage during the setting period.
Approved stand-by facilities or

approved alternative methods for curing 5.9 REMOVING FORMS
concrete pavement shall be provided at a
readily accessible location at the site of Forms shall not be removed until the
the work for use in the event of freshly placed concrete has set for at
mechanical failure of the spraying least 6 hours. The forms shall be
equipment or any other conditions removed carefully so as to avoid
which may prevent correct application damage to the pavement.
of the membrane curing compound at
the proper time. In the event of a failure As soon as forms are removed, the ends
of the regular spraying equipment, the of all expansion joints shall be cleaned
paving operation shall be stopped, and of concrete and the full width of the
the stand-by or alternative curing filler exposed for the full depth of the
method shall be used on the remaining slab. Any areas showing a minor degree
portion of the paving already placed. of honeycombing shall be repaired with
1:3 cement mortar. Where the S.O.
Concrete surfaces to which membrane considers that a major degree of
curing compounds have been applied honeycombing is present, the work shall
shall be adequately protected for the be considered defective and shall be
duration of the entire curing period from removed and replaced at the expense of
pedestrian and vehicular traffic, except the Contractor. In such cases, the
as required for joint sawing operations section of concrete removed shall be to
and surface tests, and from any other the full width and depth of the slab and
cause which will disrupt the continuity at least 3 metres long.
of the membrane. The curing
membrane so formed shall be
maintained intact for a period of not
less than fourteen (14) days.

5.10 OPENING TO TRAFFIC fixed to the slab edges so exposed. This

shall be to the full depth of the slab
No pavement shall be opened to any allowing for the depth of the groove
traffic earlier than twenty-eight (28) required for sealing. Alternatively, the
days from the completion of concreting. recesses may be sawn out after the con
crete has hardened.
The Contractor shall erect and maintain
suitable barricades and shall employ Reinforcement shall be placed as shown
watchmen to exclude public traffic and on the Drawings and concrete placed by
that of his employees and agents from hand in the space between the main slab
the newly constructed pavement. and the manhole or gully frame. This
concrete shall be of the same grade as
These barriers shall be arranged so as that of the main slab, and the mix shall
not to interfere with public traffic on any be modified as necessary to permit full
lane intended to be kept open and compaction by the methods adopted.
necessary signs and lights shall be
maintained by the Contractor clearly 5.12 HORIZONTAL ALIGNMENTS,
indicating any lanes open to traffic. SURFACE LEVELS AND
SURFACE REGULARITY
Where, as shown on the Drawings, it is
necessary to provide for traffic across The alignment, levels and regularity of
the pavement, the Contractor shall, at his the finished surface shall be in
own expense, construct suitable and compliance with Sub-Section 4.4 of this
substantial crossings to bridge the newly Specification.
constructed concrete pavement for as
long as the S.O. shall direct.
Any part of the pavement damaged by

traffic or other cause prior to its final
acceptance shall be repaired or replaced
all at the expense of the Contractor in a
manner suitably satisfactory to the S.O.
5.11 TREATMENT OF MANHOLES

AND GULLIES
Manhole covers, gullies and their frames

shall be isolated from the main
pavement slab as shown on the
Drawings and their surrounds cast in
separate operations.
Manholes and gully recesses shall be

formed by casting the main slab against
formwork boxes with vertical sides,
placed and fixed accurately. The
formwork boxes shall be removed
before the concrete around the manhole
or gully cover is to be placed and
preformed joint filler, 20 mm thick,

SECTION 6
ROADSIDE FURNITURE

SECTION 6 - ROAD FURNITURE
Page
6.1 CORRUGATED SHEET STEEL BEAM HIGHWAY GUARDRAIL S6-143

6.1.2.1 Beam Element S6-143
6.1.2.2 Posts S6-143
6.1.3 Installation of Guardrails S6-144

6.1.3.1 Setting Posts (Timber or Steel) S6-144
6.1.3.2 Placing Beams S6-144
6.1.3.3 Anchorages S6-144
6.1.4 Marking and Storage S6-144

6.1.4.1 Marking S6-144
6.1.4.2 Storage S6-144
6.1.5 Basis of Acceptance S6-144

6.1.5.1 Beam Elements S6-144
6.1.5.2 Posts and Block-Outs S6-145
6.2 TRAFFIC SIGNS S6-145
6.2.2 Sign Definitions S6-145
6.2.3 Sign Classification S6-145
6.2.4 Standards S6-146
6.2.5 Permanent Traffic Signs S6-146

6.2.5.1 General Requirements S6-146
6.2.5.2 Foundations S6-146
6.2.5.3 Posts S6-147
6.2.5.4 Sign Plate S6-147
6.2.5.5 Sign Faces S6-148
6.2.5.6 Backing Frames S6-149
6.2.5.7 Construction and Assembly S6-149
6.2.5.8 Location and Erection S6-151
6.2.5.9 Covering of Permanent Traffic Signs S6-151

Page
6.2.6 Temporary Traffic Signs S6-152
6.2.7 Traffic Signs On Gantries S6-152
6.2.8 Preparation and Finish of Metal and Other Surfaces S6-152
6.3 ROAD MARKINGS S6-153
6.3.2 Road Marking Materials S6-153
6.3.3 Preparation of Site S6-153
6.3.4 Preparation of Material on Site S6-154
6.3.5 Laying S6-154
6.3.6 Protection of Markings S6-154
6.3.7 Reflectorisation S6-154
6.3.8 Thickness S6-154
6.3.9 Tolerance on Width S6-156
6.3.10 Defective Materials or Workmanship S6-156
6.3.11 Clearing Up S6-156
6.4 CONCRETE KERB S6-157
6.4.3 Installation of Kerbs S6-157

6.4.3.2 Cast In Situ Kerb S6-157
6.4.3.3 Precast Concrete Kerb S6-157
6.4.3.4 Slipforming for Concrete Kerb S6-158

if used, shall be channel sections

SECTION 6 - ROAD FURNITURE of dimensions as shown on the
Drawings and shall be of the
6.1 CORRUGATED SHEET STEEL same material as that used for the
BEAM HIGHWAY GUARDRAIL posts. Both the posts and block-
out pieces shall be hot-dip
6.1.1 Description galvanised in accordance with
Sub-Section 6.1.2.1.
This work shall comprise the supply
and installation of corrugated sheet (b) Timber Posts
steel beam highway guardrails
inclusive of bolts, nuts, posts and Timber posts and block-out
other ancillary works, all in pieces shall be of medium
accordance with this Specification, hardwood (except the species
and the Drawings, and as directed by Merpauh and Rengas) as
the S.O. classified by the Malaysian
Timber Industry Board in its
6.1.2 Materials publication `Malaysian
Hardwood', and shall be treated
6.1.2.1 Beam Element according to M.S. 733. The
preservative retention in the
Unless otherwise specified on the outermost 25 mm shall not be
Drawings, corrugated sheet steel less than 16 kg per cubic metre.
beam highway guardrails shall Heavy hardwood can also be
conform to the requirements of used as an alternative with the
AASHTO Specification M180 approval of the S.O.
for Class À' Type II (galvanised)
guardrail with effective length of Guardrail timber posts and block-
beam 3810 mm (12 feet 6 out pieces shall be of the
inches). Guardrails shall be dimensions as shown on the
fabricated and furnished complete Drawings. The fibres of the block
with terminal or buffer sections, should run in the same direction
connecting and splicing bolts, as those of the post. The post
nuts and washers, etc., all shall be sound and free from
conforming to the requirements loose knots or decay with no
of AASHTO Specification M180 cracks at the top. All cut faces
and as necessary for erecting the shall be smooth and square as
guardrails as shown on the shown on the Drawings.
Drawings or as required by the
S.O. All timber components shall be
cut and drilled before treatment
6.1.2.2 Posts with preservative.
(a) Steel Posts
Steel posts shall be channel

sections of dimensions as shown
on the Drawings and the material
shall conform to B.S. 449 Part 1
Grade 43. The block-out pieces,

6.1.3 Installation of Guardrails 6.1.4 Marking and Storage
6.1.3.1 Setting Posts (Timber or Steel) 6.1.4.1 Marking
Before posts are erected, the In addition to the marking

alignment and finished levels of specified in AASHTO
the guardrails shall be set Specification M180, the JKR
accurately on site for approval by logo shall also be marked on each
the S.O. beam element.
Post holes at the correct positions 6.1.4.2 Storage

shall be dug either manually or
mechanically to the required All galvanised beam elements,
level. The posts shall then be set terminal sections, bolts, nuts and
plumb in the holes with the front washers and posts shall be stored
face forming a smooth line to the under a cover that will protect
approval of the S.O. After the them from rain until they are
posts are in place, the holes shall erected or used. While in
be backfilled with grade 20/20 storage, the material shall not be
concrete compacted in such a in direct contact with the soil and
manner as not to displace the there shall be a minimum space
posts from correct alignment as of 300 mm between the lowest
shown on the Drawings. Posts most elements and the ground
may be installed by means of surface.
driving with suitable equipment if
the S.O. is satisfied that the 6.1.5 Basis of Acceptance
Contractor is capable of installing
the post to the designed depth, 6.1.5.1 Beam Elements
line and level, accurately.
All material shall be subjected to
Posts shall be spaced as indicated inspection and sampling in
on the Drawings. accordance with AASHTO
Specification M180 at a sampling
6.1.3.2 Placing Beams rate of 1 in every 200 or as
The guardrail beams shall be
fixed and firmly bolted together The Contractor shall provide and
with the block-out pieces on to arrange the testing facilities and
the post to the lines and grades as the test pieces as and when
shown on the Drawings, and as requested by the S.O. The cost of
directed by the S.O. all sampling and testing shall be
borne by the Contractor. If, in
6.1.3.3 Anchorages the subsequent installation, there
is detection of non-compliance
Anchorages shall be constructed with the requirements of this
as shown on the Drawings and as Specification through random
directed by the S.O. sampling carried out by the S.O.,
then the material of the lot will be
rejected and the Contractor shall
remove the same from the Site at
his own cost.
6.1.5.2 Posts and Block-Outs It shall include all excavation and

backfilling, all necessary
(a) Steel foundations, anchorages, fixtures
and fastenings, brackets, lighting
For each lot of 200 pieces or less units and electrical installations
of either steel posts or steel where required, application of paints
block-outs supplied to the Site, and finishes, etc., to complete the
the Contractor shall submit work all to the satisfaction of the
certificates from an approved S.O.
testing laboratory certifying
compliance with the properties 6.2.2 Sign Definitions
required and the mill certificate.
However, the S.O. reserves the For the purpose of this Specification,
right to conduct further tests on traffic signs are defined as follows :-
the materials supplied.
i) Non-illuminated signs are those
The Contractor shall provide and signs which are not lit either
arrange the testing facilities and internally or externally and shall
test samples at his own expense be retro-reflective;
as and when instructed by the
S.O. The steel which has been ii) Externally illuminated signs are
rejected by the S.O. shall be those which comprise either
removed from the Site. retro-reflective or non-retro-
reflective facing with external
lighting luminaire.
(b) Timber
6.2.3 Sign Classification
For each lot of 200 pieces or
less of either timber posts or For the purpose of this Specification,
timber block-outs supplied to the the following clasifications shall
Site, the Contractor shall submit apply :-
a test report from an approved
testing laboratory certifying (a) Permanent Traffic Signs
compliance with specified timber
species and other qualities. Any of the traffic signs defined in
However, the S.O. reserves the Sub-Section 6.2.2 above or any part
right to conduct further tests on thereof as designated on the
the materials supplied. Drawings or as directed by the S.O.
to remain in position upon
6.2 TRAFFIC SIGNS completion of the Works.
(b) Temporary Traffic Signs

6.2.1 Description
Any of the traffic signs defined in
This work shall consist of the supply, Sub-Section 6.2.2 above or any part
assembly, erection and installation thereof designed by the Contractor
of sign faces, sign plates, posts and with the approval of the S.O. which
backing frames, all in accordance will not remain in position at the
with the details shown on the completion of the Works.
Drawings and as specified herein.

6.2.4 Standards transported and stored in

accordance with the
All traffic signs shall, except where manufacturer's instructions.
specified otherwise, comply with the
requirements of ARAHAN TEKNIK 6.2.5.2 Foundations
(JALAN) Series 2, published by
Cawangan Jalan, Ibu Pejabat JKR, The type and size of foundations
Kuala Lumpur. for permanent traffic signs shall
be as shown on the Drawings
6.2.5 Permanent Traffic Signs and, unless otherwise stated
therein, shall comply with this
6.2.5.1 General Requirements Specification.
Permanent traffic signs shall be All excavations, erection of

constructed, assembled, located formworks, placing of
and erected as shown on the reinforcement, etc., for
Drawings or as directed by the foundations shall be carried out in
S.O. compliance with this
Specification and shall be
Each complete traffic sign or part approved by the S.O. before
thereof shall be capable of placing of concrete and
passing the tests specified in B.S. backfilling.
873.
Unless otherwise shown on the
All externally illuminated traffic Drawings, signs supported by a
signs shall comply with Category single post placed in the ground
1 luminance of B.S. 873 unless shall have the post installed
otherwise shown on the centrally in 300 mm diameter
Drawings. holes filled with grade 20/20
concrete complying with Section
Before the commencement of 9 of this Specification to within
fabrication of any traffic sign, 450 mm of the ground surface.
unless otherwise shown on the The hole shall be excavated
Drawings, the Contractor shall either mechanically or manually.
submit for the S.O.'s approval
the details of fabrication drawings Posts shall be supported for a
for all signs. minimum of three (3) days after
placing the concrete. Backfilling
All traffic sign housings shall be shall not take place until at least
provided with vandal and 48 hours after placing the
weather resistant locks. Keys, in concrete, or other period agreed
the quantities determined by the by the S.O.
S.O., shall be provided to the
S.O. Types of lock shall be kept Where signs are illuminated,
to a minimum. provision shall be made for cable
entry through the foundation by
Traffic signs shall be carefully means of ducting as shown on
handled to prevent damage the Drawings.
(methods shall include the use of
proper slings), and shall be

Where pockets are formed in 6.2.5.4 Sign Plates

concrete foundations their plan
dimensions shall be 100 mm All permanent sign plates shall be
larger than those of the post. as shown on the Drawings and
shall comply with B.S. 873.
All backfilling of foundation pits Sign plates shall be made of 10
and reinstatement of existing S.W.G. sheets of aluminium alloy
surfaces above the foundations HS 30-WP conforming to B.S.
shall comply with the relevant 1470 with a minimum thickness
requirements of this of 3 mm.
Specification.
A sign plate not exceeding 1.2 m
6.2.5.3 Posts in height and 2.4 m in width
shall be made from a single sheet.
Posts for permanent traffic signs
shall be as shown on the Where more than one sheet is
Drawings and shall comply with used to make up a sign plate, the
B.S. 873. sheets shall be rectangular, of
approximately the same size and
Posts shall be of tubular hollow shape, and the position of the
section steel of not less than 50 joints shall be to the approval of
mm outside diameter complying the S.O.
with B.S. 1387.
Sign plates shall be drilled at all
Unless otherwise shown on the locations where rivets or bolts are
Drawings, posts shall not required for attaching the plate to
protrude above the top of the sign the backing frame or fixings
unless supporting an external before application of the sign
luminaire where the protrusion face. However, riveting shall be
shall be kept to a minimum. carried out only after the
application of the sign face.
Signs erected on a single post
shall be positioned so that the Subject to the S.O.'s approval,
post is in the centre of the sign, double sided "Very High Bond"
unless otherwise shown on the (V.H.B.) tapes may be used as an
Drawings. alternative to rivets. Nevertheless,
the tape shall comply with the
Compartments for electrical following requirements :-
equipment shall be as shown on
the Drawings. In the case of signs i) Peel Adhesion - 440 N per
supported by more than one post, 100 mm;
such compartments shall be on
the post furthest from the ii) Tensile Adhesion - 910 kPa;
carriageway unless otherwise
directed by the S.O. iii) Dynamic Shear -550 kPa.
Flange plates shall have holes or

slots as shown on the Drawings
to accommodate any holding
down bolts.

Where top and bottom light spill Only vertical and horizontal
screens are required as shown on joints shall be permitted and all
the Drawings, these shall extend joints in plastic sheeting shall be
for the whole width of the sign, overlapped by not less than 6
be fabricated out of the same mm. The overlap in the
material as the sign plate and horizontal joints shall be from the
shall have corners cut to the same top and the vertical joints shall be
radius as the other corners of the from the left; butt joints in plastic
sign plate. sheeting will not be accepted.
Plastic sheeting shall be applied
Top and bottom light spill screens evenly over the whole surface of
shall be considered part of the the sign plate and shall adhere
sign plate and any stiffeners and fully. It shall be free from twists,
mounting fittings shall be cracks, folds or cuts, air bubbles
designed to accommodate the and other blemishes.
combined size.
All plastic sheetings used on the
6.2.5.5 Sign Faces same sign shall be carefully
matched for colour to produce a
Sign faces for permanent traffic uniform appearance both by day
signs shall be as shown on the and by night. Non-uniform
Drawings and shall comply with shades of colour on any one sign
the `Draft Malaysian Standard will not be accepted.
Specification for Reflective Sign
Face Materials' (SIRIM The edges of all plastic sheeting
Reference D111 [ISCF]), and on shall be sealed. Edge sealing shall
replacement of this draft, the be continuous and uniform and
respective Malaysian Standard shall also be applied to all bolt
Specification. and rivet holes.
All retro-reflective plastic A coat of clear lacquer shall be

sheeting shall be fixed in applied to the whole of the face
accordance with the and edges of each finished sign
manufacturer's instructions. plate at the time of fabrication.
The lacquer shall be continuous
Unless otherwise agreed by the and uniform and shall be of the
S.O., sign faces shall be formed type specified or supplied by the
from a single piece of plastic manufacturer of the sheeting
sheeting. material.
Where, with the agreement of the Where sheeting is applied to

S.O., more than one plastic sheet extruded sections by pressure
is used, the number of sheets roller, it shall extend over the top
shall be kept to a minimum. All and bottom edges of these
faces up to 1 m in size shall be sections by not less than 3 mm.
produced with a single sheet and
no joint will be accepted.

Any cut-out letters, numerals, fabricated from 40 mm x 40 mm

symbols and borders shall be of x 3 mm angles. The angles used
material compatible with the for the backing frames shall be
sheeting to which they are made from aluminium alloy
applied. They shall be applied in HE9-TE conforming to B.S.
accordance with the sheeting 1474.
manufacturer's instructions.
The angles shall be welded,
Screen processed letters, bolted or riveted together to form
numerals, symbols and borders the backing frames as shown on
shall be screen printed with the Drawings.
materials in accordance with the
sheeting manufacturer's Backing frames shall not project
instructions. Any inks, pastes and beyond the face of the sign.
finishing coats used shall be
compatible with the sheeting Where large signs are built in
material. sections, the backing frames of
these sections shall be bolted
The finish of all sign faces shall together with 8 m diameter bolts
be capable of passing the tests at not more than 200 mm
described in B.S. 873, and the centres.
standards of fabrication and
workmanship shall be such that The details of joints between
under normal conditions of angles of the backing frame and
service and proper maintenance, of joints between sections of
the sign faces shall last not less large signs shall be to the
than 5 years without any serious approval of the S.O.
blemishes or defects for
Engineering Grade retro- The sign plate shall be riveted or
reflective sheeting and 8 years bonded with double sided V.H.B.
for High Intensity retro-reflective tape to the backing frame after
sheeting. The Contractor shall the application of the sign face.
furnish to the S.O. a letter of
warranty for the specified period 6.2.5.7 Construction and Assembly
for all sign faces from the
supplier of the sheeting or the Traffic signs shall be constructed
sign fabricator. and assembled as shown on the
Drawings and shall comply with
6.2.5.6 Backing Frames B.S. 873.
Backing frames for permanent All sign plates, backing frames,

traffic signs shall be as shown on purlins, posts and other
the Drawings and shall comply components shall be de-burred
with this Specification. prior to assembly.
Signs exceeding 600 mm in Where framing and stiffening are

height or width shall be stiffened not an integral part of the sign
by means of angles while signs plate, their joints shall be welded
exceeding 1 m in height or width or joined with suitable brackets
shall have a backing frame utilising nuts, bolts and washers.

Where purlins are adopted, they before final installation and they
shall be attached to each vertical and their anchorages shall be
member of the backing frame and installed so as to achieve the
the sign stiffening and framing loadings, torque settings and
shall be continuous in the vertical requirements shown on the
direction. Unless otherwise Drawings.
permitted by the S.O., purlins
shall be spaced equally apart. Sign plates shall be connected to
Connections shall be made at posts by a method approved by
every point where a purlin the S.O.
crosses a post.
Banding systems shall be of
Where purlins are not adopted, stainless steel.
the sign stiffening and framing
shall be continuous in the Where ferrous components are
horizontal direction. permitted, any drilling of such
components shall be completed
All rivets and other devices used before the application of any
in the fixing of sign plates to their finish.
stiffeners or backing frames, or
those used in the construction of Any hole drilled to accommodate
housings, shall be of a material rivets or bolts in plates with
compatible with the materials plastic sheeting shall,
being joined. immediately prior to the
insertion of the rivet or bolt,
Spacing of rivets or other devices have a clear lacquer, as
used in the fixing of sign plates to recommended by the
their stiffeners or backing frames manufacturer of the plastic
shall be uniform and shall not sheeting, applied to its edge to
exceed 150 mm around the prevent the ingress of moisture.
outside edge of any sheet or The surfaces of rivets or bolts
section of a sheet, and shall not exposed on the sign face shall be
exceed 300 mm on cross braces. coloured by a material approved
Hollow rivets shall be filled with by the S.O. to match that part of
a plastic plug flush with the head the face.
of the rivet.
Traffic signs to be erected on
An additional washer of road lighting columns shall have
neoprene, nylon or other material fixings compatible with the
approved by the S.O. shall be column cross-section and finish.
used against the sign face to Unless otherwise permitted by
protect it from the effects of any the S.O., columns shall not be
metal nuts, bolts, washers and/or drilled and wiring shall be
screws. contained in approved external
conduits.
Where traffic signs, including
external lighting luminaires or In addition to the requirements of
their supports, are required to this Specification, variable
have holding down bolt fixings, message traffic signs shall be of a
the bolts shall be lightly greased type approved by the relevant
authorities.
6.2.5.8 Location and Erection 6.2.5.9 Covering of Permanent Traffic

Signs
The approximate location of each
permanent traffic sign shall be as Where it is required in the
shown on the Drawings. All Contract that permanent traffic
traffic signs shall have their exact signs are to be blanked-out or are
location determined by the S.O. to have an alternative message,
and recorded on the as-built the covering to be adopted shall
Drawings. comply with the following
requirements.
All posts shall be erected plumb
and where two or more posts are The covering shall be 1.5 mm
provided for any one sign, the (16 S.W.G.) thick made from a
face of the posts shall be lined up. material compatible with that of
the sign plate, or a material
Signs erected on two posts shall approved by the S.O.
have each post positioned so that
the distance from the centre of Cover plates shall be fixed by
the post to the edge of the sign means of 5 mm diameter stain
plate is 300 mm unless less steel bolts, washers and nuts
otherwise directed by the S.O. or non-ferrous rivets not more
than 600 mm apart, the bolts
Any pockets formed in concrete passing through 12 mm
foundations to receive the posts diameter, 5 mm thick plastic
shall immediately prior to distance pieces between the sign
erection be cleaned out. The posts face and cover plate. Any holes
shall be placed centrally in the remaining in the finished sign
pockets and be bedded on and face shall be filled with blocked
filled up to finished foundation rivets coloured on the face by
level with grade 20/20 concrete. methods approved by the S.O.
Traffic signs mounted on posts, Where self-adhesive plastic film

except those on gantries, shall be is used, it shall be compatible
erected to have their faces plumb with the sign face materials and
and orientated in relation to the be applied and removed in
carriageway in accordance with compliance with the
ARAHAN TEKNIK (JALAN) manufacturer's instructions.
2B/85.
Any loose covering used must be
Traffic signs mounted on gantries sufficiently opaque to prevent
shall be erected as shown on the reflection from the covered sign
Drawings. and be securely fastened to the
back of the sign. Under no
No traffic sign shall be circumstances shall tape or other
dismantled, resited or removed adhesive material be applied to
without prior approval from the the face of the sign. A minimum
S.O. space of 50 mm shall be left
between the covering and the
face to permit airflow over the
sign.

Traffic signs which are to be 6.2.7 Traffic Signs On Gantries

covered shall not be erected on
trafficked highways without the Where traffic signs are erected on
covering in place. gantries, the signs shall comply with
the relevant requirements of this
Removal of any covering shall be Specification.
carried out with minimum
disturbance to traffic and only Fabrication and construction of
after the S.O. has given his gantries shall be as shown on the
approval. Drawings and as directed by the S.O.
Irrespective of any requirement in

the Contract to cover signs, any 6.2.8 Preparation and Finish
traffic sign erected at such a time of Metal and Other Surfaces
that its legend does not relate
either wholly or in part to the Traffic signs shall be prepared,
traffic movement and route in protected against corrosion and
operation, shall have its sign face finished in compliance with B.S.
securely covered with one of the 873.
materials described above until
such time as the S.O. authorises Faces of sign plates shall be prepared
its removal. to receive sign face materials in
compliance with B.S. 873 and in
6.2.6 Temporary Traffic Signs accordance with the manufacturer's
recommendations.
Temporary traffic signs shall be
constructed either as non-illuminated Steel backing frames, fittings and
or externally illuminated signs as purlins shall be prepared and
directed by the S.O.Location and protected in compliance with B.S.
erection of temporary traffic signs 873.
shall be in accordance with
ARAHAN TEKNIK (JALAN) Steel posts and post housings shall
2C/85. Erection of temporary traffic be prepared and protected in
signs mounted on posts shall comply compliance with B.S. 873.
with Sub-Section 6.2.5.8.
Backs of aluminium or aluminium
Any temporary covering of alloy sheets forming plate signs and
temporary traffic signs shall comply external parts of luminaire housings
with Sub-Section 6.2.5.9. and other permanently exposed
components shall, to prevent retro-
Removal of temporary traffic signs reflection, be dulled with paint using
shall be carried out as soon as they a method approved by the S.O.
become superfluous or a hazard to
traffic. Methods of removal and Ferrous steel shall be finished both
making good shall be submitted to inside and out by galvanising,
the S.O. for approval beforehand. electro-plating or application of zinc
Making good shall be carried out or aluminium spray or other e
immediately after removal of the quivalent finish approved by the S.O.
traffic sign to the satisfaction of the Aluminium and other metals shall be
S.O. left untreated unless otherwise
Unless otherwise shown on the (a) Thermoplastic Material

Drawings, stainless steel shall be
left untreated except where the Thermoplastic material shall
component is visible against the comply with the requirements of
sign face when it shall be B.S. 3262 Part 1. Yellow
coloured on the face by methods thermoplastic material shall be of
approved by the S.O. standard colour B.S. 381C No.
356 (Golden Yellow).
External surfaces shall be
prepared and protected as (b) Road Marking Paint
described in the Contract.
Cabinets and feeder pillars shall Road marking paint shall comply
have final coats of paint applied with the requirements of M.S.
on Site after final installation, 164. Yellow paint shall be of
including the fitting of any standard colour B.S. 381C No.
internal apparatus required as part 356 (Golden Yellow).
of the permanent Works. Internal
surfaces shall, unless otherwise 6.3.3 Preparation of Site
shown on the Drawings, receive
the same treatment as for external Thermoplastic material and road
surfaces except that final paint marking paint shall be applied only
coats shall be applied before on a surface which is clean and dry.
internal components are installed. It shall not be laid over loose
detritus, mud or extraneous matter or
6.3 ROAD MARKINGS over old material or paint marking
incompatible with the paint being
applied.
6.3.1 Description
A tack coat compatible with the
This work shall consist of the supply marking material shall be applied in
of road marking material and its accordance with manufacturer's
application to form continuous or instructions prior to the application
intermittent lines, letters, arrows, of thermoplastic material.
symbols or figures. The markings
shall be white or yellow laid to the If a primer or undercoat is necessary
dimensions and at the locations to ensure proper adhesion of the
shown on the Drawings and as marking paint to the road surface
specified herein or as directed by the without bleeding or other
S.O. The work includes the supply discoloration, the primer or
of all labour, tools, equipment, undercoat shall be fully compatible
materials, and warning and traffic with the marking paint and the road
guidance signs as necessary for the surface. The rate of application of
safe and efficient completion of the tack coat, primer or undercoat shall
entire work. be in accordance with the
manufacturer's instructions and to the
6.3.2 Road Marking Materials satisfaction of the S.O.
The marking material shall be one of

the types detailed below as indicated
on the Drawings or as directed by
the S.O.
FOR INTERNAL USE ONLY HStandard Specification For Road Works
6.3.4 Preparation of Material on Site specified. When more than one coat
is used, the succeeding coat shall not
(a) Thermoplastic Material be applied until the previous coat has
fully set.
Thermoplastic material shall be
supplied in block or powder form. If Road markings of a repetitive nature
the material is supplied in block other than centre lines, lane lines,
form it shall be broken into pieces, etc., shall, unless otherwise decided
each weighing not more than 4 kg, by the S.O., be set out with stencils
which shall be melted in a heater which comply with the size and
fitted with a mechanical stirrer to spacing requirements as shown on
prevent local overheating. the Drawings.
A thermometer of sufficient accuracy 6.3.6 Protection of Markings

shall be used during laying to ensure
that overheating of the material does All markings shall be protected from
not occur. Once molten hydrocarbon traffic until they have dried
resins shall be used within 6 hours sufficiently so that no pick-up by
and wood and gum resins shall be vehicle tyre will occur.
used within 4 hours. The material
shall not be heated beyond the 6.3.7 Reflectorisation
manufacturer's specified temperature
during application. Excess material Solid glass beads to be incorporated
shall be discarded on completion of in marking materials prior to
application. application to road surfaces shall be
Class À' glass beads complying
(b) Road Marking Paint with the requirements of Table 1 of
B.S. 6088 (see Table 6.1).
All paint shall be thoroughly stirred
before application to keep the Solid glass beads for additional
pigments in uniform suspension. The surface reflectorisation shall be
use of thinners or other additives Class `B' glass beads complying with
shall not be permitted unless the requirements of Table 2 of B.S.
otherwise approved by the S.O. 6088 (see Table 6.2).
6.3.5 Laying 6.3.8 Thickness
Centre lines, lane lines and edge The determination of thickness shall
lines shall be marked by approved be in accordance with B.S. 3262
mechanical means or as directed by Part 3, Appendices B and C.
the S.O. Other markings shall be
applied by brush, spray, screed,
hand-propelled or self-propelled
machine according to the marking
configuration and the type of
marking material approved for use.
The rate of application of the
marking material for each coat shall
be that recommended by the
manufacturer unless otherwise

TABLE 6.1 - CLASS À' GLASS BEADS : PARTICLE SIZE DISTRIBUTION, ROUNDNESS
AND DEFECTS
B.S. Percentage Min. % Spherical Max. % Defective

Sieve Retained Beads by mass Beads as tested in
as tested in accordance with
accordance with Appendix D
Appendix C
1.18 mm 0 to 3
850 um 0 to 10 70 30
425 um 90 to 100
TABLE 6.2 - CLASS `B' GLASS BEADS : PARTICLE SIZE DISTRIBUTION,

ROUNDNESS AND DEFECTS
B.S. Percentage Min. % Spherical Beads Max. % Defective Beads

Sieve Retained by mass as tested in as tested in accordance
(um) accordance with with Appendix D
Appendix C
850 0 to 5
800 5 to 20
300 30 to 75 80 20
180 10 to 30
Below 0 to 15
180

(a) Thermoplastic Material 6.3.10 Defective Materials or

Workmanship
Thermoplastic material shall be
laid to the following Materials which are defective or
thicknessess :- which have been applied in an
unsatisfactory manner or to
i) for synthetic hydrocarbon incorrect dimensions or in a
resin binder - wrong location, shall be removed
by approved chemical or
-screed lines : not less than 2 mechanical means. To the extent
mm nor more than 5 mm; necessary, the road pavement
shall be made good and the
-sprayed lines other than yellow markings reapplied all at the
lines : not less than 1.5 mm; Contractor's own expense and to
the approval of the S.O.
-sprayed yellow edge lines (for
`no parking', `no waiting', etc.) : Where directed by the S.O.,
not less than 0.8 mm. existing markings shall be
removed in the same manner as
ii) for gum or wood resin binders - above.
-screed lines : not less than 3 mm 6.3.11 Clearing Up

not more than 5mm;
The Contractor shall clean up all
-sprayed lines other than yellow lines spatters, splashes and smirches of
: not less than 2 mm; marking material completely to
the satisfaction of the S.O.
-sprayed yellow edge lines (for
`no parking', `no waiting', etc.) : not
less than 2 mm nor more than 3 mm.
(b) Road Marking Paint
Road marking paint shall be laid to

give a wet film thickness of not less
than 315 microns and not more than
400 microns.
6.3.9 Tolerance on Width
The tolerance on the specified width

of the marking shall be within the
range of + 10% and minus 0%.

6.4 CONCRETE KERB 6.4.3.2 Cast In Situ Kerb
When a cast in situ kerb is placed

6.4.1 Description next to a concrete pavement,
expansion joints in the kerb shall
This work shall consist of the supply be located in line with expansion
and installation of cast in situ or joints in the pavement. Expansion
precast concrete kerbs constructed at joints shall be formed at the
the locations and in accordance with intervals shown on the Drawings
the lines, levels, grades, dimensions using preformed filler 10 mm in
and types as shown on the Drawings, thickness in accordance with the
all in accordance with this specification for the pavement
Specification. joint filler.
6.4.2 Materials Concreting shall generally be in

accordance with the
Concrete for kerb sections shall be requirements of Section 9 of this
grade 25/20 concrete unless Specification. Forms shall not be
otherwise indicated on the removed within 24 hours of the
Drawings and shall conform to the concrete being placed. Minor
requirements of Section 9 of this defects shall be repaired with
Specification. mortar containing 1 part Portland
cement to 2 parts sand.
Unless otherwise shown on the
Drawings, bedding shall be grade After placing and compaction,
10/25 concrete. the concrete shall be covered
with suitable material and kept
6.4.3 Installation of Kerbs moist for a period of 7 days.
6.4.3.1 Excavation 6.4.3.3 Precast Concrete Kerb
Excavation shall be made to the Precast concrete kerbs shall be

required depth and the base shall cast using steel moulds and shall
be trimmed and compacted to a be of the types as shown on the
firm and even surface. All soft Drawings.
and unsuitable material shall be
removed and replaced with Each kerb shall be set so that its
suitable material as defined in front top arris conforms to the
Section 2 of this Specification. line and grade required. All
The bedding material shall then spaces under the kerb shall be
be placed and compacted to form filled with bedding material
a bed of required thickness as which shall be thoroughly
shown on the Drawings. tamped.

Kerbs shall be laid with joints as 6.4.3.5 Backfilling

narrow as possible and filled with
mortar containing 1 part Portland The spaces in the front and back
cement to 2 parts sand. Where a of each kerb shall be refilled to
Portland cement concrete the required elevation with
pavement is to be constructed suitable material approved by the
contiguous to a kerb, expansion S.O. which shall be tamped in
joints shall be constructed in the layers of not more than 150 mm
kerb directly in line with until properly compacted.
pavement expansion joints. The
expansion joint in the kerb shall The finished work shall be true to
be 20 mm in width and shall be line, grade and level to within
filled with an expansion joint ±10 mm and shall present a
filler of the same nominal smooth appearance free from
thickness as the pavement joint. kinks and distortion visible to the
Any voids between filler and the eye.
concrete kerb shall be filled with
mortar.
6.4.3.4 Slipforming for Concrete Kerb
In situ concrete kerbs shall be

laid by an approved automatic
kerbing machine or, if
practicable in the case of concrete
pavements, by the concrete
paver itself. The kerbs shall be
dense with regular sides, edges,
arrises and chamfers, finished to
a fine surface free from blow
holes and dragging, and shall be
impervious.

SECTION 7
STREET LIGHTING

SECTION 7 - STREET LIGHTING

Page
7.1 GENERAL
7.1.1 Scope of Work S7 - 162
7.1.2 On Site Commissioning Tests S7 - 162
7.1.3 As-Built Drawings S7 - 162
7.1.4 Maintenance S7 - 163
7.1.5 Traffic Safety and Control S7 - 163
7.2 LOW VOLTAGE UNDERGROUND CABLES
7.2.1 General S7 -164
7.2.2 Types of Cables S7 - 164

7.2.2.1 Power Cables S7 - 4
7.2.2.2 Earthing Conductors S7 - 4
7.2.3 Lengths of Cables S7 - 164
7.2.4 Cable Routes S7 - 164
7.2.5 Cable Trenches S7 - 165
7.2.6 Cable Ducts S7 - 165
7.2.7 Cable Termination S7 - 166

7.2.7.1 Termination of PVC Insulated Armoured Cable S7 - 166
7.2.7.2 Termination of Paper Insulated Cables S7 - 166
7.2.8 Cable Jointing S7 - 167
7.2.9 Cable Markers S7 - 167
7.2.10 Cable Laying and Installation S7 - 168
7.3 STREET LIGHTING LUMINAIRES
7.3.1 Light Distribution Requirements S7 - 170
7.3.2 Constructional Requirements S7 - 170

7.3.2.1 Luminaires S7 - 170
7.3.2.2 Lamps S7 - 171
7.3.2.3 Ballast S7 - 172
7.3.2.4 Capacitors S7 - 172
7.3.2.5 Ignitors S7 - 172

page
7.4 FEEDER-PILLARS S7 - 14
7.4.1 General S7 - 172
7.4.2 Fabrication of Feeder-Pillars S7 - 172
7.4.3 Factory Inspection S7 - 173
7.4.4 Foundation S7 - 173
7.4.5 Earthing S7 - 173
7.4.6 Time Switches S7 - 173
7.4.7 Contactors S7 - 173
7.4.8 By-Pass Switches and Selector Switches S7 - 173
7.5 COLUMNS AND BRACKETS S7 - 16
7.5.1 General S7 - 174
7.5.2 Design Loading S7 - 174
7.5.3 Fabrication of Column Sections S7 - 174

7.5.3.1 Doors and Door Openings S7 - 174
7.5.3.2 Service Slots S7 - 174
7.5.4 Bracket Arms S7 - 174
7.5.5 Base-Plates S7 - 175
7.5.6 Baseboards S7 - 175
7.5.7 Street Lighting Cut-Outs S7 - 175
7.5.8 Earthing Terminals S7 - 175
7.5.9 Cable Entry S7 - 175
7.5.10 Erection of Columns S7 - 175
7.5.11 Protection Against Corrosion S7 - 176

SECTION 7 - STREET LIGHTING Tests on cables shall include

continuity, phasing out and insulation
resistance between conductors and
between conductors and sheaths by
7.1 GENERAL employing a 500 V insulation
tester.The date of commissioning
7.1.1 Scope of Work shall be agreed to by the S.O. and the
Electrical Contractor shall ensure
This work shall comprise the design that the installation is safe before the
of cabling works and the supply and cable is energised.
installation of all luminaires, lamps,
ballasts, capacitors, ignitors, feeder The S.O. reserves the right to be
pillars, columns, ducting and cabling, present at all tests and the Electrical
and all necessary ancillary Contractor shall give at least one (1)
equipment, together with the week's notice in writing to the S.O.
transportation, storage, erection, for this purpose. In any case, no test
connection, testing and shall be carried out without prior
commissioning of the same for a approval from the S.O. Copies of all
complete street lighting system, all in test certificates shall be submitted to
accordance with the Drawings and the S.O. within one (1) week of the
this Specification. The work shall completion of the testing.
also include cabling from the nearest
specified power source of the local
supply authority to the street lighting 7.1.3 As-Built Drawings
system, if required.
Within three (3) calender months
7.1.2 On Site Commissioning Tests from the practical completion of the
installation, one set of true-to-scale
On completion of the installation negatives (110/115 g/sq.m A0 or A1
work on site, the Electrical sizes) and four sets of prints of each
Contractor shall, at his own expense, of the following as-built drawings
arrange for all necessary tests to be shall be submitted to the S.O. by the
carried out on the installation by Electrical Contractor :-
competent personnel as part of the
tests required of him for the whole of i) Site plans;
the installation under this Contract.
ii) Schematic wiring diagrams;
The tests to be carried out shall be as
prescribed in the latest edition of the iii) Layout plans showing cable
IEE Wiring Regulations and the routes with reference to easily
Electricity (Board Supplies) Rules recognisable buildings and
1949, and shall include other tests structures, sizes and types of
deemed necessary by the S.O. In the cables, locations and types of
event that the installation fails to pass joints, cable ducts, street lighting
any of these tests, the Electrical poles and luminaires, feeder
Contractor shall take such measures pillars and earthing points.
as are necessary to remedy the
defects and the installation shall not
be considered to have been
completed until all such tests have
been passed.
These as-built drawings shall be ii) replacing any broken or defective

properly stencilled and shall cable markers;
have, at the lower right hand
corner, the Electrical Contractor's iii) making good any damage to
name and address, the date of buildings, concrete areas, slopes,
commissioning, the scale, drains, culverts, existing cables,
drawing number (this shall be pipes, etc., which have not been
obtained from the S.O.) and title, properly made good as a result of
and the following particulars:- the Electrical Contractor's work;
and
JABATAN KERJA RAYA
CAWANGAN ELEKTRIK iv) carrying out any other work
CONTRACT NO. deemed necessary by the S.O.
TENDER NO.
7.1.5 Traffic Safety and Control
In addition, one (1) set of the as-
built drawings shall be properly When work is being carried out
framed and kept in the beside any public road or other
switchroom. existing road, warning signs shall be
erected. The general arrangement
If the as-built drawings submitted and location of temporary warning
are not acceptable by the S.O., signs shall be strictly in accordance
the Electrical Contractor shall with ARAHAN TEKNIK (JALAN)
amend and resubmit the drawings 2C/85, published by Cawangan
within two (2) weeks from the Jalan, Ibu Pejabat JKR, Kuala
date of return of the drawings. Lumpur, and shall be submitted by
the Electrical Contractor and
7.1.4 Maintenance approved by the S.O. before work
commences.
During the Defects Liability Period,
the Electrical Contractor shall per Where it is necessary for any pit or
form maintenance work for the trench to be left open overnight,
complete cabling and associated flashing warning lamps shall be
works. All labour, materials, tools placed at each end of the pit or
and parts necessary to rectify the trench and at intervals not greater
defects due to manufacturing or than 10 m apart. In built-up areas,
installation faults shall be supplied barricades shall be erected along the
and/or executed at no extra cost to length of the pit or trench in addition
the Government. Maintenance work to the warning lamps.
shall be carried out as soon as the
Electrical Contractor has been Where necessary, flag-men shall be
informed by the S.O. to do so. stationed to control traffic.
The work to be performed shall

include but shall not be limited to the
following :-
i) replacing or making good any

defective cables, cable joints and
cable terminations;

7.2 LOW VOLTAGE iii) B.S. 6480 Part 1 and shall

UNDERGROUND CABLES have high conductivity plain
copper stranded conductors,
7.2.1 General insulated with strong long-
fibred paper, uniform in
The Electrical Contractor shall texture, free from metallic
submit, for the approval of the S.O., particles, mass impregnated
a program of work for the excavation with non-draining insulating
of cable trenches, laying of cables, oil compound suitable for a
reinstatement of trenches, etc., one voltage of between 600 and
(1) week before the work is to be 1000 V, lead alloy sheathed,
executed. double steel tape armoured
and served.
7.2.2 Types of Cables
7.2.2.2 Earthing Conductors
7.2.2.1 Power Cables
Cables from street-lighting cut-
Power cables shall be outs and earthing cables to
manufactured and tested in luminaires shall be 2.5 sq.mm
accordance with :- PVC/PVC cables bundled
together with cable ties and
i) M.S. 274 or B.S. 6346 and terminated with lugs where
shall have high conductivity necessary.
plain copper stranded
conductors, insulated with 7.2.3 Lengths of Cables
PVC suitable for a voltage of
between 600 and 1000 V, laid The lengths of each type of cable
together and bedded with indicated on the Drawings and/or in
PVC, armoured with the B.Q. are for tendering purposes
galvanised steel wires and only. The Electrical Contractor shall
sheathed with PVC; or as certain the length of each cable
required before placing orders for
ii) B.S. 6480 Part 1 and shall cables. The actual length of each
have high conductivity plain cable installed shall be measured on
copper stranded conductors, site and the Electrical Contractor
insulated with strong long- shall be paid according to the rate
fibred paper, uniform in specified in the Contract. The rates
texture, free from metallic quoted shall include any wastage due
particles, mass impregnated to cutting to lengths, terminations,
with non-draining insulating etc.
oil compound suitable for a
voltage of between 600 and 7.2.4 Cable Routes
1000 V, lead alloy sheathed
and served; or Cable routes shown on the Drawings
are for tendering purposes only. The
Electrical Contractor shall, after
consulting the S.O., peg out cable
routes for the S.O.'s approval prior to
excavation of the cable trenches.

7.2.5 Cable Trenches complying with B.S. 1387,

complete with screwed and
Unless otherwise specified, cable socketed joints. Unless otherwise
trenches shall be 750 mm deep. They specified, the pipes shall be 150
shall be of sufficient width as to mm in diameter.
enable provision of adequate spacing
between cables but in any case shall The Electrical Contractor shall
not be less than 450 mm wide. provide pumps and other
appliances for the necessary
Trenches shall be as straight as pumping required for the disposal
possible and shall have vertical sides of water so as to prevent any risk
which shall be timbered where of the cables and other materials
necessary so as to avoid subsidence to be laid in the trench from
damage. The bottoms of trenches being detrimentally affected.
shall be firm and of smooth contour Where necessary, bailing shall be
and any objects likely to damage the provided.
cable sheathing shall be removed.
Material excavated from trenches Where it is necessary to cross
shall be placed or removed so as to drains, culverts or similar
prevent nuisance or damage to obstructions which are too deep
adjacent areas or buildings. for the cables to be buried below,
galvanised steel pipes as specified
Trench excavation and backfilling above shall be provided. The
shall be so executed that all roads, pipes shall be supported at each
walls, sewers, drains, pipes, cables, end in a concrete block and shall
structures, etc., shall be reasonably project through the blocks into
secured against risk of subsidence the ground to a depth of at least
damage. Provision shall be made 750 mm.
during excavation and until interim
restoration has been completed for All ducts shall be extended at
reasonable access of persons and least 600 mm beyond paved
vehicles to the areas of buildings areas, concrete areas, drains, road
adjacent to the trenches. crossings, pipe crossings, etc.
Where a trench passes from a foot Cables entering buildings shall be

way to a roadway or at other protected by pitch fibre ducts of
positions where a change in level is 150 mm diameter, complying
necessary, the bottom of the trench with B.S. 4108, complete with
shall rise and/or fall gradually. bend pieces, buried to a depth of
900 mm and encased in 75 mm
7.2.6 Cable Ducts of concrete all round. The ducts
shall be installed with a gradient
At road crossings, sewerage pipe so as to drain away any water in
crossings, water pipe crossings, the ducts. All ducts passing
paved areas, concrete areas and through walls shall be effectively
where specified by the S.O., cables sealed and made water-tight.
shall be protected by galvanised steel
pipes buried to a depth of 900 mm
below finished ground level. The
pipes shall be heavy duty pipes

Unless otherwise approved by the 7.2.7.2 Termination of Paper Insulated

S.O., the number of cables Cables
installed in each duct shall be
such that the space factor shall be PILCDS and PILCDSTAS paper
not less than 60%. A drawn wire insulated cables, unless otherwise
shall be provided for each duct. specified, shall be terminated by
the heat shrinkable method.
Unless specified to be provided
by others, the above galvanised The cables shall be tested for
steel pipes and /or pitch fibre moisture before termination is
ducts shall be provided by the commenced. Samples of paper
Electrical Contractor whether or both from the layers nearest to
not they are shown on the and furthest from the conductor
Drawings. shall be immersed in transformer
oil or paraffin wax heated to a
7.2.7 Cable Termination temperature of approximately
115ºC. If any residual moisture is
Unless otherwise permitted, all cable present, this will be detected
termination and jointing works shall immediately through the presence
be carried out in the presence of the of bubbles. Samples of paper
S.O. A plastic laminated plate shall be tested singly and shall
engraved with details such as size of not be touched by hand, but shall
cable, number of cores, date of com be gripped with a pair of
missioning, date of jointing, length tweezers.
of cable, distance of cable joint, etc.,
shall be securely fixed near the Phasing and insulation resistance
termination. tests shall be taken on each length
of cable laid before termination is
7.2.7.1 Termination of PVC Insulated commenced.
Armoured Cables
The heat shrinkable termination
PVC/SWA/PVC cables shall be materials used shall be supplied
provided with compression cable in a complete kit to suit various
gland termination. The cable sizes of cable and to provide
gland shall be of gunmetal or stress controlled, non-tracking,
brass and shall grip both the inner environmentally sealed
and outer PVC sheath of the termination. They shall consist of
cable. It shall be so designed that high permittivity, high resistivity,
any strain on the cable is taken by heat shrinkable, stress controlled,
the steel wire armouring which UV stable, non-tracking
shall be effectively sealed polymeric materials and heat-
between the gland itself and the activated sealants to prevent
outer cable sheath. ingress of moisture and
contamination.
Terminations shall meet the

performance tests of IEC 112,
IEC 446 and IEC 507, Section 3.
They shall also have the
following performance
characteristics :-
i) A.C. Voltage withstand Core numbers printed on papers

for 15 minutes, 50 Hz : shall be observed when jointing
4.0 kV phase to earth; and, whenever possible, such
numbers shall be maintained
ii) A.C. Voltage withstand throughout the system. Core
for 4 hours, 50 Hz : numbers `0', `1', `2' and `3' shall
3.0 kV phase to earth; denote neutral, red, yellow and
blue phases respectively. In the
iii) Impulse Voltage withstand 10 case of 2-core cables, core number
positive and 10 negative, `1' shall denote the phase conductor
1.2/50 microseconds : and `0' the neutral. Crossing of cores
8.0 kV peak phase to earth; in the cable boxes shall be avoided
wherever possible and connections
iv) Continuous A.C. Voltage : shall be consistent with the foregoing
1.5 kV phase to earth; requirements.
v) Insulation Resistance 7.2.9 Cable Markers

between phase conductor
and ground : > 1000 Cable markers with lettering and
Megaohms. signs as shown on the Drawings
shall be provided by the Electrical
7.2.8 Cable Jointing Contractor at every change of
direction of underground cable
Jointing of cables shall be routes and every 15 m on straight
undertaken only by competent and runs. Cable markers shall be of
fully experienced jointers. heavy duty reinforced concrete
construction and shall be approved
Cable boxes, compounds and by the S.O.
jointing materials used shall be of an
approved type. Every cable joint The cable marker shall form a
shall be started and finished on the trapezoidal block with a 100 mm
same day. square top face and 150 mm square
bottom face, and shall be 400 mm in
Wherever cables are to be jointed in height as shown on the Drawings.
the open during wet weather The top face shall be indented in
conditions, the Electrical Contractor bold lettering with the initials "L.V."
shall take all necessary precautions and a directional sign or signs
to prevent moisture from getting into indicating the direction/directions of
the cables. Where cable sheaths are the cable route. The cable marker
to be used as earth continuity shall be buried to a depth of 300 mm
conductors, the glands shall have the or any other depth as directed by the
necessary contact surface to provide S.O. Cable joint markers of similar
a low resistance path under fault construction but with the symbol "X"
conditions. shall be provided and installed at
every cable joint in a similar manner.
Phasing and insulation resistance
tests shall be taken before jointing is
commenced.

7.2.10 Cable Laying and Installation (a) Cable Laid Direct In Ground
All cables shall be handled, laid Before any cable is laid, the
and installed according to this trench shall be thoroughly
Specification, the latest edition of inspected and any debris and
the IEE Wiring Regulations, the other sharp objects shall be
cable manufacturer's removed. The bottom of the
recommendations and ERA trench shall be covered with a
Reports, using proper installation layer of clean sand 75 mm thick.
equipment, all to the satisfaction The cables shall then be laid on
of the S.O. this bedding in an orderly manner
without overlapping and crossing
All cables shall be supplied in each other. 75 mm of clean sand
complete lengths to suit the shall cover the laid cables and
circuits they serve and no straight shall be spread over the trench
through joints shall be used. before placing the cable
Straight through joints in the protective covers.
cable shall only be permitted in
very exceptional circumstances Cable protective covers shall be
such as those arising from of clay bricks. The bricks shall be
unavoidable limitations in new, well burnt and in complete
manufactured length. Where pieces. They shall be laid
straight through joints or other lengthwise from end to end along
approved joints are permitted by the entire route of the
the S.O., the cost of such joints underground cable if the cable
shall be borne by the Electrical size is not more than 120 sq.mm.
Contractor. No joints in the cable For cable sizes in excess of 120
will be allowed unless approved sq.mm, more than one row of
in writing by the S.O. bricks shall be laid. Each cable
shall be seperately protected by
The minimum bending radius of these bricks and the cover shall
the cables shall be in accordance have at least 25 mm overhang on
with Table 52 C of the latest each side of the cable.
edition of the IEE Wiring
Regulations. Wherever cables are The trench shall then be
cut, the ends shall be immediately backfilled with earth and shall be
sealed in an approved manner compacted in layers of 150 mm
unless it is intended to proceed using a mechanical rammer. An
with cable jointing or termination orange coloured multi-strand
immediately. nylon rope of minimum 6 mm
diameter shall be laid at a depth
Unless otherwise permitted by of 300 mm along the trench to
the S.O., no cable shall be laid identify the cable route. At every
and/or covered up in the absence 10 m interval, an extra 2 m of
of the S.O. nylon rope shall be coiled and
laid. The finished surface shall be
left proud by 50 mm to allow for
subsidence and the Electrical

Contractor shall be responsible The minimum thickness of the

for the removal of any surplus sheet steel used shall be 1.5 mm
material to a position indicated by for cable trays with widths of up
the S.O. to 300 mm, and 2.0 mm for
widths exceeding 300 mm. Cable
The surface of the refilled trench trays shall be supported at least
shall be temporarily reinstated 25 mm from the trench wall by
and maintained in a thoroughly mild steel brackets at 600 mm
safe condition until complete intervals. Brackets shall be
consolidation of the soil has been anti-rust treated and painted with
achieved. As soon as the soil has one coat of primer. Samples of
consolidated, the trench shall be cable trays and brackets shall be
made good to its original submitted to the S.O. for
condition, all to the satisfaction of approval prior to installation.
the S.O.
To provide electrical continuity,
(b) Cable Installed In Precast all cable joints shall be bridged
Concrete Trenches by means of tinned copper tape
of dimensions not less than 25
Methods of installation of cables mm x 3 mm. All saddles for
in precast concrete trenches shall cables on cable trays shall be
be in accordance with Type L, installed by bolts, washers and
Type M, or Type N of Table 9A nuts. All tees, intersection units,
of the latest edition of the IEE adaptor units, etc., shall be
Wiring Regulations. However, if factory manufactured unless
the method is not specified, the otherwise approved by the S.O.
cables shall be installed as Trenches inside buildings shall be
directed by the S.O. filled with clean sand up to a
level above the cable ducts.
Cables laid in the bottoms of
trenches shall be in accordance (c) Cable Run On Walls and
with Method Type L of Table 9A Under Floor Slabs
of the latest edition of the IEE
Wiring Regulations. Cable run on walls and under
floor slabs shall be mounted on
Cables installed on trench walls perforated hot-dipped galvanised
shall be in accordance with sheet steel cable trays. The
Method Type M or Type N of the construction and finish of the
latest edition of the IEE Wiring cable trays and the method of
Regulations and shall be secured installation of cables on cable
on a cable tray by means of trays shall be as described in Sub-
saddles at suitable intervals. In Section 7.2.10 (b) above.
the case of single core cables,
whether secured individually or Cable trays shall be suspended
in a group to the cable tray, non- from floor slabs by hangers or
ferrous saddles shall be used. mounted on walls by brackets at
Cable trays shall be fabricated 600 mm intervals. The materials
from perforated hot-dipped and finishes used for the hangers,
galvanised sheets finished in an brackets and other suspending
orange enamel. and supporting structures shall be

the same as those described for 7.3.2 Constructional Requirements

brackets in Sub-Section 7.2.10
(b) above. 7.3.2.1 Luminaires
Where cable trays pass through All luminaires shall be new,

floors or fire resistant walls, the totally enclosed, dust proof,insect
surrounding holes shall be sealed proof and watertight and shall be
to the full thickness of the floor tested in accordance with B.S.
or wall with non- hygroscopic 4533. All exposed parts shall be
fire-resisting material of of non-corrosive materials. The
minimum 2-hour fire rating as luminaires shall provide the
approved by the Jabatan Bomba requisite light distribution with
Malaysia. the size and type of lamp
specified. Each luminaire shall
consist of a lamp compartment
7.3 STREET LIGHTING made up of an upper canopy or
LUMINAIRES housing and a lower bowl
assembly, a lampholder, cable
clamps, mains connectors and
7.3.1 Light Distribution Requirements earth terminations, as well as all
necessary control gear. The
Unless otherwise specified, the control gear shall be pre-wired
performance and light distribution of and integral with the luminaire.
street lighting luminaires shall be of The luminaire wiring shall be of
the Low Threshold Increment (LTI) a size and insulated with a
type. material that will more than
effectively withstand the current,
The direction of maximum intensity voltage and temperatures
of flux shall lie between 0º and 65º expected within the luminaire
of the downward vertical and the during both the starting and
maximum permissible value of the operating modes in the ambient
intensity emitted at 90º and 80º shall temperature of the Site.
not exceed 10 cd/1000 lumens and
30 cd/1000 lumens respectively. The lamp compartment of the
luminaire shall be accessible via a
Each luminaire shall normally direct hinged bowl made of ultraviolet
two beams along the length of the stabilised plastic material such as
road. The polar light distribution acrylic which shall, in the closed
curves for the luminaire shall position, bed firmly upon a soft
generally be smooth and free from resilient neoprene or non-ageing
any abrupt variations so that the felt gasket. The gasket shall be
luminous intensity diminishes positively secured in the
smoothly and progressively from its luminaire housing and shall be
maximum. weather-resistant. The bowl shall
be secured firmly to the luminaire
body by means of stainless steel
clips and hinged pins.In the
lowered position of the bowl, it
shall be restrained from
becoming detached or being

blown towards the other portion The lamps supplied shall have a
of the luminaire or the column mortality rate not greater than
arm. If independent reflectors are 10% at 5,000 switched operating
incorporated in the luminaire, hours and shall not take longer
such reflectors shall be of high than 4 minutes after the initial
purity aluminium mirrors, "switch on" to attain 80% of their
chemically anodised to yield guaranteed output at the rated
optimum reflection of light voltage of 200/250 V and
distribution. Full details of the frequency 50 Hz. The reignition
luminaire and accessories shall be period after an interruption of the
furnished as required in the supply shall not be longer than 1
Appendices to this Specification. minute to attain 80% of the
lumens output.
7.3.2.2 Lamps
(a) High Pressure Sodium Vapour

(HPSV) Lamps (b) Low Pressure Sodium Vapour
(LPSV) Lamps
High presssure sodium vapour
(HPSV) lamps shall conform to Low pressure sodium vapour
IEC Publication 662 and shall (LPSV) lamps shall conform
have a colour temperature of to the requirements as laid
approximately 21,000 K. The down in B.S. 3767. The
majority of the light output shall majority of the lumens output
fall within the 560-610 shall be within the 580-590
nanometre waveband, i.e. in the nanometre waveband range.
yellow/orange, range. The lamps shall have an
initial luminous efficacy of
The lamps shall have an initial approximately 160 lumens per
luminous efficiency of watt for a 135 watt lamp. The
approximately 115 lumens per lumens output after 100
watt for a 400 watt lamp and 100 operating hours shall be not
lumens per watt for a 250 watt less than 50 lumens per watt.
lamp. The lumens output after
100 operating hours shall be The lamps shall be of tubular
45,000 lumens for a 400 watt shape with a bayonet cap
lamp and 25,000 lumens for a (B.C.), shall take no longer
250 watt lamp. than 11 minutes after initial
"switch on" to attain 90% of
The lamps shall be of tubular or of their quoted lumens output.
of any other approved shape and
shall have plated brass caps All LPSV lamps shall be
securely fitted to the glass guaranteed for a minimum
envelopes. The cap shall be of operating life of 4,000
GESE40 material to fit the operating hours. All lamps
luminaire supplied. shall be suitable for use, in
conjunction with their control
gears, on 220/240 V supply
and shall be capable of being
started and operated at 10%
reduction in rated voltage.
7.3.2.3 Ballast 7.4 FEEDER-PILLARS
The ballast shall be manufactured

to B.S. 4782. It shall be correctly 7.4.1 General
rated for its duty and shall be
designed to operate on a dual Feeder-pillars shall be supplied
mains voltage of 220/240 V by completely assembled with control
means of suitable tappings. The gear and all internal electrical and
tappings shall be brought out to mechanical inter-connections and
marked terminals. The ballast structural parts for voltages up to and
shall have laminated cores and including 1,000 volts A.C. They
high conductivity windings with shall comply with and be tested to
power loss and noise kept to a the requirements of B.S. 5486.
minimum.
7.4.2 Fabrication of Feeder-Pillars
7.3.2.4 Capacitors
The Electrical Contractor shall
Capacitors shall be manufactured submit a design drawing of the
to B.S. 4017 and housed in shape, size, electrical and mechanical
extruded aluminium canisters connections, materials, etc., of the
with shrouded screw terminals. feeder-pillar for the approval of the
They shall not be fused but shall S.O. prior to manufacture. The
have an an external safety dis plinth, foundation work, etc., shall be
charge resistor. The capacitor included in the design drawing.
shall be capable of raising the
power factor of each circuit to at The feeder-pillar housing shall
least 0.85 lagging. consist of a drip canopy, rigidly
welded channeled steel framework
7.3.2.5 Ignitors manufactured from 2.64 mm (12
s.w.g.) sheet steel. It shall be hot-dip
Ignitors for the discharge lamps galvanised and the process of
shall be of the electronic / galvanising, treatment before
superimposed pulse type rated for galvanising and treatment after
the appropriate wattage. The unit galvanising shall be as described in
shall be capable of operating on a Sub-Section 7.5.10 of this
voltage ranging from 200 to 250 Specification. On the front and rear
volts. The unit shall be totally sides of the feeder-pillar, the
enclosed with an external following sign shall be stencilled in
terminal block for the supply red paint using a lettering height of
connection and a length of high 90 mm :-
tension cable shall be included
for the lamp connection. It shall BAHAYA
be compatible with the normal 415 V
control gear. LAMPU JALAN
The case of the unit shall carry a The door of the feeder-pillar shall be
label showing the connections rigidly reinforced and hinged internally
and listing the appropriate to prevent unauthorised access. The
voltage. feeder-pillar shall be lockable with either
wedge-type locks protected by screw

plugs or some other secret locks copper tape, precast concrete earth
approved by the S.O. The feeder- chambers with covers, etc.
pillar shall be self-ventilated and
weather proof and such ventilation 7.4.6 Time Switches
openings shall be protected by wire
mesh to prevent the entry of vermin, Time switches supplied for the
rodents and birds. control of luminaires, etc., shall be of
the synchronous/step-by-step motor-
A baseboard made of tufnol or wound handset dial plug-in type.
other approved treated hardwood They shall incorporate a 24-hour
of at least 16 mm thickness shall spring reserve or a battery back-up
be included to mount equipment system. Time switches shall be rated
such as time switches, contactors, as specified in the Drawings and
etc. shall be operational on a 220/240 V,
50 Hz supply.
7.4.3 Factory Inspection
7.4.7 Contactors
The Electrical Contractor shall make
arrangements to witness the Contactors shall comply with B.S.
electrical tests and for joint 5424 with uninterrupted ratings,
inspection to be carried out at the mechanical duty Class 2 and a
factory prior to transportation to the utilisation category of at least AC3.
Site. The contactor coils shall be fully
tropicalised and wound for
7.4.4 Foundation continuous operation for a 220/240
V, 50 Hz supply. The contacts of the
The Site of the foundation of the contactor shall be rated for the
feeder-pillar shall be filled where breaking capacity of the connected
required, compacted and levelled load.
before the reinforced concrete base
of minimum 250 mm height above 7.4.8 By-Pass Switches and Selector
the finished earth level is Switches
constructed. Cable entry ducts shall
also be provided. Single or three-phase by-pass
switches as applicable shall be
7.4.5 Earthing connected in parallel with the
contactors for use in the event of the
The earthing system for the feeder- failure of the contactors. These shall
pillar shall comply with the Rules be manufactured to B.S. 5419 and
and Regulations of the Supply shall be capable of breaking the load
Authority, The British Code of connected to the contactors without
Practice C.P. 1013, the relevant undue ageing or damage.
sections of the latest edition of the
IEE Wiring Regulations and the A four-position selector switch shall
Contract Drawings. be provided to select the mode of
operation and shall be appropriately
Each feeder-pillar shall be effectively labelled.
earthed using 4.8 mm x 16 mm
diameter steel core copper-jacketted
earth electrodes, 25 mm x 3 mm

7.5 COLUMNS AND BRACKETS minimum overlapping position of 1.5

times the external across-faced
dimension.
7.5.1 General
7.5.3.1 Doors and Door Openings
All columns and brackets shall be of
tapered, octagonal, hot-dip Weather proof doors shall be
galvanised interchangeable sections provided with an anti-vandal
complying in all respects with the locking device over the door
Drawings. They shall be opening of each column as
manufactured to comply with B.S. shown on the Drawings. The
1840 and B.S. 5649 with Grade 43C complete locking device shall be
or 50C steel conforming to B.S. made from stainless steel. Door
4360. The base-plates and bracket openings shall have internal
arms shall be manufactured as reinforcement to compensate for
seperate units suitable for mounting the loss of stiffness in the
or fixing on to the columns. columns caused by forming the
door openings.
7.5.2 Design Loading
7.5.3.2 Service Slots
The columns shall be designed to
withstand loadings comprising :- For flange mounted types of
columns, cable entries shall be
i) loads due to wind speeds of up to through the flange plates via a
27 m/sec.; hole of suitable diameter as
shown on the Drawings. A
ii) loads due to the weight of the suitable duct for cable entry shall
columns, lighting luminaires and also be provided at the concrete
bracket arms; base.
iii) other applied loads if applicable. For planted root types of

columns, service slots shall be on
7.5.3 Fabrication of Column Sections the same side and vertically
below the service doors.
Each column section shall be
mechanically formed and 7.5.4 Bracket Arms
longitudinally welded by the
continuous automatic gas shielded Bracket arms shall be of suitable
electric arc process (M.I.G. process) outreach as indicated on the
to B.S. 5135. The sections shall be Drawings and in the B.Q. The
constructed so as to overlap each bracket arms shall be octagonal in
other by a minimum of 1.5 times the shape for up to 2.0 m in length. For
diameter of the immediate lower bracket arms longer than 2.0 m in
section (external across-faced length, the extra length shall be
dimension) and to be easily formed from Grade 43C tubular steel
assembled on site by using simple conforming to B.S. 4360. The
tools without employing welding bracket arms shall be arranged so as
techniques. The manufacturer shall to give a 50 uplift as shown on the
provide a mark on the finished Drawings. A tubular steel spigot of
column section indicating the appropriate dimensions for the

luminaire shall be welded at the end cables as appropriate. Cut-outs shall

of each bracket arm. After welding, be provided with adequate shrouding
etc., bracket arms shall be treated as to prevent cross-phasing or
described in Sub-Section 7.5.10 accidental contact with live metal.
before being hot-dip galvanised.
The fuse carriers shall be self-
7.5.5 Base-Plates aligning and shall accept any of the
standard rated fuses for the purpose.
For flange mounted types of Each unit shall possess high
columns, flange-plates of substantial mechanical and di-electric strength
thicknesses as shown on the and shall be suitable for use in the
Drawings shall be welded on to the tropics. Samples of complete cut-out
columns. units shall be submitted for the
approval of the S.O.
For planted root types of columns,
detachable anti-sink plates shall be 7.5.8 Earthing Terminals
supplied.
Columns shall be provided with a
Base-plates, nuts and bolts, etc., shall corrosion resistant terminal having
be hot-dip galvanised after substantial contact surfaces for the
manufacture. attachment of an earthing lead. This
terminal shall be provided close to
7.5.6 Baseboards the door opening inside each
column. Where bolts are used, they
A piece of baseboard shall be shall be not less than 6 mm in
included in each base compartment diameter and shall be provided with
for cable termination or control gears two suitable washers and nuts.
assembly. Baseboards shall be made
from fibre board of 10 mm 7.5.9 Cable Entry
thickness. Alternative baseboards
made from galvanised perforated Armoured cables brought into the
metal may also be used with the columns shall be provided with
approval of the S.O. Baseboards compression cable gland
shall be made to the dimensions as terminations.
indicated on the Drawings and shall
be fixed securely in position inside An appropriate type of earthing
the columns. clamp shall be provided to bond the
armouring of the cables which shall
7.5.7 Street Lighting Cut-Outs be effectively earthed.
Street lighting cut-outs shall be of a 7.5.10 Erection of Columns

type manufactured for use in street
lighting installations. They shall Columns shall be installed in
have facilities for double fusing accordance with the manufacturer's
loop-in loop-out terminals. The cut- recommendations and as shown on
out bases shall have a supply cable the Drawings. The Electrical
contact block rating of at least 50 A Contractor shall peg out the positions
and shall be capable of accepting of the columns for the approval of
circular cable cores of up to 25 the S.O. before planting the columns.
sq.mm copper 2-core or 4-core

Columns shall be erected such that Treatment prior to galvanising shall

the service doors shall face away include degreasing, rinsing, pickling,
from on-coming traffic except at further rinsing and fluxing.
parapets of bridges and retaining
walls. At such locations, the The minimum average weight of the
orientation of the service doors shall zinc coating shall be 460 g/sq.m for
be determined by the S.O. After any individual test area.
erecting each column, backfill shall
be compacted by means of suitable The galvanised columns and bracket
ramming equipment. arms shall be of prime finish and of
good uniformity, i.e. they shall be
7.5.11 Protection Against Corrosion free from injurious defects such as
blisters, flux and uncoated spots.
Individual sections of the columns,
base-plates, doors and bracket arms The planted sections of columns and
shall be protected against corrosion the base-plates shall be factory-
by hot-dip galvanising the sections coated with bitumen using the hot-
both internally and externally, all in dipping process conforming to
accordance with B.S. 729. All AASHTO M 190.
welding works shall be completed
before galvanising.

SECTION 8
TRAFFIC SIGNALS

SECTION 8 - TRAFFIC SIGNALS
Page
8.1 GENERAL
8.1.1 Scope of Work S8-182
8.1.2 Design and Construction

8.1.2.1 Contractor's Responsibility S8-182
8.1.2.2 Cleanlines S8-182
8.1.2.3 Metric Range of preferred Dimensions S8-182
8.1.2.4 Self-Tapping Screw S8-182
8.1.2.5 Corrosion S8-182
8.1.3 Compliance With Manufacturer's Instruction S8-183
8.1.4 Component and materials

8.1.4.1 Conditions of Operation S8-183
8.1.4.2 Maintenance To Be Kept To A Minimum S8-183
8.1.4.3 Components S8-183
8.1.4.4 Metering S8-183
8.1.5 Identification of Equipment S8-184
8.1.6 Protective Requirements

8.1.6.1 General S8-184
8.1.6.2 Insulating Bushes S8-184
8.1.6.3 Isolation From Main Supply S8-184
8.1.6.4 Earthing of Transformer Secondary Circuits S8-184
8.1.6.5 Current Loading of Wires S8-184
8.1.6.6 Danger Notices S8-185
8.1.6.7 Cable Connecting Units S8-185
8.1.6.8 Insulation S8-185
8.1.6.9 Whiskering of Tin S8-185
8.1.7 Electricity Supply S8-185
8.1.8 On-Site Commisioning Test Procedures S8-185
8.1.9 Documentation
8.1.9.1 General S8-186
8.1.9.2 Hardware, Software and maintenance Manual S8-186
8.1.10 Guarantee of Supply S8-187
8.1.11 Warranty Period S8-187

Page
8.2 LOW VOLTAGE UNDERGROUND CABLES
8.2.1 Type of Cables S8-187

8.2.1.1 Power Cables S8-187
8.2.1.2 Feeder Cables for Vehicle Detectors S8-188
8.2.1.3 Loop Cables for Vehicle Detectors S8-188
8.2.1.4 Earthing Conductors S8-188
8.2.2 Cable Termination S8-188
8.2.3 Cable Jointing S8-188
8.2.4 Cable Markers S8-188
8.3 SIGNAL LANTERNS
8.3.1 Standard Requirements S8-189
8.3.2 Optical Requirements S8-189

8.3.2.1 Optical Arrangement for Drivers S8-189
8.3.2.2 Optical Arrangement for Pedestrians S8-189
8.3.2.3 Height of Signal S8-189
8.3.3. Constructional Requirements S8-190

8.3.3.1 Lamps S8-190
8.3.3.2 Target Boards S8-190
8.4 SIGNAL POSTS AND MAST ARMS
8.4.2 Cable Entry S8-191
8.4.3 Connecting Facilities for Cables S8-191
8.4.4 Location and Erection S8-191
8.4.5 Finish S8-191
8.5 PEDESTRIAN PUSH-BUTTONS
8.5.2 Location S8-192
8.5.3 Pedestrian Demand Indicator S8-192
8.5.4 Audible Signal S8-192

Page
8.6 TRAFFIC CONTROLLER
8.6.1 General Requirements S8-1192
8.6.2 Housing S8-193
8.6.3 Controller Mains Switch Board S8-193
8.6.4 Facility Switch S8-194
8.6.5 Pedestrian Facilities S8-194
8.6.6 Logic Module S8-194

8.6.6.1 Microcomputer System S8-194
8.6.6.2 Input/Output Interfaces S8-195
8.6.6.3 Real 'Time-Of-Day' Clock S8-195
8.6.6.4 Operator Interface and Controller Display S8-195
8.6.6.5 Supply Monitor S8-195
8.6.6.6 Watchdog Timer S8-196
8.6.7 Mains Supply Interruptions S8-196
8.6.8 Circuit Breakers S8-196
8.6.9 Inputs S8-196
8.6.10 Interchangeability S8-196
8.6.11 Vibration and Noise S8-196
8.6.12 Radio Interference S8-196
8.6.13 Safety S8-196
8.6.14 Timing S8-197
8.7 VEHICLE DETECTORS
8.7.2 Number of Traffic Lanes S8-197
8.7.3 Supply Voltage S8-197
8.7.4 Equipment Construction S8-197
8.7.5 Performance Requirements S8-197

Page
8.8 ROADWORKS
8.8.1 General S8-197
8.8.2 Permission to Excavate Road S8-198
8.8.3 Excavation, Backfilling, Reinstatement and maintenance of

Excavations S8-198
8.8.3.1 General S8-198
8.8.3.3 Bedding of Excavation S8-199
8.8.3.4 Cable Ducts S8-199
8.8.3.5 Cable Laying and Installation S8-199
8.8.3.6 Cable Laid Direct On The Ground S8-200
8.8.3.7 Cables Installed in Precast Concrete Trenches S8-200
8.8.3.8 Backfilling of Excavations And Reinstatements S8-201
8.8.3.9 Sensing Loop Slots S8-201
8.8.3.10 Maintenance of drains and Services During Excavations S8-201
8.8.3.11 Reinstatement of Drains and Precast Units S8-202
8.8.3.12 Completion of Works S8-202
8.8.3.13 Maintenance of Excavation S8-202
8.8.4 Traffic Arrangements S8-203
8.8.4.1 General S8-203

8.8.4.2 Arrangement and Location of Signs Barriers and Barricades S8-203
8.8.4.3 Temporary Warning lamps S8-204
8.8.4.4 Use of Traffic Guidance Cones S8-204
8.8.4.5 Temporary Traffic Diversions S8-204
8.8.4.6 Temporary Traffic Control S8-204
8.8.4.7 Plant and Equipment S8-205
8.8.4.8 Vehicles S8-205
8.8.4.9 Maintenance of Signs, Lights, Barriers,Temporary Traffic
Diversions, etc. S8-205

be responsibile for the design,

SECTION 8 - TRAFFIC SIGNALS material quality and
workmanship of the system and
8.1 GENERAL every part of the system offered,
whether manufactured by him or
8.1.1 Scope of Work supplied to him by other
manufacturers. Approval by the
This work shall comprise the design S.O. does not relieve the
of cabling works and the supply and Contractor of these
installation of all signal lanterns, responsibilities.
traffic controllers, detectors, posts,
ducting and cabling, and switchgears Materials shall as far as possible
with all necessary ancillary be of Malaysian origin except
equipment, together with the where such materials can be
transportation, storage, erection, shown to be unavailable in
connection, testing and Malaysia.
commissioning of the same for a
complete traffic signal installation, 8.1.2.2 Cleanliness
all in accordance with the Drawings
and this Specification. The work Particular attention shall be given
shall also include cabling from the in the design of the equipment for
nearest specified power source of the the exclusion of dust, dirt, etc.,
local supply authority to the traffic especially in the case where
control system, if required. forced ventilation is employed.
The type of signal operation, number 8.1.2.3 Metric Range of Preferred

of plans, number and sequence of Dimensions
phases, cycle times, timings of each
phase, offset times, locations of Except as may be agreed for
controllers and power source tapping practical reasons, design shall
points, and other specific make use of the metric range of
requirements shall be as shown on preferred dimensions and
the Drawings. tolerances.
8.1.2 Design and Construction 8.1.2.4 Self-Tapping Screws
8.1.2.1 Contractor's Responsibility Self-tapping screws shall be used

only for retaining duties. They
The Contractor shall design the shall not be used for fixing
interconnecting signal cabling for removable covers, nor for the
the proposed signal system as support of direct loads.
shown on the Drawings. The
cabling design drawings are to be 8.1.2.5 Corrosion
approved by the S.O. before
construction commences. All equipment shall be designed
Equipment offered shall be in all to resist corrosion in the
respects suitable for the Malaysian environment for a
requirements and for the period of 20 years from the date
environmental conditions of installation.
specified. The Contractor shall

8.1.3 Compliance With Manufacturer's replaceable may be accepted with

Instructions the aproval of the S.O.
The Contractor shall ensure that the 8.1.4.3 Components

equipment and parts used shall be
entirely suitable for the work to be All active and passive
performed and that they shall be components, their mounting and
manufactured to proper tolerances the plugs, sockets and
and fit. He shall further ensure that connections, shall be designed
the loading of equipment shall under for a life expectancy of 20 years
all normal circumstances not exceed as specified in Sub-Section
the maximum laid down or agreed to 8.1.4.2. All shall operate well
in writing by the manufacturer. within their ratings with due
consideration for the
The Contractor shall be responsible environmental conditions and
for the inspection of all equipment temperature rises within cabinets
and parts before their incorporation or enclosures.
in the Works to ensure that they
comply with the requirements of this Thermionic valves other than
Specification and that they are not cathode-ray tubes shall not be
defective in any way as regards used.
materials or workmanship. Should
any such non-compliance or defects Metal oxide or grade II carbon
be found during the inspection, the resistors shall be used. Grade I
Contractor shall correct or cause to carbon film resistors shall not be
be corrected such non-compliance used.
and defects, all at the Contractor's
expense and to the satisfaction of the Where high dissipation power
S.O. resistors are used, metal oxide
resistors shall be used whenever
8.1.4 Components and Materials they are available, in preference
to wire wound types.
8.1.4.1 Conditions of Operation
Metal can transistors shall be
The system shall be designed to used wherever possible.
operate continuously. Account Germanium transistors shall not
shall be taken of equipment being be used unless approved by the
sited in all exposed locations. S.O.
8.1.4.2 Maintenance To Be Kept To A 8.1.4.4 Metering

Minimum
The equipment shall be provided
The materials and components, with waveforms and voltage test
excluding expendable items such points as necessary for indicating
as lamps, shall be such as to circuit conditions.
provide a life expectancy of up to
20 years unless specifically stated
otherwise in this Specification.
Components which have a
shorter life span but are easily

8.1.5 Identification of Equipment 8.1.6.3 Isolation From Main Supply
The Contractor shall mark or label Unless otherwise agreed by the

clearly all modules, units and main S.O., systems shall be
parts of the system with a functional completely isolated from the
code or title, type number, trade mains supply by means of a
name and serial number. The suitable double-wound
marking or labelling of main items transformer which shall include
shall be clearly visible on the an earthed screen. The primary
outside. The labels and markings of and secondary output
encased units or modules shall be terminations shall be separated in
visible when the case or cover is an approved manner.
removed. Components shall not be
marked with circuit references. The The main transformers at the
marking shall be adjacent to the controller shall be provided with
component. Markings required for primary tappings so that the
controls, maintenance or warning equipment operates with mains
shall be adjacent to the part supply in the range of 200 to 260
concerned. Markings shall maintain volts.
legibility throughout the life of the
equipment in the specified 8.1.6.4 Earthing of Transformer
environmental conditions. Secondary Circuits
Techniques used shall be approved When a dangerous voltage is

by the S.O. connected to the primary winding
of a transformer, the secondary
8.1.6 Protective Requirements circuit shall be connected where
practicable to an earthed point.
8.1.6.1 General
8.1.6.5 Current Loading of Wires
All metal work not normally
required to carry current shall be All wirings shall be suitably rated
connected to an earth point to carry in excess of the current
except where otherwise dictated permitted by their fuses, circuit
by transmission or other breakers or other current linking
requirements (such metal work devices. Similar precautions shall
shall include cases, screens, be taken to reduce the possibility
cores, cable glands, cable of overheating components.
conduits and cable sheaths, etc.).
Provisions shall be made in the
8.1.6.2 Insulating Bushes equipment :-
Insulating bushes shall be i) to prevent damage to circuits

provided wherever conductors due to failure of any pulses,
carrying dangerous voltages pass power supplies or mains
through holes in metal parts and supply;
where the conductors would be
likely to touch the edge of the ii) to prevent damage to power
holes. supplies by inadvertent
removal of the load.

8.1.6.6 Danger Notices 8.1.6.9 Whiskering of Tin
All equipment or units working Where non-insulated electronic

at a voltage at or above 150 circuits are positioned within 4
volts D.C. or 100 volts A.C. mm of a non-insulated tinned
(RMS) shall be protected by an surface, a loose barrier of
approved cover, which shall be insulated materials shall be
removable. The cover shall have provided between the surface and
a sign with a danger symbol the connection to prevent the
indication of the voltage. The possibility of unwanted contact.
highest voltage to which access Approved soldered-in-lead
can be had by removal of the through connectors are exempted
cover shall be shown, where from this requirement.
dangerous voltages exist.
8.1.7 Electricity Supply
8.1.6.7 Cable Connecting Units
The Contractor shall comply with all
Terminal strips and terminals LLN or the power source authority
shall be clearly and indelibly requirements in getting an electricity
coded. Terminals carrying mains supply to the installation, and any
electrical power shall be costs associated with obtaining this
segregated from other terminals. supply shall be included in the
Unless approved by the S.O., not Tendered rates. The Contractor shall
more than three cable cores shall ensure that the equipment supplied
be retained by any terminal. All will function correctly at the supply
wiring and cabling shall be neat, voltage, and shall allow for normal
adequately supported to prevent variation and surges.
vibration, and so arranged as to
prevent strain on individual 8.1.8 On-Site Commissioning Test
wires, particularly on hinged Procedures
panels.
Testing and commissioning of all
8.1.6.8 Insulation equipment shall be successfully
completed within one (1) month
If no value is specified, the from the date of completion of the
insulation resistance between any installations.
two parts not intended to be in
electrical contact shall not be less The Contractor shall notify the S.O.
than 100 megaohms when when the on-site commissioning
measured at a voltage appropriate tests are to be undertaken. The
to the equipment. Where `n' such Contractor and the Supervisor shall
paths are effectively connected in forward to the S.O. duly certified
parallel, the resistance of the copies of the test results when the
combination shall be not less than tests have been successfully
100/n megaohms. completed. When the S.O. has
received these test results and is
satisfied that the system has passed
the test, the S.O. shall notify the
Contractor in writing that the system
has passed the on-site

commissioning tests. The S.O. shall 8.1.9.2 Hardware, Software and

notify the Contractor in writing of all Maintenance Manual
faults detected during these tests. If
the S.O. decides the system is not in The manual shall contain
accordance with the Contract, he descriptions of the complete
may reject the system, and he shall hardware system followed by
inform the Contractor of the reasons maintenance procedures. A
in writing within a reasonable time. description of the complete
software system shall also be
8.1.9 Documentation included.
8.1.9.1 General The hardware description shall

start with the overall
System manuals for each configuration of the system, with
equipment associated with the layouts showing the location of
Contract shall be delivered to the every unit, with block diagrams
S.O. Reissues shall be provided and an explanation of the
if site commissioning and testing operation of the system.
make this necessary.
Detailed descriptions of
All documentation shall be component units shall explain
indexed and shall carry an issue their operation. Block diagrams
number and date. showing the flow and interaction
of data, logic diagrams, circuit
Two copies each of the diagrams with component
documentation shall be supplied valves, and layout diagrams
to the S.O. shall be provided. Parts lists and
wiring schedules shall be
All documentation shall be provided, but care shall be taken
produced in uniform style in A4 to avoid these obscuring the
size. All diagrams relating to the operational description.
final documentation shall be Maintenance procedures shall
reduced to page height, bound cover the diagnosis of faults,
and correctly referenced to the testing and setting up
text. They shall fold clear of the adjustments, replacement of units
text for ease of use. and routine mechanical servicing.
Great care shall be taken to The software description should

ensure that in the writing of all aim at enabling new programs for
documentation, expert familiarity an intersection to be written, and
with apparently simple features is to provide the basic standard
not advertently assumed. techniques used in writing the
Difficulties should be anticipated. system programs. Where
programming technique is
All documentation shall be in dependent on particular features
English or Bahasa Malaysia. of the system, it is important that
program material is specially
written. This shall be in the form
of guidance, referring to
operational features in the
software manual.
An as-built plan showing the The Contractor shall carry out any
final wiring diagrams, pole repair within 24 hours of being
locations, controller locations, informed of the damages. Upon
detector placement, conduit runs failure to do so, the S.O. has the
and timing plan shall be option to appoint another party for
included in each controller repair and the cost thus incurred will
cabinet. be borne by the Contractor.
8.1.10 Guarantee of Supply All maintenance conducted shall be

entered into the Local Controller
The Contractor shall be required to Logbook, dated and signed by the
ensure that for a period of not less maintenance staff of the Contractor.
than 10 years from the date of
commissioning the system, a supply Repainting of the signal aspects,
of replacement components and posts, and local controllers shall be
materials or their agreed equivalent performed just before the end of the
is available, as the S.O. may require. Warranty Period.
A Contractor who is not a
manufacturer is required to submit a 8.2 LOW VOLTAGE UNDER
letter from the manufacturer GROUND CABLES
certifying that the manufacturer will
support the equipments and 8.2.1 Types of Cables
components.
8.2.1.1 Power Cables
8.1.11 Warranty Period
Power cables shall be
After acceptance of the installation, manufactured and tested in
the Contractor shall still be subject to accordance with M.S. 274 and
obligation of free servicing, change shall have high conductivity plain
in phasing, maintenance and free copper stranded conductors,
replacement of all defective parts and insulated with PVC suitable for a
fused bulbs for a period of twelve voltage of between 600 and 1000
(12) months from the date of issue of V, laid together and bedded with
the Certificate of Completion. A PVC, armoured with galvanised
qualified Service Engineer provided steel wires and sheathed with
by the Contractor must be available PVC. The copper conductors for
on 24 hours service a day to attend to Mains Power cables running
any breakdown at anytime including from the power source to the
public holidays. controller shall have a nominal
cross-sectional area not less than
All repairs and replacements 16 sq.mm. Other interconnecting
required during the Warranty Period signal cables shall be multicore
shall be carried out with despatch cables having copper conductors
and an adequate supply of spares of nominal cross-sectional area
shall be available for this purpose. not less than 1.5 sq.mm with a
The Contractor shall be liable for minimum of 5 cores.
damages if he does not undertake
remedial works within 24 hours.

The current rating of cables shall 8.2.1.4 Earthing Conductors

comply with the appropriate
Tables of the latest IEE Wiring Earthing conductors shall have a
Regulations for the class of nominal cross-sectional area of
conductor used. 2.5 sq.mm and earthing rods shall
have a minimum cross-sectional
8.2.1.2 Feeder Cables for Vehicle area of 10 sq.mm.
Detectors
8.2.2 Cable Termination
The material for feeder cables to
vehicle detectors shall be Unless otherwise permitted, all cable
screened, twisted balanced-twin termination and jointing works shall
cables which shall be be carried out in the presence of the
manufactured and tested in S.O. A plastic laminated plate
accordance with M.S. 274. The engraved with details such as size of
core conductors shall be of cable, number of cores, date of
annealed copper having a commissioning, date of jointing,
nominal cross-sectional area of length of cable, distance of cable
1.5 sq.mm unless otherwise joint, etc., shall be securely fixed
specified. The cable shall have a near the termination.
nominal characteristic impedance
(Zc) of 90 ohms at 50 kHz. PVC/SWA/PVC cables shall be
provided with compression cable
The conductors shall be insulated. gland termination. The cable gland
The insulation shall be shall be of gunmetal or brass and
waterproof and, when installed, shall grip both the inner and outer
shall withstand a temperature of PVC sheath of the cable. It shall be
70ºC without suffering damage or so designed that any strain on the
deformation. cable is taken by the steel wire
armouring which shall be effectively
8.2.1.3 Loop Cables for Vehicle sealed between the gland itself and
Detectors the outer cable sheath.
The material for inductive type 8.2.3 Cable Jointing

vehicle-detector loop cables shall
be in accordance with Australian No cable jointing shall be allowed
Standard 2276.3 unless for interconnecting signal cables.
otherwise specified herein. Any Jointing of mains power cables shall
deviation from A.S. 2276.3 shall be allowed only when approved by
be at the request of or subject to the S.O.
the approval of the S.O. The
detector sensing shall be of a type 8.2.4 Cable Markers
which can be easily assembled
from bulk cable on Site, and Cable markers with lettering and
shall be approved by the S.O. signs as shown on the Drawings
shall be provided by the Contractor
at every change of direction of
underground mains power cable
routes and at every 15 metres on
straight runs. Cable markers shall be

of heavy duty reinforced concrete For horizontal overhead signals,

construction and shall be approved the coloured lens of the left-most
by the S.O. optical system shall be green,
the middle one amber, and the
The cable marker shall form a right-most one red, as seen by the
trapezoidal block with a 100 mm driver.
square top face and 150 mm square
bottom face, and shall be 400 mm in Primary signals shall be fitted
height as shown on the Drawings. with a type A visor and secondary
The top face shall be indented in signals shall be fitted with a type
bold lettering with the initials `L.V.' B visor as described in A.S.
and a directional sign or signs 2144.
indicating the direction/directions of
the cable route. The cable marker 8.3.2.2 Optical Arrangement for
shall be buried to a depth of 300 mm Pedestrians
or any other depth as directed by the
S.O. Cable joint markers of similar Each signal face shall contain
construction but with the symbol `X' two optical systems arranged
shall be provided and installed at vertically, each having a diameter
every cable joint in a similar manner. of not less than 295 mm nor
more than 305 mm, which shall
8.3 SIGNAL LANTERNS incorporate pedestrian symbols as
shown on the Drawings. The
upper optical system shall
8.3.1 Standard Requirements illuminate a red `DON'T WALK'
symbol and the lower one a green
All components, their installation `WALK' symbol. The optical
and performance, shall be in system spacings shall be as
accordance with A.S. 2144 unless shown on the Drawings.
otherwise specified herein. Any
deviation from A.S. 2144 shall be at 8.3.2.3 Height of Signal
the request of or subject to the
approval of the S.O. (a) Post-Mounted Signals
Intended For Drivers
8.3.2 Optical Requirements
The height of signals shall be
8.3.2.1 Optical Arrangement for Drivers such that when erected the centre
of the amber optical system shall
Each signal face shall, unless be not less than 2.4 metres nor
otherwise shown on the more than 4 metres above the
Drawings, contain three optical carriageway level. Where no
systems arranged vertically, each amber signal is installed these
having a diameter of not less dimensions apply to the centre of
than 295 mm nor more than 305 the green signal.
mm. For post-mounted signals,
the coloured lens of the upper
optical system shall be red, the
middle one amber, and the lower
one green.

(b) Light Signals Intended For iv) overall length : 44 mm

Pedestrians maximum;
The height of signal shall be v) overal diameter : 12 mm

such that when erected the maximum;
height of the lower edge of
the housing enclosing the green vi) nominal operating voltage :
signal shall be not less than 2.1 11.7 V.
metres nor more than 2.6 metres
above the carriageway level.
Each tungsten halogen lamp shall
(c) Overhead Mounted Traffic be provided with an appropriate
Control Light Signals transformer complying with the
requirements of B.S. 9720,
The height of overhead mounted mounted within the signal head
signals shall be such that when and connected to a terminal block
erected, the lowest point of the which may be mounted remotely.
signal head assembly shall be not Wiring between the lamp holder
less than 5.5 metres nor more and the transformer and the
than 8.5 metres above the terminal block shall be in
carriageway level. compliance with the requirements
of M.S. 136 and B.S. 6007.
8.3.3 Constructional Requirements
8.3.3.2 Target Boards
8.3.3.1 Lamps
Unless otherwise specified, a
The lamp used in the optical target board shall be provided
system, to meet the requirements with each signal face intended for
of A.S. 2144 Section 3, shall be vehicle drivers, extending not less
a 12 V, 50 W, long life tungsten than 275 mm above the centre
halogen lamp. of the upper optical system nor
less than 275 mm below the
The bulb shall be clear, centre of the lower optical
uncoloured and the filament shall system. It shall extend not less
only be used in the horizontal than 280 mm horizontally either
position. The lamp shall meet the side of the vertical centre line of
following requirements as tested the optical system. Other types
in A.S. 2144 :- of target boards shall be as shown
on the Drawings. The target
i) nominal lumens : 820 boards shall be manufactured
lm at 12 V; from a durable resilient material
and shall be stiffened where
ii) nominal life : 2000 hours necessary to resist distortion due
continuous to wind and extreme ambient
burning at temperature. All target boards
12 V input; shall have an orange border not
less than 45 mm nor more than
iii) nominal colour temperature : 55 mm wide.
2850 K at 12 V input;

8.4 SIGNAL POSTS AND MAST 8.4.3 Connecting Facilities for Cables
ARMS
Provision shall be made for the
8.4.1 Standard Requirements connection of terminating and inter
connecting cables coming from
All signal posts, signal mast arms within the post or mast arm and of
and mountings of signal lanterns cables from the traffic signal
shall be as shown on the Drawings. lanterns.
The posts and mast arms shall be so
designed and constructed as to 8.4.4 Location and Erection
provide adequate support and
stability for the signal head assembly. The posts and mast arms shall be
erected at the approximate locations
All signal posts shall be of tubular as shown on the Drawings. On
hollow section of steel with a roadways whose edges are defined
nominal diameter of 100 mm and by a raised kerb, the posts shall be
fitted with a weather-proof cap to erected so that no part of the signal
prevent ingress of water. head other than overhead signals
projects over the roadway.
Mast arms shall be tubular hollow
sections of steel of a generally Where possible, the signal should
tapered form mounted on a baseplate have a clearance of 300 mm to 450
as shown on the Drawings. mm behind the kerb line. The post
shall be at a distance not less than 1
Every post shall be provided with metre before the edge line.
one nickel-plated brass earthing
screw located within the post, 25 In areas where there is no kerb, the
mm below the top. steel posts should be erected so that
the signal head is clear of the
The posts and mast arms shall be shoulder (or usable area) and
capable of having holes drilled in the should not be less than 2 m nor
vertical section, 1 metre above the more than 3 m from the edge of the
ground, for the mounting of one nearest traffic lane.
pedestrian push-button assembly in
accordance with Sub-Section 8.5. All posts and mast-arms shall have
their exact location determined by
8.4.2 Cable Entry the S.O. and recorded on the as-built
Drawings.
Buried posts shall incorporate a
cable-entry aperture as shown on the 8.4.5 Finish
Drawings. Baseplate-mounted posts
shall provide for entry of the cable Unless otherwise specified, the
into the interior of the post through a interior and exterior of steel posts
hole in the baseplate having a shall be protected by a finish
diameter not less than the inside complying with the requirements of
diameter of the post. M.S. 740.

The exterior surface of steel posts shall be 8.5.4 Audible Signal

painted with alternate black and orange bands
of 300 mm width in weather resisting plastics An audible signal shall, unless
material as specified in Clause 6 of B.S. 873, otherwise specified, be provided
Part 1, and as shown on the Drawings. with all pedestrian push-buttons in
accordance with A.S. 2353.
Any surface cut after galvanizing, painting, or
the application of the plastics finish, shall be 8.6 TRAFFIC CONTROLLER
wire brushed and given two coats of good qual-
ity zinc-rich paint in accordance with B.S. 8.6.1 General Requirements
4652.
A controller is the complete timing
8.5 PEDESTRIAN PUSH-BUTTONS mechanism which controls the
signal phases at an intersection. The
8.5.1 Standard Requirements controller shall be microprocessor-
based consisting of :-
All pedestrian push-buttons, their
mechanism and operation, shall be i) a microprocessing unit;
in accordance with A.S. 2353
unless otherwise specified herein. ii) interfacing for inputs and outputs;
Any deviation from A.S. 2353 shall
be at the request of or subject to iii) ancillary equipment.
the approval of the S.O.
The control equipment and
8.5.2 Location components shall be housed in a
weatherproof cabinet as specified in
Pedestrian push-button detectors Sub-Section 8.6.2.
shall be provided facing the footpath
at each end of each crosswalk where The controller shall be able to
pedestrian actuated signals are provide four phases and shall be
required as shown on the Drawings. capable of expansion to at least eight
phases by the addition of modules on
8.5.3 Pedestrian Demand Indicator site, which shall be in addition to any
special phase required in connection
When the button is pressed, an with start up sequences, all reds,
internally illuminated panel shall etc. It shall also provide a variety of
light up bearing the legend `NANTI', timing functions and differing
which shall be white on a black or operational modes. The controller
blue background. It shall continue to unit shall be capable of operating a
be displayed until the cross signal minimum of eight plans in a 24 hour
(green man) commences. The period. All active and passive
pedestrian demand indicator shall be components, their mountings and
provided with all pedestrian push- plugs, sockets and connections
buttons unless otherwise shown on shall be suitable for their application.
the Drawings.

8.6.2 Housing All means of access shall be

protected by locks of different
The housing shall have a patterns and the corresponding locks
weatherproof enclosure for the and keys shall be identical for
protection of :- controller housings of the same
make, type and series. Not less
i) the logic module; than two keys of each type shall be
supplied with each controller and
ii) interfacing and/or lamp switching they shall be handed over to the S.O.
modules; after the completion of testing and
commissioning.
iii) power supplies;
A log book shall be provided in each
iv) a `call-recorded' tranformer; housing for the purpose of
maintenance and inspection records.
v) mains switch board; The log book shall be attached to the
housing by a cord or similar method
vi) facility switch; to prevent removal from the housing
cabinet. A pocket or shelf shall be
vii)shelf space for mounting of provided within the housing for its
vehicle detectors. storage.
The housing cabinet shall be in 8.6.3 Controller Mains Switch Board

accordance with A.S. 2578, Part 1,
unless otherwise specified herein. The controller mains switch board
Any deviation from A.S. 2578, Part shall consist of :-
1, shall be at the request of or
subject to the approval of the S.O. i) one mains switch and one mains
fuse (rated 30 A);
Housing shall be manufactured from
such material approved by the S.O. ii) one isolation switch together with
a fuse to control mains supply,
Appropriate means of entry and active to all lamps;
support for cables shall be provided.
iii) one flashing yellow feature
Sufficient ventilation shall be switch and fuse;
provided to prevent condensation
inside the cabinet under all weather iv) one equipment switch and fuse
conditions. Charcoal or some other (rated 15 A) to supply four
dehydration agent shall be placed in sub-circuits labelled as :-
the housing as directed by the S.O. . controller
. detectors
All non-current carrying metal parts . auxiliary
shall be bonded together and . general purpose outlet;
effectively earthed in accordance
with CP 1013. v) neutral link;
vi) earth link.

The controller shall be suitable for When the pedestrian indications are
operation at 240 V + 6%, 50 Hz + allowed an exclusive phase, the
1%, single phase A.C. supply. pedestrian steady green shall be
controlled by the appropriate control
8.6.4 Facility Switch command and followed by the
flashing green pedestrian signal. The
A facility switch shall be provided to intergreen periods shall be inserted
switch the signal lanterns to ON, before the pedestrian steady green
OFF or FLASH or other facilities and between the end of the flashing
such as manual operation. The green and the start of the next
switch shall only control the signal vehicle phase green. It shall be
lamps and flashing yellow circuits possible to operate the pedestrian
while leaving the control equipment phase with or without pedestrian
fully operative. detection. This shall be selected by a
switch or other methods within the
Access to this facility shall be via a controller, subject to the approval of
separate locked door or some other the S.O.
means which does not give access to
the controller. The facility shall be 8.6.6 Logic Module
located not less than 1 metre from
the ground level. Arrangement of the microprocessor
based logic module shall be subject
8.6.5 Pedestrian Facilities to the approval of the S.O.
Pedestrian indications shall be 8.6.6.1 Microcomputer System

allocated as exclusive phases or be
connected in parallel to a green The microcomputer system shall
phase(s). contain a stored program in read-
only-memory (ROM). Part or all
When the pedestrian indications are of the ROM shall be
connected in parallel to a green reprogrammable. The stored
vehicle phase, the steady pedestrian program shall permit the traffic
green shall commence at a preset controller to be operated in
period adjustable to 0, 1, 2, 3, 4 different traffic modes as
or 5 seconds before or after the start follows :-
of the green vehicle phase. The
steady pedestrian green shall persist i) isolated traffic-actuated
until the end of a preset period. operation;
It shall be followed by the flashing ii) cableless/Synchronous

pedestrian green. The flashing operation;
pedestrian green shall flash at 76 to
84 flashes per minute, and the lamp iii) fixed time operation.
shall be on for between 50% to
70% of the time. The amber signal All information relating to a
terminating the vehicle green phase particular signal installation,
shall not commence until a preset such as number of plans, signal
period adjustable to 0, 1, 2, 3, 4 or groups, detector logic, time
5 seconds has elapsed after the setting and description of logical
termination of the flashing pedestrian
green.
and conditional features, shall be The clock shall derive its timing
contained in the reprogrammable from two sources, either from the
ROM. 50 Hz mains supply or a crystal
oscillator. When the mains
Time settings may be stored by supply is normal, the 50 Hz
means of :- mains frequency shall provide the
time. The crystal reference signal
i) reprogrammable ROM; and shall be phase locked to the
mains frequency by a digital
ii) battery back-up RAM. phase locked loop. The real time
clock shall provide time in
The RAM settings shall be such seconds, minutes, hours and
that they may be changed by days to the microprocessor via a
means of a detachable keyboard data bus.
while the controller is
functioning. The reprogrammable 8.6.6.4 Operator Interface and Controller
ROM shall be separate from the Display
CPU and its associated circuitry
to facilitate field servicing. A keyboard display unit shall be
provided as an operator interface
8.6.6.2 Input/Output Interfaces with the controller logic module.
Visual indicators shall be
The Contractor shall provide for provided to indicate the status of
the approval of the S.O., detailed various traffic parameters such as
technical information on the the phase currently running, base
input and output interfaces. phase step for each phase,
Inputs include those from vehicle demand for each phase, pedestri
detectors, pedestrian push an demands recorded, etc.
buttons and signal links. The
output shall be to the vehicle When operated in link mode, the
signal lamps, pedestrian lamps, display shall be able to provide
wait indicators and signal all traffic parameters associated
linking. with the appropriate link mode.
8.6.6.3 Real `Time-of-Day' Clock 8.6.6.5 Supply Monitor
For cableless/synchronous All D.C. power supplies to

linking operations, a hardware various cards in the logic module
clock shall be provided. The shall be constantly monitored to
circuit generating the hardware ensure correct operation of the
clock shall be backed up by a controller.
standby battery for up to 48
hours or more (when fully The monitor shall be arranged so
charged). that if one or more of the supply
output voltages falls below
certain preset levels, the power
failure detection circuit will
activate to cause the controller to
black out the intersection.

The mains supply voltage shall 8.6.10 Interchangeability

also be monitored. Any voltage
drop below certain levels shall All parts shall be interchangeable
cause a black out situation. with like parts for equipment of the
same make, type and series.
8.6.6.6 Watchdog Timer
8.6.11 Vibration and Noise
A watchdog timer shall be used
to detect failure of the The apparatus shall be reasonably
microprocessor system to execute quiet and the mechanism shall not
its traffic control program. Any cause undue vibration. The
failure to execute traffic apparatus shall be constructed so as
instruction shall black out the to reduce to a minimum any damage
intersection. to lamps and equipment due to
vibration caused by traffic.
8.6.7 Mains Supply Interruptions
8.6.12 Radio Interference
In the event of a mains supply
interruption equal to or less than The design of equipment shall be
50 milliseconds, the controller shall such as to prevent interference to
continue to function correctly. When telegraphic, telephonic or
a controller commences to fail (after radiotransmissions. The
a mains supply interruption in apparatus will be considered to
excess of 50 milliseconds) it shall meet this requirement, as far as
shut down for the duration of the radio interference is concerned,
mains interruption plus a nominal if the interference produced by it
period of about 5 - 10 seconds. At does not exceed the limits laid
the expiration of this nominal period down in M.S. 71 and B.S. 800.
the controller shall commence
operation at an all red state. This 8.6.13 Safety
state shall persist for at least 5
seconds and shall be followed by Where right of way signals are
the pre-selected phase. shown for any controlled traffic
in one phase, it shall not be
8.6.8 Circuit Breakers possible through failure of any
operating component of the
Appropriate fuses or circuit breakers controller to give a right of way
shall be provided by the Contractor signal to a conflicting traffic
for the connection of the controller to signal.
the mains supply. A mains isolation
switch shall also be provided. The Contractor shall satisfy the
S.O. as to how the conflicting
8.6.9 Inputs green state can be detected and
what action is to be taken on its
All inputs shall be suitably protected detection. The use of two
against high voltage peaks and short independent safeguard systems is
circuits. favoured. A method of testing
the operation of the safeguards
shall be provided.

The Contractor shall satisfy the 8.7.3 Supply Voltage

S.O. as to how the conflicting
green state can be detected and The detectors shall operate on 240
what action is to be taken on its V + 6%, 50 Hz + 1% single phase
detection. The use of two A.C. power supply. Power shall be
independent safeguard systems is supplied from the traffic controller.
favoured. A method of testing
the operation of the safeguards 8.7.4 Equipment Construction
shall be provided.
The Contractor shall be responsible
8.6.14 Timing for the manufacture, installation and
commissioning of the detector
The duration of all periods timed system.
by the controller shall be within
+ 10% of the nominal time when 8.7.5 Performance Requirements
the applied main voltage is within
the range between + 10% of the The detector shall respond to any
nominal value and + 4% of its vehicle, except bicycles and
nominal frequency. This shall trishaws, normally encountered on
apply to those timing public roads travelling at any speed.
arrangements which measure The Contractor shall satisfy the S.O.
selected fixed periods. The with respect to the accuracy of the
flashing rate of any flashing detector unit in terms of false or nil
signals shall be between 76 and presence actuation at normal
84 flashes per minute within the operating sensitivity for all types of
same voltage and frequency vehicles including high-bodied
limits. vehicles and multi-axle vehicles.
8.7 VEHICLE DETECTORS 8.8 ROADWORKS
8.7.1 Standard Requirements 8.8.1 General
All equipment, its construction and The Contractor shall carry out all
performance, shall be in accordance necessary roadworks in connection
with A.S. 2703 unless otherwise with the installation of the system.
specified herein. Any deviation from These shall include any roadworks
A.S. 2703 shall be at the request of associated with :-
or subject to the approval of the
S.O. i) installation of Local Controller
and Detector Recording
8.7.2 Number of Traffic Lanes housings;
The loop detector shall sense traffic ii) installation of signal poles and
flow on one to four traffic lanes heads;
depending on where it is installed. It
shall sense traffic moving in one iii) installation of cable ducting;
direction only and detection on a two
way road shall be achieved by using
two sets of detectors so that the
information obtained for each
direction is separate.
If an existing conduit has been 8.8.3 Excavation, Backfilling

installed across the road carriageway, Reinstatement and Maintenance of
all cross-carriageway cabling shall Excavations
be carried by this conduit.
8.8.3.1 General
8.8.2 Permission to Excavate Road
The Contractor shall cause as
The Contractor shall apply to the little obstruction as possible to
S.O. for approval to excavate the the general public during the
roadway. This approval shall not be execution of all works under this
unreasonably withheld. Contract, and shall pay due
regard to the interests and
The application shall be made not convenience of the public and of
less than seven (7) days before the all private persons who have
commencement of the work. property in or are resident in the
neighbourhood of the works.
The Contractor shall comply with the
following conditions and other The Contractor shall ensure that
additional instructions from the no delay occurs between opening
S.O. :- excavations, laying cables,
backfilling and reinstatement and
i) trenching in sidetables, footpaths that these actions form a
and carriageways shall be continuous process.
excavated, backfilled, reinstated
and maintained as specified in 8.8.3.2 Excavation
this Sub-Section;
Each trench shall be excavated to
ii) cables to be laid in carriageway the required level and materials
shall be at least 750 mm below taken out shall not be re-used
the carriageway level; unless otherwise specified or
iii) cables running longitudinally in
footpaths and side-tables shall be For excavation in side-tables,
at least 600 mm clear of the turfs shall be carefully removed,
edge of the kerb line or stacked and periodically watered
carriageway and at least 750 mm for later re-use. The remaining
below the adjacent carriageway excavated materials may be
channel level; stockpiled on the Site for later
backfilling but excavated topsoil
iv) no work shall be done during shall be kept separate.
traffic peak hours unless
approved by the S.O. For excavation in carriageways
and footpaths, selected granular
materials, excavated premix and
subbase may be stockpiled on
Site for later backfilling. All
other unsuitable excavated
material must be removed to
spoil on the day it is excavated.

All excavated materials shall be necessary to cross drains, culverts

kept clear of the carriageways at or similar obstructions which are
all times. too deep for the cables to be
buried below, galvanised steel
All sides of excavations shall be pipes shall be provided. The
vertical. In soft or unstable pipes shall be supported at each
ground the sides shall be end in a concrete block and
adequately supported. shall project through the blocks
into the ground to a depth of a
All excavations shall be kept free least 750 mm. All ducts shall be
of standing water. extended at least 600 mm beyond
paved areas, concrete areas,
If, for unavoidable reasons, a drains, road crossings, pipe
trench running laterally across a crossings, etc.
road cannot be backfilled and
must be left open overnight or for Unless otherwise approved by the
a longer period, then steel plates, S.O., the number of cables
securely bolted and adequate to installed in each duct shall be
take traffic loading, shall be such that the space factor shall
placed across the trench and the not be less than 60 %. A drawn
section of road opened to traffic. wire shall be provided in each
duct.
8.8.3.3 Bedding of Excavation
Unless specified to be provided
Before ducts are laid, the trench by others, the above galvanised
beds shall be levelled and sand steel pipes shall be provided by
placed on the bed and hand the Contractor whether they are
tamped to a thickness of not less shown on the Drawings or not.
than 75 mm. All ducts shall be
covered by a layer of sand hand 8.8.3.5 Cable Laying and Installation
tamped to a thickness of at least
75 mm above the crown of the All cables shall be handled, laid
duct. and installed according to this
Specification, the IEE Wiring
8.8.3.4 Cable Ducts Regulations, cable manufacturer's
recommendations and ERA
At road crossings, sewerage pipe Reports by using proper
crossings, water pipe crossings, installation equipment.
paved areas, concrete areas and
areas specified by the S.O., All cables shall be supplied in
cables shall be protected by complete length to suit the
galvanised steel pipes buried to a circuits they serve and no straight
depth of 900 mm below through joints shall be used.
finished ground level. The pipes Straight through joints in the
shall be heavy duty pipes, cable will only be permitted in
complying with B.S. 1387, very exceptional circumstances
complete with screwed and such as those arising from
socketed joints. Unless otherwise unavoidable limitations in
specified, the pipes shall be 150 manufacturing length. If straight
mm in diameter. Where it is through joints or other approved

joints are permitted by the S.O., the underground cable if the

the cost of such joints shall be cable size is not more than 120
borne by the Contractor. No sq.mm. For cable sizes
joints in the cable will be allowed exceeding 120 sq.mm, more
unless approved in writing by the than one row of bricks shall be
S.O. laid. Each cable shall be
separately protected by these
The minimum bending radius bricks and the cover shall have at
of the cable shall be in least 25 mm overhang on each
accordance with Table 52C of side of the cable.
the IEE Wiring Regulations (15th
Edition). Wherever cables are An orange coloured, multi-strand
cut, the ends shall be nylon rope of minimum 6 mm
immediately sealed in an diameter shall be laid at a depth
approved manner unless it is of 300 mm along the trench to
intended to proceed with cable identify the cable route. At every
jointing or termination straight 10 metres interval, an extra 2
away. metres length of nylon rope shall
be coiled and laid.
Unless otherwise permitted by
the S.O., no cable shall be laid 8.8.3.7 Cables Installed in Precast
and covered up in the absence of Concrete Trenches
the S.O.
Methods of installation of cables
in precast concrete trenches shall
8.8.3.6 Cable Laid Direct On The be in accordance with Table 9A
Ground of the IEE Wiring Regulations
(15th Edition) for Type L, Type
Where trench beds have been M or Type N cables. However,
covered with sand, the cables if the method is not specified, the
shall then be laid on this bedding cables shall be installed as
in an orderly manner without directed by the S.O.
overlapping and crossing each
other. After laying the cables, a Cables laid at the bottom of
layer of 75 mm clean sand shall trenches shall be Type L cables
cover the cables and shall be in accordance with Table 9A of
carefully spread over the trench the IEE Wiring Regulations (15th
before placing the cable Edition). Cables installed on the
protective covers. trench walls shall be Type M or
Type N cables in accordance
The cable protective covers shall with Table 9A of the IEE Wiring
be clay bricks. The bricks shall Regulations (15th Edition) and
be new, well burnt and in the cables shall be secured on a
complete pieces. They shall be cable tray by means of saddles at
laid lengthwise from end to end suitable intervals. In the case of
along the entire route of the single core cables, whether
underground cable if the cable secured individually or in groups
size is not more than 120 sq.mm. to the cable tray, non ferrous
For cable sizes exceeding 120 saddles shall be used.
sq.mm, more than one row of

The cable tray shall be fabricated For excavations in carriageways

from perforated hot-dipped and footpaths the backfilling shall
galvanised sheets finished in an be done in 150 mm layers to
orange enamel. The minimum within 300 mm of the surface
thickness of the sheet steel used level using clean sand and
shall be 1.5 mm for cable trays suitable excavated granular
with widths of up to 300 mm material or other approved
and shall be 2.0 mm for widths granular material. Each layer
exceeding 300 mm. The cable shall be compacted using a power
tray shall be supported at least driven rammer. The next 230
25 mm from the trench wall by mm of backfill shall consist of
mild steel brackets at 600 mm crushed aggregate roadbase con
intervals. The brackets shall be forming to Sub-Section 4.1.4 of
treated with anti-rust and painted this Specification, laid and
with one coat of primer. Samples compacted by a power driven
of the cable tray and brackets rammer. A tack coat of cationic
shall be submitted to the S.O. for bituminous emulsion shall be
approval prior to installation. applied on the crushed aggregate
surface and a 75 mm thick layer
To provide electrical continuity, of compacted asphaltic premix
all cable joints shall be bridged shall be placed as the final layer,
by means of tinned copper tape all in accordance with the
of dimensions not less than 25 relevant requirements of Section
mm x 3 mm. All saddles for 4 of this Specification.
cables on cable trays shall be
installed using bolts, washers 8.8.3.9 Sensing Loop Slots
and nuts. All tees, intersection
units, adaptor units, etc., shall The Contractor shall be
be factory manufactured unless responsible for providing the slot
otherwise approved by the S.O. in the roadway for the loop
sensor; the installation and
8.8.3.8 Backfilling of Excavations and jointing of the loop feeder cable;
Reinstatements the backfilling of the slot in the
roadway; and the slot or trenches
For excavations in sidetables, for the feeder cables, all as
berms and slopes, the excavated shown on the Drawings.
material shall be replaced in 150
mm layers in the reverse order to 8.8.3.10 Maintenance of Drains and
which the material was Service During Excavations
excavated. Each layer shall be
compacted with a power driven The Contractor shall ensure that
rammer. The top 150 mm of he has full knowledge of the
the excavation and adjacent location of all drains and services
disturbed ground shall be filled in the area of any excavation
with good loamy topsoil and prior to the excavation
hand tamped. Approved quality commencing. The Contractor
grass turfs shall be closely and shall ensure that all precautions
continuously fitted over the are taken not to disturb such
topsoiled area where necessary drains and services and shall be
and directly pegged down to
prevent displacement.
responsible for their maintenance 8.8.3.13 Maintenance of Excavation

during the reinstatement of such
excavations. The Contractor shall be entirely
responsible for the proper
The Contractor should note if the maintenance and good condition
Site of the Works is subject to of each excavation and each
frequent and heavy rainfall and reinstatement up to a period of
all precautions shall be taken to three (3) calendar months after
maintain existing drainageways the date of the S.O.'s written
to prevent flooding. approval of such reinstatement
works.
8.8.3.11 Reinstatement of Drains and
Precast Units All excavation sites prior to,
during, and after reinstatement
The Contractor shall carry out the shall be maintained in a sound
reinstatement of all existing and firm condition, free from
precast channel drains, gulleys, depressions, humps, loose stones
pavement slabs, dividers, kerbs, and any other similar defects
etc., which have been affected by such as not to constitute danger
any trench opening. Only or unreasonable nuisance to
excavated units in a sound and traffic or members of the public.
undamaged condition may be Loose materials or stones shall
replaced, otherwise the not be allowed to accumulate
Contractor shall supply and lay over or around any excavation,
similar new units. The units shall but shall be promptly swept clear.
be replaced to the original lines
and levels and shall be bedded, Any part of reinstatement in a
backed and jointed to the footpath or carriageway that
satisfaction of the S.O. settles more than 15 mm below
the adjacent undisturbed surface
8.8.3.12 Completion of Works level shall promptly be re-
surfaced to a level not more than
On completion of reinstatement 15 mm above the adjacent
works at any one site, the undisturbed surface level. The
Contractor shall clear away all resurfacing shall be carried out by
debris, surplus materials and applying a prime/tack coat and
plant and leave the site in a clean asphaltic premix as specified in
and tidy condition. The Section 4 of this Specification.
Contractor shall carry out any
further remedial works as The Contractor shall be required
directed by the S.O. and shall to maintain a small mobile gang
obtain the S.O's written approval of workmen for the above
for the reinstatement works. purpose, and a regular system of
daily inspection shall be instituted
for all trenches awaiting
temporary and permanent rein
statement. Should the Contractor
default in the maintenance of
excavations and reinstatement
where, in the S.O.'s judgement,

such default would constitute in On multilane roads, not more

any way a traffic hazard, then than one traffic lane in either
the S.O. shall have the power to direction shall be closed except as
attend forthwith to such defects may be otherwise directed by the
and the entire cost of the work S.O. On roads of not more than
plus 25% shall be borne by the one traffic lane in each direction,
Contractor. the Contractor shall ensure that
both lanes are kept open during
Before the expiration of the peak periods as previously
maintenance period of each item defined. This may be
of work, the Contractor shall accomplished by the use of steel
write to the S.O. for final plates as specified in Sub-Section
inspection of the work to 8.8.3.2.
determine any outstanding
defects which have to be When the work is such that the
rectified. The Contractor will simultaneous closing of several
only be absolved of all the lanes cannot be avoided and
responsibilities of the would cause undue interference
maintenance after such defects with traffic, the work should
are rectified to the satisfaction of either be carried out at night or
the S.O. during weekends. However, the
S.O. may give permission for the
In the event that the Contractor simultaneous closing of lanes for
fails to notify the S.O. of the date emergency works or other works
of expiration of the maintenance as deemed necessary.
period and has not arranged for
the inspection of the work, the 8.8.4.2 Arrangement and Location of
maintenance period of each item Signs, Barriers and Barricades
of work shall be deemed to have
been extended by the Contractor The general arrangement and
due to his fault to such time until location of temporary signs at
the final inspection is carried out. works in progress shall be strictly
in accordance with ARAHAN
8.8.4 Traffic Arrangements TEKNIK (JALAN) 2C/85,
published by Cawangan Jalan,
8.8.4.1 General Ibu Pejabat JKR, Kuala Lumpur,
and shall be submitted by the
Obstructions and excavations Contractor and approved by the
shall be adequately fenced and S.O. before work commences.
guarded at all times for the
protection of all persons who use Work on a road involving less
the roadway. Particular attention than one-third of a traffic lane
shall be paid to the positioning of and work on a footpath in the
the barriers. The whole immediate vicinity of the
obstruction or excavation shall be carriageway of a high speed road
completely fenced off, but shall be deemed to be minor
unnecessary blocking of traffic obstructions. In these cases, as it
lanes shall not be permitted. will not be necessary to close up
Roads shall not be used for the one full lane, shorter barriers
unnecessary storage of materials. shall be used.

All traffic signs used in Cones shall be of rubber or

temporary signing must be equivalent flexible material and
reflectorised. When practicable, shall be bright orange in colour.
signs shall be sited where they
will receive maximum benefits 8.8.4.5 Temporary Traffic Diversions
from street lighting.
For the duration of the work, a
8.8.4.3 Temporary Warning Lamps satisfactory roadway shall be
provided for the traffic. Where a
Temporary warning lamps shall sufficient width of carriageway is
be used during the hours of not available, a temporary traffic
darkness in conjunction with all diversion shall be constructed if
temporary signs, barriers and possible. The extra carriageway
other traffic control devices shall be properly maintained in a
which are to remain in position at smooth and hard condition at all
night. Lamps shall be kept alight times for the duration of the
at all times during the hours of work.
darkness.
The maintenance of pedestrian
Warning lamps shall consist of movement shall be provided by
standard battery operated flashing construction of temporary walks,
lights and shall be placed at barricades and handrails. Certain
salient points of the site every areas along the construction site
night. may be restricted to pedestrian
use where such restrictions are in
8.8.4.4 Use of Traffic Guidance Cones the interest of pedestrian safety.
When a portion of a roadway is 8.8.4.6 Temporary Traffic Control

closed to traffic by the use of
barriers, barricades or signs, It is essential that traffic control at
traffic guidance cones shall be the site be exercised diligently
placed on the road so as to guide and by competent personnel, if
traffic smoothly from the wide the need arises.
section to the narrow section in
which a portion of the roadway The methods of temporary traffic
has been closed to traffic. control are :-
Cones shall be used only when i) Police supervision : this

the work is in progress or where applies where the works are
there is a watchman who can of a very short duration with
reposition any of the cones which some special feature, such as
may have been dislodged by the a busy road junction;
traffic. Otherwise they shall be
removed from the roadway when ii) Manually operated 'Stop' and
work ceases at night. At night, 'Go' signs : this applies at
continuously operating flashing works of short duration,
lights shall be used to guide the provided that traffic is not
traffic. dense. Red and green flags
should, under no

circumstances, be used for flashing lights on the top of the

traffic control, but could be vehicles. They should also have a
used to supplement the disc plate on the rear side with the
signs. words `SLOW MOVING' or
`KENDERAAN PERLAHAN'.
8.8.4.7 Plant and Equipment
8.8.4.9 Maintenance of Signs, Lights,
In all cases where traffic is Barriers,Temporary Traffic
permitted to use the whole or a Diversions, etc.
portion of the existing road, all
plant items and similar Signs, lights, barriers and other
obstructions shall be removed traffic control devices shall be
from the road at night, if at all maintained in good order and in
practicable. During the day, a red the correct position day and
flag shall project beyond the night. Signs shall be neat, clear
extremity of all plant items (other and legible at all times.
than vehicles) adjacent to the Temporary traffic diversions shall
traffic lane. be maintained in good order at all
times.
Plant and equipment shall be lit at
night if within 5 metres of the
edge of the carriageway by two
red lights suspended vertically
from the point of obstruction
nearest to the carriageway. The
lights may be omitted in cases
where there are permanent
obstructions, such as trees less
than 5 metres from the edge of
carriageway and the plant or
equipment are not closer to the
road than the permanent
obstructions.
8.8.4.8 Vehicles
Vehicles which carry out

operations on the road and which
are required to travel slowly or to
stop at frequent intervals should
be made as conspicuous as
possible. This shall be achieved
by painting such vehicles a
distinctive colour, and/or
painting their rear portions with
diagonal stripes of a contrasting
colour, and/or providing

SECTION 9
CONCRETE

SECTION 9 - CONCRETE
Page
9.2 MATERIALS S9-211
9.2.1 Cement S9-211

9.2.1.1 Transportation and Storage S9-211
9.2.2 Aggregates S9-211

9.2.2.1 Coarse Aggregates S9-211
9.2.2.2 Fine Aggregates S9-211
9.2.2.3 Grading S9-211
9.2.2.4 Sampling and Testing of Aggregates S9-212
9.2.2.5 Storage of Aggregates S9-213
9.2.3 Water S9-213
9.2.4 Admixtures S9-214
9.3 CLASSIFICATION OF CONCRETE MIXES S9-214
9.3.1 Requirements for Prescribed Mixes S9-214
9.3.2 Requirements for Designed Mixes S9-215

9.3.2.1 Target Mean Strength S9-215
9.3.2.2 Suitability of Proposed Mix Proportions S9-216
9.3.2.3 Mixes S9-217
9.3.2.4 Control of Strength of Designed Mixes S9-217
9.3.3 Requirements for Concrete

9.3.3.1 Workability S9-218
9.3.3.2 Concrete Grade S9-218
9.3.3.3 Minimum Cement Content S9-218
9.3.3.4 Maximum Cement Content S9-218
9.3.3.5 Total Chloride Content S9-219
9.3.3.6 Maximum Sulphate Content S9-220
9.4 COMPLIANCE WITH SPECIFIED REQUIREMENTS
9.4.1 Prescribed Mix S9-220
9.4.2 Designed mix S9-221

9.4.2.1 Characteristic Strength S9-221
9.4.2.2 Sampling and Testing S9-221
9.4.2.3 Testing plan S9-222
9.4.3 Additional Cubes S9-223

Page
9.5 PRODUCTION OF CONCRETE
9.5.1 Supervision S9-223
9.5.2 Batching and Mixing S9-223
9.5.3 Transporting S9-224
9.5.4 Placing S9-224
9.5.5 Temperature Requirements S9-226
9.5.6 Compaction S9-226
9.5.7 Curing and protection S9-227

9.5.7.1 Normal Curing S9-227
9.5.7.2 Accelerated Curing S9-228
9.5.8 Ready-Mixed Concrete S9-228
9.6 CONSTRUCTION WITH CONCRETE
9.6.1 Construction Joints S9-228
9.6.2 Fixing Blocks, Brackets, built-In-Bolts, Holes, Chases, etc. S9-229
9.6.3 Precast Concrete Construction

9.6.3.1 Manufacturer Off the Site S9-230
9.6.3.2 Storage S9-230
9.6.3.3 Handling and Transport S9-230
9.6.3.4 Assembly and Erection S9-230
9.6.3.5 Forming Structural Connections S9-230
9.6.3.6 Protection S9-231
9.7 STEEL REINFORCEMENT
9.7.3 Construction Method S9-232

9.7.3.1 Cutting and Bending of Reinforcement S9-232
9.7.3.2 Fixing of Reinforcement S9-232
9.7.3.3 Splicing S9-233
9.7.3.4 Supporting and Spacer Blocks S9-233
9.7.3.5 Welding of Reinforcement S9-233

Page
9.8 FORMWORK AND SURFACE FINISH FOR STRUCTURE
9.8.1 Design and Construction

9.8.1.2 Voids In Concrete S9-234
9.8.1.3 Form Lining S9-235
9.8.1.4 Projecting Reinforcement, Fixing Devices S9-235
9.8.2 Finishes
9.8.2.1 Formed Surfaces S9-235
9.8.2.2 Unformed Surfaces S9-236
9.8.2.3 Remedial Treatment of Surfaces S9-236
9.8.3 Preparation of Formwork Before Concreting S9-237
9.8.4 Removal of Formwork S9-237

SECTION 9 - CONCRETE Manufacturer's certificates of test will, in

general, be accepted as proof of
9.1 DESCRIPTION soundness. Additional tests shall be
carried out on any cement which
This work shall consist of the appears to have deteriorated through
construction of all structures or parts of age, damage to containers, improper
structures to be composed of Portland storage or any other reason. In any
cement concrete with or without steel event, the batch of cement which has
reinforcement, except for reinforced been sampled and tested and found not
concrete pipe culverts, which shall be to have complied with the requirements
constructed in accordance with the shall be rejected and removed from the
provisions of Section 3.9, and Portland Site.
cement concrete pavement, which shall
be constructed in accordance with the 9.2.1.1 Transportation and Storage
provisions of Section 5. The work
shall be carried out all in accordance The cement shall be transported
with this Specification and the lines, to the Site in covered vehicles
levels, grades, dimensions and cross- adequately protected against
sections shown on the Drawings and as water. It shall be stored in a
required by the S.O. weather-proof cement store to the
approval of the S.O. and shall be
9.2 MATERIALS taken for use in the Works in the
order of its delivery into the store.
9.2.1 Cement Cement delivered in bulk shall be
stored in silos of an approved
The cement to be used throughout design.
the work shall be Portland cement
obtained from an approved 9.2.2 Aggregates
manufacturer. The cement shall be
described under one of the following Aggregates shall be naturally
headings :- occurring sand, gravel or stone,
crushed or uncrushed except as
i) Ordinary Portland Cement otherwise specified, and shall
- the cement shall comply with comply with M.S. 29. They shall be
M.S. 522; obtained from a source approved by
the S.O. and shall be hard, strong,
ii) Rapid Hardening Portland durable and clean. They shall be free
Cement from adhering coatings and shall not
- the cement shall comply with contain any harmful material in
M.S. 522; sufficient quantity so as to affect
adversely the strength, durability and
iii) Moderate Sulphate Resisting impermeability of the concrete.
Portland Cement
- the cement shall comply with Marine aggregates shall not be used
B.S. 12; unless otherwise specified.
iv) Sulphate Resisting Portland

Cement
- the cement shall comply with
B.S. 4027.

9.2.2.1 Coarse Aggregate 9.2.2.3 Grading
Coarse aggregate shall comply (a) Coarse Aggregate

with M.S. 29.
The grading of coarse aggregate
9.2.2.2 Fine Aggregate shall be analysed as described in
M.S. 30 and shall be within the
Fine aggregate shall comply with limits given in Table 9.1.
M.S. 29. If it is found necessary,
the fine aggregate shall be
washed and screened to the
TABLE 9.1 - COARSE AGGREGATE
B.S. % Passing By Weight

410
Test
Sieve
Nominal Size of Nominal Size of
graded aggregate single-sized aggregate
(mm) 37.5mm 20.0mm 14.0 mm

to to to 63.0 37.5 20.0 14.0 10.0
5.0 mm 5.0 mm 5.0 mm mm mm mm mm mm
75.0 100 - - 100 - - - -
63.0 - - - 85 - 100 100 - - -
37.5 95 - 100 100 - 0 - 30 85 - 100 100 - -
20.0 30 - 70 95 - 100 100 0-5 0 - 20 85 - 100 100 -
14.0 - - 90 - - - - 85 - 100 -
100
10.0 10- 35 25 - 55 - 0-5 0 - 20 0 - 45 85 - 100
40 - 85
5.0 0- 5 0 - 10 0 - - 0-5 0 - 10 0 - 20
0 – 10
2.36 - - - - - - -
-

(b) Fine Aggregate
The grading of fine aggregate shall be analysed as described in M.S. 30 and shall be with
in the limits of one of the grading zones given in Table 9.2.
TABLE 9.2 - FINE AGGREGATE
B.S. 410 % Passing By Weight

Test
Sieve Grading Grading Grading Grading
Zone 1 Zone 2 Zone 3 Zone 4
10.0 mm 100 100 100 100
5.0 mm 90 - 100 90 - 100 90 – 100 95 – 100
2.36 mm 60 – 95 75 – 100 85 – 100 95 – 100
1.18 mm 30 - 70 55 – 90 75 – 100 90 – 100
600 um 15 - 34 35 – 59 60 – 70 80 – 100
300 um 5 - 20 8 – 30 12 – 40 15 – 50
150 um 0 - 10 0 – 10 0 - 10 0 - 15
9.2.2.4 Sampling and Testing of Tests shall be carried out on

Aggregates samples of the latter taken at
intervals as required by the S.O.
Samples of the fine and coarse The method of sampling and
aggregates approved by the S.O. testing shall be in accordance
shall be kept on Site, and shall with M.S. 30 and other standards
give a fair indication of the as specified in Table 9.3. Any
general quality of the aggregates batch of aggregate rejected by the
for comparison with the S.O. shall be removed from the
aggregates delivered during the Site.
course of the work.

TABLE 9.3 - TESTING OF AGGREGATE
Properties Test Methods Limits
Grading M.S. 30 Table 9.1 & Table 9.2
Elongation Index M.S. 30 not exceeding 30%
Flakiness Index M.S. 30 not exceeding 25%
Water Absorption M.S. 30 not exceeding 1.5%
Clay, Silt and Dust M.S. 30 not exceeding 2%
Organic Impurities M.S. 30 not exceeding 0.4%
Aggregate Crushing M.S. 30 not exceeding 20%

Value
AASHTO Test loss not exceeding 12%
Soundness Test Method T104
(Sodium Sulphate)
B.S 812 not exceeding 0.06% by
Chloride Content Part 4 weight
of chloride ions
B.S 1377
Sulphate Content Test 9 not exceeding 0.4% be
weight of SO3
9.2.2.5 Storage of Aggregates 9.2.3 Water
Separate storage facilities with Water shall comply with the

adequate provision for drainage requirements of M.S. 28. It shall be
shall be provided for each clean and free from harmful matter
different size of aggregate used. and shall be from a source approved
by the S.O. The Contractor shall
Aggregate shall be handled and make adequate arrangements to
stored so as to minimise supply and store sufficient water at
segregation and contamination. the work site for use in mixing and
curing concrete. All costs for
installing and maintaining the supply
shall be borne by the Contractor.

9.2.4 Admixtures Admixtures which contain calcium

chloride or calcium formate as the
Suitable admixtures may be used in active constituents shall not be used
concrete mixes with the prior for structural concrete containing
approval of or as directed by the reinforcement, prestressing tendons
S.O. or other embedded metal.
All requirements for sampling, 9.3 CLASSIFICATION OF

acceptance tests, uniformity tests, CONCRETE MIXES
independant tests, chloride content,
information to be provided by
manufacturer, compliance and The concrete mixes shall be
storage certificates and marking shall classified as :-
be in accordance with M.S. 922.
(a) Prescribed Mix
All admixtures shall be used strictly
in accordance with manufacturer's The Contractor shall provide
instructions. concrete that contains constituents in
the specified proportions.
Before allowing the admixture to be
used in the work, relevant tests based (b) Designed Mix
on trial mixes shall be carried out.
The trial mix shall be made using The Contractor shall select the mix
job-site materials and under job-site proportions and unless otherwise
conditions. A control mix shall be specified, the workability, in order to
made using a conventional trial mix, satisfy the strength and other
that is without using the admixture, requirements of the Contract.
to determine the water/cement ratio
and mix proportions required to give 9.3.1 Requirements for Prescribed Mixes
the specified strength with the
required slump. Using the same mix Unless otherwise specified, the
proportions as in the control mix, a concrete mix shall be as detailed in
test shall be prepared using the Table 9.5 which shows the weights
recommended dosage of the of cement and total dry aggregates,
admixture. The results of relevant in kilograms, to produce
tests obtained from the control mix approximately one cubic metre of
and test mix shall be compared. The fully compacted concrete, together
S.O. may allow the use of the with the percentages by weight of
admixture only when the results are fine aggregates in total dry
found to be satisfactory and aggregates.
comparable to the effects as claimed
by the manufacturer. Table 9.4 of
admixture acceptance test
requirements shall be complied with.

9.3.2 Requirements for Designed Mixes Where there are insufficient data
to satisfy (i) or (ii) above, the
9.3.2.1 Target Mean Strength margin for the initial mix design
shall be taken as 7.5 N/sq.mm
The concrete mix shall be for concrete of grade 15 and 12
designed to have at least the N/sq.mm for concrete of grade
required minimum cement 20 or above. This margin shall
content and to have a target mean be used as the current margin
strength greater than the required only until sufficient data are
characteristic strength by at least available to satisfy (i) or (ii)
the current margin. above. However, subject to the
approval of the S.O., when the
The current margin for each specified characteristic strength
particular type of concrete shall approaches the maximum
be determined by the Contractor possible strength of concrete
and shall be taken as the lesser made with a particular aggregate,
of :- a smaller margin not less than 5
N/sq.mm for concrete of grade 15
i) 1.64 times the standard or 7.5 N/sq.mm for concrete of
deviation of cube tests on at grade 20 or above may be used
least 100 separate batches of for the initial mix design.
concrete of nominally similar
proportion of similar materials
and produced over a period
not exceeding 12 months by
the same plant under similar
supervision, but not less than
2.5 N/sq.mm for concrete of
grade 15 or 3.75 N/sq.mm
for concrete of grade 20 or
above;
ii) 1.64 times the standard

deviation of cube tests on at
least 40 separate batches of
concrete of nominally similar
proportions of similar
materials and produced over a
period exceeding 5 days but
not exceeding 6 months by
the same plant under similar
supervision, but not less than
5 N/sq.mm for concrete of
grade 15 or 7.5 N/sq.mm for
concrete of grade 20 or above.

TABLE 9.5 - PRESCRIBED MIXES FOR GENERAL USE

PER CUBIC METRE OF CONCRETE
Nominal Max.
Grade of 28-day Sizes of 40 20
Concrete Characteristic Aggregate
Strenght of (mm)
Concrete
(N/sq.mm) Workability Medium High Medium High
Slump Limits 50 -100 100 - 150 25 - 75 75 - 125

(mm)
15P 15 Cement (kg) 250 270 280 310
Total aggregate 1850 1800 1800 1750

(kg)
30 - 45 30 - 45 35 - 50 35 – 50
Fine aggregate
(%)
20P 20 Cement (kg) 300 320 320 350
Total aggregate
(kg) 1850 1750 1800 1750
Fine aggregate 25 - 35 25 – 40 25 – 40 20 - 45
(%)
25P 25 Cement (kg) 340 360 360 390
Total aggregate 1800 1750 1750 1700

(kg)
25 - 35 25 - 40 25 - 40 30 - 45
Fine aggregate
(%)
Fine aggregate is expressed as a i) the nature and source of each

percentage by weight to the total material;
dry aggregates. The lower value
shall be used for finer grading. ii) appropriate existing data as evidence
of satisfactory previous performance
9.3.2.2 Suitability of Proposed Mix for target mean strength, current
Proportions margin, workability and
water/cement ratio; OR
The Contractor shall submit for full details of tests on trial mixes
the approval of the S.O., prior to carried out in accordance with Sub-
the supply of any designed mix, Section 9.3.2.3;
the following :-

iii) the proposed quantities of During production, the S.O. may

each material per cubic metre require additional trial mixes to
of fully compacted concrete. be made before a substantial
change is made in the materials
9.3.2.3 Trial Mixes or in the proportion of the
materials to be used. Trial mixes
The Contractor shall give notice need not be carried out when
to enable the S.O. to be present at adjustments are made to the mix
the making of trial mixes and proportions in accordance with
preliminary testing of the cubes. Sub-Section 9.3.2.4.
The Contractor shall prepare trial
mixes, using samples of approved 9.3.2.4 Control of Strength of Designed
material typical of those he Mixes
proposes to use in the Works, for
all grades to the satisfaction of (a) Adjustment to Mix
the S.O. prior to commencement Proportions
of concreting.
Adjustment to mix proportions
Sampling and testing procedures shall be made subject to the
shall be in accordance with M.S. approval of the S.O. in order to
26. Three separate batches of minimise the variability of
concrete shall be made. The strength and to maintain the
workability of each of the three target mean strength. The
trial batches determined by specified limits of minimum
means of the slump test, cement content and maximum
compacting factor test or vebe water/cement ratio shall be
consistometer test in accordance maintained. Changes in cement
with M.S. 26, shall be have to be declared. Such
appropriate to the proposed uses adjustment shall not be taken to
and methods of placing and imply any change in the current
compaction of the mix and shall margin.
be approved by the S.O. Six
cubes shall be made from each (b) Change of Current Margin
batch. Three from each set of six
shall be tested at an age of 7 days A change in the current margin
and three at an age of 28 days. used for judging compliance with
The average strength of the nine specified characteristic strengths
cubes tested at 28 days shall becomes appropriate when the
exceed the specified characteristic results of a sufficiently large
strength by the current margin number of tests show that the
minus 3.5 N/sq.mm. The previously established margin is
approved trial mix shall then be significantly too large or too
designated as the "designed mix" small.
and its corresponding workability
as the "designed workability".

Recalculation of the margin shall - ±0.04 where the "designed

be carried out in accordance with workability" is between 0.8
Sub-Section 9.3.2.1. Although a and 0.9.
recalculated margin is almost
certain to differ numerically from - ±0.05 where the "designed
the previous value, the adoption workability" is 0.8 or less.
of the recalculated value will not
generally be justified if the two iii) Vebe
values differ by less than 18%
when based on tests on 2 separate - ±3 seconds or ±one-fifth
batches or less than 11% when of the "designed
based on tests on 100 separate workability", whichever is
batches, or less than 5% when less.
based on tests on 500 separate
batches. 9.3.3.2 Concrete Grade
On the adoption of a recalculated The grade of concrete to be used

margin it shall become the in the Works shall be as stated on
current margin for the judgement the Drawings and in the Bill of
of compliance with the specified Quantities.
characteristic strength of concrete
produced subsequent to the (Concrete grade shall be
change. designated as GRADE X/Y
where `X' is the numerical value
9.3.3 Requirements for Concrete of the characteristic strength in
N/sq.mm as determined from
9.3.3.1 Workability test cubes at 28 days, and `Y' is
the nominal size of aggregate in
The workability of the fresh mm. For a prescribed mix, a
concrete shall be such that the suffix `P' shall be added after
concrete is suitable for the `X').
conditions of handling and
placing so that after compaction, 9.3.3.3 Minimum Cement Content
it surrounds all reinforcement,
tendons and ducts and completely The minimum cement content
fills the formwork. shall be in accordance with Table
9.6 unless otherwise shown on
Workability of the concrete shall the Drawings.
be within one of the following
limits :- 9.3.3.4 Maximum Cement Content
i) Slump The maximum cement content

- ±25 mm or ± one-third of shall not exceed 550 kg/cu.m
the "designed unless otherwise described in the
workability", whichever is Contract or agreed by the S.O.
the greater.
ii) Compacting Factor

- ±0.03 where the
"designed workability" is
0.9 or more.
TABLE 9.6 - MINIMUM CEMENT CONTENT AND MAXIMUM FREE

WATER/CEMENT RATIO FOR DESIGNED MIX
Prestressed Reinforced Plain Max.

Concrete Concrete Concrete Free
Exposure Water/
Nominal max. Nominal max. Nominal max.
Cement
size of size of Size of aggregate
Ratio
aggregate aggregate (in mm)
(in mm) (in mm) 40 20
40 20 40 20
Surfaces sheltered from (kg/cu.m) (kg/cu.m) (kg/cu.m)

severe rain :-
1) surface protected
by a water-proof
membrane;
2) internal surfaces, 300 320 270 300 250 280 0.55

whether or not subject
to condensation;
3) surfaces continuously
buried and/or submerged
under water.
1) soffits;
2) surfaces exposed to
driving rain, alternate
wetting and drying 320 350 320 350 270 300 0.50
e.g.in contact with
backfill.
1) surfaces exposed to
the action of sea
water with abrasion 350 350 380 320 350 0.45
having a pH of 4.5 380
or less.
9.3.3.5 Total Chloride Content Tests shall be carried out in

accordance with B.S. 1881 for
The total chloride content of the each grade of concrete, to
concrete mix arising from the demonstrate that these limits are
aggregate or any other source not exceeded.
shall not in any circumstances
exceed the limits in Table 9.7
expressed as a percentage
relationship between chloride
ions and weight of cement in the
mix.

TABLE 9.7 - MAXIMUM TOTAL CHLORIDE
Type of Concrete Maximum Total Chloride

(%)
Reinforced Concrete
made with cement complying
with M.S. 522.
0.35 for 95%
of test results
with no result
Plain Concrete greater than 0.50.
containing embedded metal
and made with cement complying
with M.S. 522.
Concrete made with

cement complying with B.S. 4027. 0.2
Prestressed Concrete and

Structural Concrete that is steam 0.1
cured.
Notes on Table 9.7 :- 9.4 COMPLIANCE WITH SPECIFIED

REQUIREMENTS
(1) % Chloride ionsx 1.648
= % equivalent sodium 9.4.1 Prescribed Mix
chloride.
A prescribed mix shall be judged on
(2) % Chloride ionsx 1.56 the basis of the specified mix
= % equivalent anhydrous proportions. The workability shall be
calcium chloride. chosen to suit the construction
requirements.
9.3.3.6 Maximum Sulphate Content
Notwithstanding this, strength tests
The total estimated sulphate shall be carried out during the
content of any mix, including that progress of work. The rate of
present in the cement shall not sampling shall be as per Rate 2 for
exceed 4.0% by weight of ordinary structural concrete as in
cement in the mix. Tests shall be Table 9.8. For each sampling, three
carried out in accordance with test cubes shall be made. One test
B.S. 1881 for each grade of cube from each sample-batch shall
concrete to demonstrate that these be tested for the 7-day compressive
limits are not exceeded. strength.

If the cube strength falls below 9.4.2 Designed Mix

75% of the 28-day compressive
strength, then the S.O. may direct 9.4.2.1 Characteristic Strength
the Contractor to take necessary
steps to review the process of the The characteristic strength of
production of concrete for future concrete is that 28-day cube
use. strength, below which not more
than 5% of the test results may
The remaining two test cubes be expected to fall. Compliance
from the sample-batch shall be with the specified characteristic
tested for the 28-day compressive strength shall be judged by tests
strength. The appropriate made on cubes at an age of 28
strength requirement shall be days.
considered to be satisfied if at
least one of the following is 9.4.2.2 Sampling and Testing
complied with :-
All sampling and testing of
i) none of the two test cubes is constituent materials shall be
below the specified carried out in accordance with the
compressive strength; provisions of the appropriate
available Malaysian Standards.
ii) the average strength of the In particular, sampling and testing
two test cubes is not less than of fresh and of hardened concrete
the specified compressive shall be carried out in accordance
strength and the difference with the provisions of M.S. 26.
between the two strengths is
not more than 20% of the The rate of sampling shall be as
average strength. given in Table 9.8, but not less
than one sample shall be taken
In the event that the results of the from each source of production
test do not meet the specified on each day that concrete of any
requirements, the S.O. shall particular grade is used.
determine the action to be taken
in respect of the concrete member
represented by the sample-batch
test cubes. Such action may
include demolition of the
member. The Contractor shall, if
required by the S.O., take cored
samples from the hardened
concrete member and carry out
the compressive strength test.

TABLE 9.8 - MINIMUM RATE OF SAMPLING
Rate Volume of concrete from

which a sample shall be taken
Rate 1 Every 10 cu.m

(Prestressed Concrete) or every group of 10 batches *
Rate 2 Every 20.0 cu.m

(Ordinary Structural or every group of 20 batches *
Concrete)
Rate 3 Every 50 cu.m

(Mass Concrete) or every group of 50 batches *
* The sample shall be taken The remaining two test cubes

from one single batch randomly from the same sample shall be
selected from the group of tested for the 28-day
batches. compressive strength. The
average strength of the two cubes
9.4.2.3 Testing Plan shall constitute the 28-day
compressive strength of the
Three test cubes shall be made sample.
from a single sample taken from
a randomly selected batch of For compliance purposes :-
concrete. The samples shall be
taken at the point of discharge i) the average 28-day strength
from the mixer or, in the case of determined from any group of
ready-mixed concrete, at the four consecutive samples shall
point of discharge from the exceed the specified
delivery vehicle. characteristic strength by at
least 0.5 times the curent
One test cube from each sample margin.
shall be tested for the 7-day
compressive strength. If the cube The current margin shall be taken
strength falls below the 7-day as 7.5 N/sq.mm for concrete of
strength as determined from the grade 15 or 12 N/sq.mm for
trial mixes, then the Contractor concrete of grade 20 or above
shall take the necessary steps to unless, in accordance with Sub-
review the process of the Section 9.3.2.1 or 9.3.2.4 (b), a
production of concrete and make smaller margin has been
certain adjustments where appli established to the satisfaction of
cable. the S.O.

In this respect, consecutive 9.4.3 Additional Cubes

samples are samples taken at
intervals not exceeding 14 days. Additional cubes may be reuqired for
In all cases, at least four samples various purposes. These shall be
shall be taken of concrete on the made and tested in accordance with
first day of concreting for each M.S. 26 but the methods of sampling
grade of concrete to be used in and the conditions under which the
the Works, irrespective of the cubes are stored shall be varied
volume of concrete produced or according to the purpose for which
the sampling rate. they are required.
ii) Each individual sample test result For determining the cube strength of
shall be at least 85% of the prestressed concrete before transer or
specified characteristic strength. of concrete in a member before
striking formwork, sampling shall be
If any one sample test result fails to at the point of placing and the cubes
meet the second requirement (ii), shall be stored as far as possible
then that result may be considered to under the same conditions as the
represent only the particular batch of concrete in the members.
concrete from which the sample test
cubes were taken. The extra cubes shall be indentified
at the time of making and shall not
If the average strength of any group be used for the normal quality
of four consecutive sample test control or compliance procedures.
results fails to meet the first
requirement (i), or more than one 9.5 PRODUCTION OF CONCRETE
sample test result in a group fails to
meet the second requirement (ii), 9.5.1 Supervision
then all the concrete in all the
batches represented by all such The Contractor shall ensure the
sample test results shall be deemed required standard of control over
not to comply with the strength materials and workmanship. The
requirements. S.O. shall be afforded all reasonable
opportunity and facility to inspect the
For the purpose of this Sub-Section, materials and the production of
batches of concrete represented by concrete, to take any samples and to
groups of four consecutive sample make any test.
test results shall include the batches
from which samples were taken to 9.5.2 Batching and Mixing
obtain the first and the last sample
results in the group of four, together The quantities of cement, fine
with all the intervening batches. aggregate and various sizes of coarse
aggregate shall be measured by
weight unless otherwise approved
by the S.O. A separate weighing
machine shall be provided for
weighing the cement. Alternatively
the cement may be measured by
using a whole number of bags in
each batch. The quantity of water

shall be measured by volume or Mixing plant shall be thoroughly

by weight. Any solid admixtures cleaned before changing from
to be added shall be measured by one type of cement to another.
weight but liquid or paste ad
mixtures may be measured by The water content of each batch
volume or weight. of concrete may be adjusted so as
to produce a concrete of the
The batch weight of aggregate workability required.
shall be adjusted to allow for the
moisture content of the aggregate 9.5.3 Transporting
being used. The accuracy of the
measuring equipment shall be Concrete shall be transported from
within :- the mixer to the formwork as rapidly
as practicable by methods which will
± 3% of the quantity of cement prevent segregation or loss of the
per batch; ingredients and maintain the required
workability. It shall be deposited as
±3% of the quantity of water near as practicable in its final
per batch; position to avoid rehandling. The
concrete shall be conveyed by chutes
±3% of the quantity of total or concrete pumps only with
aggregate per batch; permission from the S.O.
± 5% of the quantity of 9.5.4 Placing

admixture per batch.
For all concrete whether mixed on or
The mixer shall comply with the off the site of the Works, each batch
requirements of B.S. 1305 or shall be placed and compacted with
B.S. 4251 where applicable. The in 2 hours of adding the cement to
mixing time shall be not less than the dry aggregates and within 45
two minutes or more than five minutes (or any other period of time
minutes after all the ingredients as approved by the S.O. if admixture
have been placed in the mixer. is used) of adding water to the
For cements other than ordinary cement and aggregates. Concrete
Portland cement, the mixing shall not be placed in any part of the
time shall not be less than that structure until the S.O.'s approval
recommended by the has been obtained. If concreting is
manufacturer and subject to the not started within 24 hours of
S.O.'s approval of the trial mix. approval given, approval shall again
be obtained from the S.O.
Mixers that have been out of use
for more than 30 minutes shall be All formwork and reinforcement
thoroughly cleaned before any contained in it shall be clean and free
fresh concrete is mixed. Unless from standing water immediately
otherwise agreed by the S.O., the before the placing of the concrete.
first batch of concrete through the Concreting shall be carried out
mixer shall then contain only continuously between and up to pre
two-thirds of the normal quantity determined construction joints in one
of coarse aggregate. sequence of operation. In the event
of unavoidable stoppage in positions

not predetermined, the concreting No concrete shall be placed in

shall be terminated on a flowing water. Underwater
horizontal plane and against concrete if deemed unavoidable
vertical surfaces by the use of by the S.O. shall be placed in
stopping-off boards. position by tremies or pipelines
from the mixer. Concrete to be
Fresh concrete shall not be placed placed under water shall be an
against in situ concrete which has approved mix with the amount of
been in position for more than cement increased by 20%.
45 minutes (or any other period During and after concreting under
of time as approved by the S.O. if water, pumping or dewatering
admixture is used) unless a operations in the immediate
construction joint is formed in vicinity shall be suspended until
accordance with Sub-Section the S.O. permits them to
9.6.1. When in situ concrete has continue. Where the concrete is
been in place for 4 hours, no placed by a tremie, the following
further concrete shall be placed requirements shall be
against it for a further 20 hours. applicable :-
Except where otherwise agreed i) unless otherwise agreed by

by the S.O., concrete shall be the S.O, when concreting of
deposited in horizontal layers to a bored piles is being carried
compacted depth not exceeding out under water, temporary
450 mm where internal vibrators casing shall be installed to the
are used; or 300 mm in all other full depth of the borehole so
cases. The surface of the that fragments of ground can
concrete shall be maintained not drop from the sides of the
reasonably level during placing. hole into the concrete as it is
placed;
Concrete shall not be dropped
into place from a height ii) the hopper and tremie pipe
exceeding 1500 mm. When shall be a closed system. The
trunking or chutes are used, they bottom of the tremie shall be
shall be kept clean and used in kept as far as practicable
such a manner as to avoid beneath the surface of the
segregation. placed concrete;
The Contractor shall maintain an iii) the tremie pipe shall be large
experienced steel fixer at the site enough with due regard to the
of reinforced concrete works size of aggregate. For 20 mm
during the placing of concrete to aggregate the tremie pipe
reposition any reinforcement shall be of diameter not less
which may be displaced during than 150 mm and for larger
the work. aggregate, larger diameter
tremie pipe shall be required;

iv) unless otherwise agreed by iv) no concrete shall be placed

the S.O., the first charge of when the air temperature at
concrete shall be placed with the point of deposition
a sliding plug pushed down exceeds 36ºC.
the tube ahead of it to prevent
mixing of concrete and water; 9.5.6 Compaction
v) the tremie pipe shall always Unless otherwise agreed by the S.O.,
penetrate well into the concrete shall be thoroughly
concrete with an adequate compacted by vibration and
margin of safety against thoroughly worked around the
accidental withdrawal if the reinforcement, tendons, or
pipe is surged to discharge the duct formers, around embedded
concrete; fixtures and into corners of the
formwork to form a dense
vi) the concrete shall be homogenous mass free from voids
deposited wholly by tremie and which will have the required
and the method of deposition surface finish when the formwork is
shall not be changed part way removed. Vibration shall be applied
up to prevent the laitance continuously during the placing of
from being entrapped within each batch of concrete until the
the structure; expulsion of air has practically
ceased and in a manner which does
vii)all tremie pipes shall be not promote segregation of the
scrupulously cleaned after ingredients.
use.
The concrete maintained between the
9.5.5 Temperature Requirements two walls of formwork shall be
compacted by vibrating of the
During hot weather, additional internal type and concrete in slabs
precautions shall be taken to prevent with no formwork on its upper
premature setting and loss of water surface shall be compacted either by
during placing of concrete in the vibrators of the pan type or by a
formwork. These precautions shall vibrating screed.
include :-
The internal vibrators shall be
i) no concrete having an internal inserted and withdrawn slowly and at
temperature exceeding 33ºC a uniform pace of approximately
shall be deposited; 100 mm per second. Compaction
shall be deemed to be completed
ii) concrete shall not be placed in when cement mortar appears in an
formwork or around annulus around the vibrator. Over
reinforcement whose temperature vibration leading to segregation of
exceeds 36ºC; the mix must be avoided. The
internal vibrators shall be inserted at
iii) newly placed concrete shall be points judged by the area of mortar
protected from direct sunlight and showing after compaction, with a
from loss of moisture by certain allowance made for
covering, shading or other means; overlapping, and they shall not be
allowed to come into contact with

the formwork or the Concrete shall not be subjected to

reinforcement and shall be any disturbance within 24 hours
inserted at a distance of not less after compaction. No standing or
than 75 mm from the former. flowing water shall be allowed to
come into contact with exposed
The pan vibrator shall be placed concrete surfaces during the first
on the surface of the concrete two hours after placing and
which shall have previously been compaction of the concrete.
tamped and levelled leaving an
allowance in height for 9.5.7 Curing and Protection
compaction until the cement
mortar appears under the pan. All work shall be protected from
The vibrator shall then be lifted damage by shock or overloading or
and placed on the adjoining falling earth or flowing water, etc.
surface and this operation shall be
repeated until the whole surface 9.5.7.1 Normal Curing
has been compacted.
Alternatively a vibrating screed Exposed surfaces, immediately
spanning the full width of the after compaction, shall be
surface may also be used. protected from the sun and rain in
a manner approved by the S.O.
Whenever vibration has to be All concrete, after it has set, shall
applied externally, the design of be kept continuously damp until
formwork and disposition of thoroughly cured. Provision shall
vibration shall receive special be made for adequate water
consideration to ensure efficient distribution to all parts of the
compaction and to avoid surface Works, so that if required, this
blemishes. The mix shall be such treatment can be continued
that there will be no excess water efficiently throughout the whole
on the top surface on completion period of construction. In order
of compaction. to keep the concrete continuously
damped, all exposed surfaces
External vibrators shall be firmly shall be covered with
secured to the formwork which continuously damped gunny bags
must be sufficiently rigid to or shall have water impounded
transmit the vibration and strong on them for the full period of
enough not to be damaged by it. curing which shall be not less
than 7 days.
Internal vibrators shall be capable
of operating at not less than Other methods of curing may be
10,000 cycles per minute and used subject to the approval of
external vibrators at not less than the S.O.
3,000 cycles per minute.
Sufficient vibrators in serviceable
condition shall be on Site so that
spare equipment is always
available in the event of break
down.

9.5.7.2 Accelerated Curing relevant production details in

suitable format. In addition the
Elevated temperature curing may manufacturer shall supply to the S.O.
be used only with ordinary test certificates for testing of
Portland cement. After the materials, indicating the sources of
completion of the placing of the supplies and other relevant details.
concrete, 4 hours shall elapse
before its temperature is raised. 9.6 CONSTRUCTION WITH
The rise in temperature within CONCRETE
any period of 30 minutes shall
not exceed 10ºC and the 9.6.1 Construction Joints
maximum temperature attained
shall not exceed 70 ºC. The rate The position and detail of any
of subsequent cooling shall not construction joints not described in
exceed the rate of heating. The the Contract shall be subject to the
use of accelerated curing methods approval of the S.O. and shall be so
for concrete containing other arranged as to minimise the
types of cement or any admixture possibility of the occurance of
shall be subject to the approval of shrinkage cracks.
the S.O.
If for any reason the Contractor has
9.5.8 Ready-Mixed Concrete to interrupt a planned pour for more
than 45 minutes (or any other period
Ready-mixed concrete shall comply of time as approved by the S.O. if
with the requirements of M.S. 523. admixture is used), additional
The concrete shall be carried in construction joints shall be
purpose-made agitators operating positioned and constructed as
continuously or truck mixers. The directed by the S.O.
concrete shall be compacted and in
its final position within 2 hours of The number of construction joints
the introduction of cement to shall be kept as few as possible
aggregate and within 45 minutes (or consistant with reasonable
any other period of time as approved precautions against shrinkage.
by the S.O. if admixture is used) Concreting shall be carried out
after the addition of water to the continuously up to construction
cement-aggregate mix unless joints. The joints shall be at right
otherwise agreed by the S.O. The angles to the general direction of the
time of such introduction shall be member and shall take due account
recorded on the Delivery Note of shear and other stresses.
together with the weight of the
constituents of each mix. Concrete shall not be allowed to run
to a feather edge and vertical joints
Ready-mixed concrete delivered to shall be formed against a stop board.
the job site shall be accompanied by The top surface of a layer of concrete
manufacturer's certificates stating shall be level and flat unless design
the details of mix proportions by considerations make this undesirable.
weight, grade of concrete, type and Joint lines shall be so arranged that
size of aggregate, date and time of they coincide with features of the
production, type and dosage of finished work, wherever possible.
chemical admixtures and other

At horizontal construction joints, mortar skin and expose the larger

gauge strips about 25 sq.mm in aggregates without disturbing them.
section shall be placed inside the Where this treatment is
forms along all exposed surfaces to impracticable, sand blasting or a
ensure a straight joint on those needle gun shall be used to remove
surfaces. the surface skin and laitance.
Hardened surfaces shall not be
If a kicker (i.e. starter stub) is used hacked.
it shall be at least 70 mm high and
carefully constructed. It is preferable
for the kicker to be incorporated with 9.6.2 Fixing Blocks, Brackets, Built-In-
the previous concrete. Where Bolts, Holes, Chases, etc.
possible, the formwork shall be
designed to facilitate the preparation All fixing blocks, brackets, built-in-
of the joint surface, as the optimum bolts, holes, chases, etc., shall be
time for treatment is usually two to accurately set out and formed and
four hours after placing. carefully sealed prior to the concrete
being placed. No cutting away of
Where vertical construction joints concrete for any of these items shall
are necessary in mass concrete be done without the permission of
structures, reinforcing bars shall be the S.O.
placed across the joints so as to make
the structure monolithic, all to the Bolts and other inserts to be cast into
satisfaction of the S.O. the concrete shall be securely fixed
to the formwork in such a way that
Prior to recommencement of they are not displaced during the
concreting on a joint, the surface of concreting operations, and that there
the concrete against which new is no loss of materials from the wet
concrete will be cast shall be free concrete through holes in the form
from laitance and shall be roughened work.
to the extent that the largest
aggregate is exposed but not Unless shown otherwise on the
disturbed. Care shall be taken to Drawings or instructed by the S.O.,
avoid damaging the lines of the joint. reinforcement shall be locally moved
Care shall also be taken that the joint so that the minimum specified cover
surface is clean and damp but not is maintained at the locations of
wet. Immediately before the fresh inserts, holes, chases, etc.
concrete is placed against the joint,
fresh cement mortar shall be applied Temporary plugs shall be removed
to the exposed surface. and the threads of built-in-bolts shall
be proved to be free and shall be
Where the S.O. considers that greased before handing over any part
special preparation is necessary, e.g. of the Works.
for an in situ structural connection,
preparation shall be carried out,
preferably when the concrete has set
but not hardened, by spraying with a
fine spray of air and water or
brushing with a stiff brush
sufficiently to remove the outer

9.6.3 Precast Concrete Construction 9.6.3.3 Handling and Transport
9.6.3.1 Manufacture Off the Site Items shall be lifted only at points
described in the Contract or
After the method of manufacture otherwise agreed by the S.O. and
has been approved, no changes shall be handled and placed
shall be made without the consent without impact. The method of
of the S.O. lifting, the type of equipment and
transport to be used, and the
The Contractor shall inform the minimum age of the items to be
S.O. in advance of the date of handled shall be subject to the
commencement of manufacture approval of the S.O.
and casting of each type of item.
9.6.3.4 Assembly and Erection
When the S.O. requires tests to
be carried out, no items to which The method of assembly and
the tests relate shall be dispatched erection described in the Contract
to the Site until the tests have shall be strictly adhered to on
been satisfactorily completed and Site.
the results approved by the S.O.
Immediately a unit is in position,
All items shall be indelibly and before the lifting equipment
marked to show the item mark as is removed, temporary supports
described in the Contract, the or connections between items, as
production line on which they necessary, shall be provided.
were manufactured, the date on The final structural connections
which the concrete was cast and, shall be completed as soon as is
if they are of symmetrical practicable.
section, the face that will be
uppermost when the member is 9.6.3.5 Forming Structural Connections
in its correct position in the
Works. No structural connections shall be
made until approval has been
9.6.3.2 Storage given by the S.O.
When items are stored, they shall Unless otherwise agreed by the
be firmly supported only at the S.O., the composition and
points described in the Contract. water/cement ratio of the in situ
The accumulation of trapped concrete or mortar used in any
water and deleterious matter in connection and the packing of
the units shall be prevented. Care joints shall be in accordance with
shall be taken to avoid rust the assembly instructions.
staining and efflorescence.
Levelling devices shall only be
Items shall be stacked in such a released or removed with the
manner that their removal in cor approval of the S.O.
rect order of age is facilitated.

9.6.3.6 Protection used for debonding shall be of

approved synthetic material. The
At all stages of construction, closed end of the sleeve shall be
precast concrete units and other filled with 25 mm thick
concrete associated therewith compressible foam filler and the
shall be properly protected to sleeve shall fit tightly over the length
prevent damage to permanently of bar to be debonded.
exposed surfaces, especially
arrises and decorative features. The Contractor shall furnish
manufacturer's certificates for rein
forcement supplied by him, and
9.7 STEEL REINFORCEMENT these shall be submitted for
acceptance by the S.O. before any
material is brought onto the Site.
9.7.1 Description The characteristic strengths of steel
reinforcement are given in Table
The work shall consist of furnishing 9.9.
and placing reinforcing steel in
accordance with this Specification TABLE 9.9 - CHARACTERISTIC
and in conformity with the Drawings STRENGTH OFSTEEL REINFORCEMENT
or as directed by the S.O.
9.7.2 Materials Designation Nominal Characteristic

Sizes Strength, fy
( mm ) ( N/sq.mm )
Hot rolled mild steel and high yield
bars shall comply with the
requirements of M.S. 146, as Hot rolled grade All sizes 250
250 ( M.S. 146 )
denoted on the Drawings. Cold
worked steel bars shall comply with Hot rolled grade All sizes 460
the requirements of B.S. 4461. 460 ( M.S. 146 )
Hard drawn mild steel wire shall
comply with the requirements of Cold worked All sizes 460
M.S. 144. ( B.S. 4461 )
Hard drawn steel Up to and 485

Steel fabric reinforcement shall wire( M.S. 144 ) including 12
comply with the requirements of
M.S. 145 and shall be delivered to
the Site in flat sheets.
Binding wire shall be 1.6 mm
Bar-mats shall conform to the diameter soft annealed steel wire
requirements of M.S. 146 and shall complying with the requirements of
consist of bars of the sizes and B.S. 1052.
spacings as shown on the Drawings.
The Contractor shall, on request,
Dowel bars shall be plain round furnish the S.O. with samples of
bars conforming to the reinforcement brought onto the Site,
requirements of M.S. 146. They not withstanding any previous
shall be free from burring or other acceptance on the manufacturer's test
deformations restricting slippage in certificates. The reinforcement
the concrete. Dowel bar sleeves represented by by the sample may

be rejected by the S.O. and shall, if it Special care shall be taken that
fails to meet the Specification, the overall length of bars with
require its removal from the Works multiple bends is accurate and
Site. that after bending and fixing in
position the bars remain in place
Steel reinforcement shall be stored in without wrap or twist.
clean and dry conditions. When
placed in the Works it shall be clean 9.7.3.2 Fixing of Reinforcement
and free from loose rust, mill scale,
oil, grease, paint, dirt or anything The number, size, length, form
which may reduce its bond with and position of all reinforcing
concrete. bars, links, stirrups, spacer bars
and other parts of the steel
If directed by the S.O., the steel reinforcement, shall be in
shall be brushed or otherwise accordance with the Drawings.
cleaned before use, at the
Contractor's expense. Reinforcement shall be secured
against displacement. Unless
9.7.3 Construction Methods specified otherwise, the actual
concrete cover shall be not less
9.7.3.1 Cutting and Bending of than the required nominal cover
Reinforcement minus 5 mm. In a member
where the nominal cover is
Bars shall be of their correct dimensioned to the links, spacers
lengths and bent to the exact between the links and formwork
shapes required before being shall be of the same dimension as
fixed in the work. the nominal cover.
Bars shall be cut and bent cold by Unless otherwise permitted by

the application of slow, steady the S.O., all intersecting bars
pressure or in an approved bar- shall be tied together with
bending machine. Bending at binding wire and the ends of the
temperatures in excess of 100 oC wire shall be turned into the main
may only be carried out with the body of the concrete.
S.O.'s approval and under his
supervision. Except where The Contractor shall take
otherwise indicated on the particular care that the
Drawings, bars shall be bent and reinforcement is laid out correctly
measured in accordance with in every respect and temporarily
B.S. 4466. suspended by annealed wire or
supported on concrete blocks or
Cold worked and hot rolled bars other approved spacers in the
shall not be straightened or bent forms to prevent displacement
again once having been bent. before or during the placing and
Where it is necessary to bend compacting of concrete.
mild steel reinforcement already
cast in the concrete, the internal
radius of bend shall be not less
than twice the diameter of the
bar.

Stirrups and distance pieces shall be as described in Sub-Section

be kept tight to the bars they 9.7.2. Other types of spacers
embrace or support and all may be used only with the
reinforcement shall be kept away approval of the S.O.
from the face of the concrete at
the distances shown on the 9.7.3.5 Welding of Reinforcement
Drawings.
Reinforcement in structures shall
No concrete shall be placed until not be welded except where
the reinforcement has been detailed on the Drawings or
inspected and approved by the required by the Specification. If
S.O. the reinforcement needs to be
welded, the reinforcement shall
Reinforcement temporarily left comply with the requirements of
projecting from the concrete at B.S. 4360.
construction or other joints shall
not be bent out of position during Welding shall be carried out in
the periods in which concreting is accordance with B.S. 5135 and
suspended except with the B.S. 638. Butt welds shall be of
approval of the S.O. the double V type and two butt
weld bond tests shall be carried
9.7.3.3 Splicing out on a specimen prepared to
represent each form of butt
Laps and joints including lapping welded joint used in welding the
bars, sleeving, threading and reinforcement and for each
other mechanical connections position of welding. The method
shall be made strictly in of making butt weld tests shall be
accordance with the method that laid down in B.S. 709. The
specified and at the positions specimen shall pass the test to the
shown on the Drawings or as satisfaction of the S.O. before
otherwise approved by the S.O. approval is accorded to use the
joint which the specimen
9.7.3.4 Supporting and Spacer Blocks represents.
Supporting and spacer blocks Welded joints shall not be made

required for ensuring that the at bends in reinforcement.
reinforcement is correctly Unless otherwise approved by the
ositioned shall be as small as S.O., joints in parallel bars of the
possible consistent with their principal tensile reinforcement
purpose, of a shape acceptable to shall be staggered in the
the S.O., and designed so that longitudinal direction at a
they will not overturn when the distance not less than the end
concrete is placed. They shall be anchorage length for the bar.
made of concrete with 10 mm
maximum aggregate size and All welding shall be performed
they shall be of at least the same by a competent welder approved
strength and material source as by the S.O.
the adjacent concrete. Wire cast
in the block for the purpose of
tying it to the reinforcement shall

The S.O. shall be informed in Formwork (including supports)

advance of when welding is to be shall be sufficiently rigid to
carried out so that he may maintain the forms in their
supervise and inspect the work. correct position, shape, profile
Welding shall not be performed and dimensions. The supports
in the field during rain or other shall be designed to withstand the
adverse conditions. worst combination of forces due
to self weight, formwork weight,
9.8 FORMWORK AND SURFACE formwork forces, reinforcement
FINISH FOR STRUCTURE weight, wet concrete weight,
construction and wind loads,
9.8.1 Design and Construction together with all incidental
dynamic effects caused by
9.8.1.1 Description placing, vibrating and
compacting the concrete.
Formwork shall include all
temporary or permanent forms Where internal metal ties are
required for forming the concrete, permitted they or their removable
together with all temporary parts shall be extracted without
construction required for their damage to the concrete and the
support. remaining holes filled with
mortar of the same strength as the
The design and construction of cast concrete. No permanently
formwork shall be carried out by embedded metal parts shall have
competent persons. Where less than the specified cover to
required by the S.O., strength the finished concrete surface.
and deflection calculations and Except for ties used for anchoring
drawings of the proposed form void formers all ties shall be at
work shall be submitted by the least 1.2 metres apart and
Contractor for prior approval. through bolts will not be
Not withstanding any approval permitted on exposed faces. All
by the S.O. with respect to the holes left by ties shall be made
design submitted by the good within one day of the
Contractor, the responsibility or removal of the formwork using a
the adequacy and safety of the mortar of the same strength as the
design shall remain with the cast concrete.
Contractor.
The formwork shall be so
The formwork shall be arranged as to be readily
sufficiently rigid and tight to dismantled and removed from the
prevent loss of grout or mortar cast concrete without shock,
from the concrete at all stages of disturbance or damage. Where
construction and shall be necessary, the formwork shall be
appropriate for the methods of so arranged that the soffit form,
placing and compacting. properly supported, can be
retained in position for such
period as may be required by the
condition of the maturing
concrete or the Specification. If a
component is to be prestressed

whilst still resting on the soffit reinforcement and prestressing

form, provision shall be made to cable ducts, to demonstrate that
allow for elastic deformation and the proposed methods of fixing
any vibration in weight the formers and placing concrete
distribution. As far as practicable, around them and the
formwork joints shall coincide reinforcement will produce voids
with construction joints. within the tolerances, surrounded
with properly compacted
9.8.1.2 Voids In Concrete concrete of the required strength.
Voids, where shown on the The attention of the Contractor is

Drawings, shall be formed with drawn to the inflammation nature
non-recoverable void formers of of expanded polystyrene and he
expanded polystyrene, or by shall take all necessary
other methods approved by the precautions to minimise the risk
S.O. They shall not deviate by of fire.
more than 12 mm from the
positions shown on the Drawings, Concreting of voided slabs in
nor shall the cross-section deviate structures shall not commence
from the specified shape by more until the model test has been
than 12 mm. completed and approved by the
S.O.
Void formers shall be secured and
adequately anchored to prevent 9.8.1.3 Form Lining
movement or flotation outside the
limits specified above, during the The type and treatment of any
concreting operation. lining (plywood, metal, plastic,
etc.) of the forms shall be
Anchor ties secured to the soffit ppropriate to the concrete finish
form will be permitted providing required.
they comply with the
requirements of Sub-Section 9.8.1.4 Projecting Reinforcement, Fixing
9.8.1.1. Devices
Void formers of expanded Where holes are needed in form

polystyrene need not be vented. to accomodate projecting
Hollow void formers shall be reinforcement or fixing devices,
vented by the provision of 50 care shall be taken to prevent loss
mm diameter holes between each of grout when concreting or
void and the soffit at positions damage when removing forms.
9.8.2 Finishes
As soon as possible and at least
three (3) months prior to the 9.8.2.1 Formed Surfaces
casting of the first deck slab with
voids, the Contractor shall Formed concrete surfaces shall
construct a model of a size and have one of the following classes
form to be agreed with the S.O. of finish. Unless otherwise
using the proposed formers, specified, all exposed concrete
method of fixing, and simulating surfaces shall be of Class F2, all

unexposed surfaces shall be of After the concrete has been

Class F1 and Class F3 finish properly cured, the surface shall
shall be used only where shown be rubbed down where necessary,
on the Drawings. to produce a smooth and even
surface.
(a) Class F1
9.8.2.2 Unformed Surfaces
This finish shall be obtained by
the use of properly designed (a) Class U1
formwork of closely jointed sawn
timber or other approved The concrete shall be uniformly
material. Small blemishes caused levelled and screeded to produce
by entrapped air or water may be a plain, ridged or broom
expected but the surface shall be roughened surface. No further
free from voids and work shall be applied to the
honeycombing. surface unless it is used as the
first stage for a Class U2 or
(b) Class F2 Class U3 finish.
This finish shall be obtained by (b) Class U2

the use of properly designed
formwork of closely jointed After the concrete has hardened
wrought boards, approved ply sufficiently, the concrete Class
wood or other approved U1 surface shall be floated by
material. Only very minor surface hand or machine to produce a
blemishes shall occur, with no uniform surface free from screed
staining or discolouration. marks.
(c) Class F3 (c) Class U3
This finish shall be obtained by When the moisture film has

the use of properly designed steel disappeared and the concrete has
forms or plastic coated plywood hardened sufficiently to prevent
or wrought boards or other laitance from being worked to the
approved material. The surface surface, a Class U1 surface shall
shall be improved by carefully be steeltrowelled under firm
removing all fins and other pressure to produce a dense,
projections, thoroughly washing smooth uniform surface free from
down and then filling the most trowel marks.
noticeable surface blemishes with
a cement and fine aggregate paste
to match the colour of the 9.8.2.3 Remedial Treatment of Surfaces
original concrete. Form release
agent shall be carefully chosen to Any remedial treatment of
ensure that the surface shall not surfaces shall be agreed with the
be stained or discoloured. S.O. following inspection
immediately after removing the
formwork and shall be carried out
without delay.

Any concrete, the surface of Where the concrete compressive

which has been treated before strength is confirmed by tests on
being inspected by the S.O., concrete cubes stored under
shall be liable to rejection. conditions that simulate the field
conditions, formwork supporting
9.8.3 Preparation of Formwork Before concrete in bending may be struck
Concreting when the cube strength is 10
N/sq.mm or twice the stress to
Before concreting, all forms shall be which it will be subjected, whichever
thoroughly cleaned out, free from is the greater. In the absence of such
sawdust shavings, dust, mud or tests, the minimum periods between
other debris. concreting and the removal of forms
are given in Table 9.10.
The inside surfaces of forms shall,
except for permanent formwork, or TABLE 9.10 - MINIMUM PERIODS
unless otherwise agreed by the S.O., BETWEEN CONCRETING AND REMOVAL
be coated with an approved non- OF FORMS
staining form oil or other approved
material to prevent adhesion of the Vertical faces of beams, wall
concrete. Such release agents shall columns, piles, foundation 3 days
be applied strictly in accordance with plinths and precast items.
the manufacturer's instructions and
shall not come into contact with the Underside of slabs. 14 days
reinforcement or prestressing
Underside of beams. 28 days
tendons and anchorages. For any
exposed surface only one release
agent shall be used throughout the
entire area.
All formwork shall be inspected by

the S.O. after preparation and
immediately prior to depositing
concrete and no concrete shall be
deposited until approval of the
formwork has been obtained from
the S.O.
9.8.4 Removal of Formwork
The Contractor shall inform the S.O.

and obtain his approval before
striking any formwork, but such
approval shall not relieve the
Contractor of his responsibilities for
the safety of the work.
The removal shall be done in such a

manner as not to damage the
concrete, and shall take place at
times to suit the requirements for its
curing.
The periods stated above are based

on the use of ordinary Portland
cement. They may be changed if
other types of cement are used,
subject to the S.O.'s agreement.
For prestressed in situ decks,

temporary supports shall not be
removed until the deck is stressed to
the satisfaction of the S.O.
Where it is intended that formwork

is to be reused it shall be cleaned and
made good to the satisfaction of the
S.O.
Following the removal of formwork,

no further loads shall be imposed
upon concrete until at least after the
completion of the curing period or
until such later time as in the opinion
of the S.O. the concrete shall have
attained sufficient strength to safely
withstand such loads. Full design
loads shall not be applied to any
structure until all load bearing
concrete is at least 28 days old.

SECTION 10
PILING WORKS

SECTION 10 - PILING WORKS
Page
10.2 GENERAL REQUIREMENTS FOR TOLERANCE
10.2.1 Setting Out S10-245
10.2.2 Position S10-245
10.2.3 Verticality S10-245
10.2.4 Rake S10-245
10.2.5 Forcible Corrections S10-245
10.2.6 Piles Out of Alignment or Position S10-245
10.2.7 Records S10-245
10.3 PRECAST REINFORCED CONCRETE PILES

10.3.2.1 Concrete S10-246
10.3.2.2 Reinforcement S10-246
10.3.2.3 Pile Shoes S10-246
10.3.3 Manufacture and Storage of Precast Reinforced Concrete Piles S10-246

10.3.3.1 Casting S10-246
10.3.3.2 Handling and Storage S10-247
10.3.4 Installation of Precast Reinforced Concrete Piles S10-247

10.3.4.1 Pitching of Piles S10-247
10.3.4.2 Driving of Piles S10-247
10.3.4.3 Repair of Damaged Pile Heads S10-248
10.3.4.4 Lengthening of Piles S10-248
10.3.4.5 Cutting and preparation of Pile Heads S10-249

Page
10.4 PRESTRESSED SPUN CONCRETE PILES
10.4.2 Materials
10.4.2.1 Concrete S10-250
10.4.2.2 Reinforcement S10-250
10.4.2.3 End Plates S10-250
10.4.2.4 Pile Shoes S10-250
10.4.3 Manufacture and Storage of Prestressed Spun Concrete Piles S10-250

10.4.3.1 Casting S10-250
10.4.4 Installation of Prestressed Spun Concrete Piles S10-251

10.4.4.1 Pitching and Driving of Piles S10-251
10.4.4.2 Lengthening of piles S10-251
10.5 BORED CAST-IN PLACE PILES

10.5.2 Materials
10.5.2.1 Concrete and Reinforcement S10-252
10.5.2.2 Permanent Casings S10-252
10.5.2.3 Drilling Fluid S10-252
10.5.3 Boring Operations

10.5.3.1 Diameter of Piles S10-252
10.5.3.2 Boring S10-252
10.5.3.3 Temporary Casings S10-253
10.5.3.4 Stability of Piling Excavations Using Drilling Fluid S10-253
10.5.3.5 Spillage and Disposal S10-253
10.5.3.6 Pumping of Boreholes S10-253
10.5.3.7 Continuity of Construction S10-253
10.5.3.8 Enlarged pile Bases S10-254
10.5.3.9 Cleanliness of Pile Bases S10-254
10.5.3.10 Inspection S10-254
10.5.4 Placing of Reinforcement S10-254

10.5.4.1 Joints in Longitudinal Bars S10-254
10.5.4.2 Positions of Reinforcement S10-254

page
10.5.5 Concreting Operations S10-254

10.5.5.1 Placing Concrete S10-254
10.5.5.2 Workability of Concrete S10-254
10.5.5.3 Compaction S10-255
10.5.5.4 Placing Concrete In Dry borings S10-255
10.5.5.5 Placing Concrete Under Water or Drilling Fluid S10-255
10.5.6 Extraction of Casing

10.5.6.1 Workability of Concrete S10-256
10.5.6.2 Concrete Level S10-256
10.5.6.3 Vibrating Extractors S10-256
10.5.7 Construction of Pile Heads S10-257

10.5.7.1 Water levels S10-257
10.5.7.2 Cutting and preparation of Pile heads S10-257
10.5.7.3 Temporary Backfilling Above Pile Casting Level S10-257
10.6 STEEL H-SECTION PILES
10.6.3 Manufacture and Storage of Steel H-Section Piles S10-257

10.6.3.1 Manufacture S10-257
10.6.4 Installation of Steel H-Section Piles S10-258

10.7 STEEL PIPE PILES
10.7.3 Manufacture and Storage of Steel Pipe Piles S10-258

10.7.3.1 Welding S10-258
10.7.3.2 Fabrication of Piles S10-259
10.7.3.3 Matching of Pile Lengths S10-259
10.7.3.4 Straightness of Piles S10-259
10.7.3.5 Fabrication of Piles On Site S10-259
10.7.3.7 Marking of Piles S10-259

Page
10.9.4 Installation of Pressure-Treated Timber Piles

10.9.4.3 Cutting and preparation of Pile heads S10-265
10.10 BAKAU PILES
10.10.3 Delivery and Inspection of Bakau Piles S10-266
10.10.4 Installation of Bakau Piles S10-266

10.10.4.1 Pitching of Piles S10-266
10.10.4.2 Driving of Piles S10-266
10.10.4.4 Cutting and Preparation of Pile Heads S10-267
10.11 PILE TESTING
10.11.1 Test Piles S10-267
10.11.2 Preliminary Pile Load Tests S10-267
10.11.3 Production Pile Load Tests S10-267
10.11.4 Testing Procedure S10-267

10.11.4.1 Preparation of Test Pile S10-267
10.11.4.2 Method of Loading S10-267
10.11.4.3 Measurement of Settlement S10-268
10.11.5 Method of Testing S10-268

10.11.5.1 General S10-268
10.11.5.2 Maintained Load Test S10-269
10.11.5.3 Constant Rate of Penetration (CRP) Test S10-269
10.11.6 Submission of Results S10-269
10.11.7 Interpretation of Test Results S10-269
10.11.8 Load Testing of Bakau Piles S10-270

SECTION 10 - PILING WORKS deviation of the finished pile from

the specified rake or the rake shown
on the Drawings is 1 in 25.
10.1 DESCRIPTION
10.2.5 Forcible Corrections
This work shall consist of the supply,
installation and testing of piles in Forcible corrections to concrete piles
accordance with this Specification and shall not be permitted. Forcible
the lines, levels, grades and cross- corrections may be permitted to
sections shown on the Drawings and as other types of piles if approved by
directed by the S.O. the S.O. However, no forcible
corrections shall be made to piles
which have deviated beyond the
10.2 GENERAL REQUIREMENTS permissible limits specified in Sub-
FOR TOLERANCES Sections 10.2.2, 10.2.3 and 10.2.4
above.
10.2.1 Setting Out
10.2.6 Piles Out of Alignment or Position
Setting out shall be carried out using
the data and reference points as The Contractor shall, if ordered by
shown on the Drawings. the S.O., extract and reinstall any
Immediately before installation of pile which has deviated out of
the pile, the pile position shall be position or alignment by more than
marked with suitable identifiable the specified limit, or alternatively
pins, pegs or markers. the substructure shall be modified to
the approval of the S.O. The cost of
10.2.2 Position such extraction and reinstallation or
any extra cost in the design and
For a pile cut off at or above ground construction of a modified
level the maximum permitted foundation shall be borne by the
deviation of the pile centre from the Contractor if, in the opinion of the
centre points shown on the Drawings S.O., such extra works have been
shall not exceed 75 mm in any made necessary due to the error
direction. For a pile cut off below and/or negligence of the Contractor.
ground level an increase in this
tolerance is permitted in accordance 10.2.7 Records
with Sub-Sections 10.2.3 and
10.2.4 hereinbelow. The Contractor shall keep records of
the installation of each pile as
10.2.3 Verticality required by the S.O. and shall
submit two signed copies of these
The maximum permitted deviation records to the S.O.not later than at
of the finished pile from the vertical noon of the next working day after
is 1 in 75. the pile has been installed. The
signed records shall form part of the
10.2.4 Rake records for the Works.
The piling rig shall be set and Any unexpected driving or boring
maintained to attain the required conditions shall be noted in the
rake. The maximum permitted records.

10.3 PRECAST REINFORCED Other means of jointing

CONCRETE PILES reinforcement, such as by means
of mechanical couplings shall be
to the approval of the S.O.
10.3.1 Description
10.3.2.3 Pile Shoes
and installation of precast reinforced The type of pile shoes to be
concrete piles, inclusive of pitching used shall be as shown on the
and driving, lengthening and cutting Drawings and shall comply
and preparation of pile heads, all in with the following as relevant :-
accordance with this Specification
and to the details shown on the i) "Chilled-hardened" cast iron
Drawings. shoes as used for making grey
iron castings to B.S. 1452,
10.3.2 Materials Grade 10; or
10.3.2.1 Concrete ii) Mild steel to B.S. 4360,

Grade 50B; or
Unless otherwise specified,
ordinary Portland cement shall be iii) Cast steel to B.S. 3100, Grade
used for the casting of piles. A.
The materials and workmanship Mild steel straps cast into the
shall be as specified under shoes shall be as shown on the
Section 9 of this Specification. Drawings. Rock shoes where
The grade of concrete and the required shall consist of wrought
details of reinforcement to be iron shoes and mild steel straps
used shall be as shown on the cast into "Chilled-hardened" cast
Drawings. iron blocks, as shown on the
Drawings.
10.3.2.2 Reinforcement
10.3.3 Manufacture and Storage of Precast
The main reinforcing bars in piles Reinforced Concrete Piles
not exceeding 12 m in length
shall be in one continuous length 10.3.3.1 Casting
unless otherwise approved by the
S.O. The length of piles to be cast
shall be as shown on the
In piles exceeding 12 m long, Drawings, subject to revision by
joints shall be permitted in main the S.O. Based on the results of
longitudinal bars at 12 m nominal pile driving resistance and/or load
intervals. Joints in adjacent bars tests carried out on piles driven
shall be staggered at least 1 m on the site, the S.O. may from
apart along the length of the pile. time to time order the lengths of
Joints shall be butt welded as piles to be modified.
specified in Sub-Section 9.7.5 of
this Specification.

Piles shall be cast on a horizontal thicknesses shall be provided

platform in approved moulds to between piles at the lifting points.
the dimensions as shown on the
Drawings. The concreting of 10.3.4 Installation of Precast Reinforced
each pile shall be completed in Concrete Piles
one continuous operation and no
interruptions will be permitted. 10.3.4.1 Pitching of Piles
Lifting holes shall be formed
during casting in the positions Piles shall be pitched accurately
and in accordance with the details in the positions as shown on the
shown on the Drawings. Drawings. At all stages during
driving and until the pile has set
The cross-sectional dimensions of or been driven to the required
the pile shall not be less than length, all exposed piles shall be
those shown on the Drawings and adequately supported and
shall not exceed them by more restrained by means of leaders,
than 6 mm. Any face of a pile trestles, temporary supports or
shall not deviate by more than 6 other guide arrangements to
mm from a straight edge 3 m maintain position and alignment
long laid on the face, and the and to prevent buckling and
centroid of any cross-sections of damage to the piles.
the pile shall not deviate by more
than 12 mm from the straight line 10.3.4.2 Driving of Piles
connecting the centroids of the
end faces of the pile. Each pile shall be driven
continuously until the specified
After a pile has been cast, the set and/or depth has been
date of casting, reference number, reached, unless otherwise
and the length shall be clearly approved by the S.O. The
marked with indeletable marker driving equipment used shall be
on the top surface and on the of such type and capacity to the
head of the pile. In addition, approval of the S.O. A follower
each pile shall be marked at (long dolly) shall not be used
intervals of 0.5 m along its length unless otherwise approved by the
before being driven. S.O.
10.3.3.2 Handling and Storage A detailed record of the driving

resistance over the full length of
The method and sequence of each pile shall be kept. The log
lifting, handling, transporting and shall record the number of blows
storing piles shall be such that for every 0.5 m of pile
piles are not damaged. Only the penetration. The Contractor shall
designed lifting and support inform the S.O. without delay if
points shall be used. During an unexpected change in driving
transport and storage, piles shall characteristics is encountered.
be placed on adequate supports
located under the lifting points of Where required by the S.O. set
the piles. All piles within a stack shall be taken at approved
shall be in groups of the same intervals during the driving to
length. Packings of uniform establish the behaviour of the
piles.
A set shall be taken only in the driving. If a pile has been driven
presence of the S.O. unless to the required set or depth but
otherwise approved. The sound concrete of the pile is
Contractor shall provide all below cut-off level, the pile shall
facilities to enable the S.O. to be made good to the cut-off level
check driving resistances. The as described above.
final set of a pile other than as
friction pile, shall be recorded as 10.3.4.4 Lengthening of Piles
the penetration in millimeters per
10 blows. The temporary Where piles have to be
compression of the pile shall be lengthened, other than by means
recorded if required. of welding of steel plates as
detailed on the Drawings, the
Piles shall be driven in an reinforcement shall be stripped of
approved sequence to minimise all surrounding concrete for a
the detrimental effects of heave distance equal to thirty times the
and lateral displacement of the diameter of the main
ground. When required, careful reinforcement measured from the
levelling from a datum unaffected pile head for spliced joints and
by the piling shall be made on 300 mm for butt welded joints
the pile heads already driven, and all lateral reinforcement shall
before and after driving be removed. The lengthening
subsequent piles. Piles which bars shall butt on the exposed
have been displaced as a result bars in true alignment and shall
of driving adjacent piles shall be be butt welded as specified or
redriven to the required shall be spliced with bars of the
resistance. same diameter as the main pile
bars, 60 diameters in length and
10.3.4.3 Repair of Damaged Pile Heads lapping the main bars for a
distance of 30 diameters above
If a pile is to be subjected to and below the joint, and shall be
further driving, concrete in the securely bound with 1.63 mm
damaged pile head shall be cut soft annealed iron wire. New
off square at sound concrete, binders of similar size shall be
and all loose particles shall be provided and spaced at half the
removed by wire brushing, fol centres of the binders in the main
lowed by washing with water. body of the pile and shall be
Care shall be exercised to ensure securely bound with 1.63 mm
that the reinforcement in the pile soft annealed iron wire and the
head is not in any way damaged. pile extended by concreting in
Any damaged reinforcement properly constructed mounds to
shall be made good to the the length required.
satisfaction of the S.O. The head
shall be replaced with concrete of
an approved grade. The new
head shall be cast truly in line
with the remainder of the pile and
be properly cured and allowed to
harden sufficiently to develop
the strength necessary for further

Care shall be taken to form the (b) Splicing

joint between the old and new
concrete as specified The projecting bars shall be
hereinbefore. The extension shall stripped of all surrounding
be truly in line with the concrete as necessary to allow
remainder of the pile, , and be splices of length 60 diameters
properly cured and allowed to with extension bars. The
harden sufficiently to develop the extension bars shall be securely
strength necessary for further bound to the projecting bars with
driving. 1.63 mm soft annealed iron wire.
The concrete of the pile shall be
10.3.4.5 Cutting and Preparation of Pile made good either before or
Heads together with the casting of the
pile cap, all to the satisfaction of
When a pile has been driven to the S.O.
the required set or depth, the head
of the pile shall be cut off to the Care shall be taken to avoid
level specified or shown on the cracking or otherwise damaging
Drawings. The length of the rest of the pile. Any cracked
reinforcing bars projecting above or defective concrete shall be cut
this level shall be as shown or away and made good with new
specified on the Drawings. If the concrete properly bonded to the
length of reinforcing bars left old.
projecting is insufficient, then
they shall be extended by
either of the following
methods :-
(a) Butt Welding
The extension bars shall butt on

the projecting bars in true
alignment and shall be
butt welded in accordance with
Sub-Section 9.7.3.5 of this
Specification.

10.4 PRESTRESSED SPUN 10.4.2.4 Pile Shoes

CONCRETE PILES
If specified, the type of pile shoes
to be used shall be as shown on
10.4.1 Description the Drawings and shall be in
accordance with Sub-Section
This work shall comprise the supply 10.3.2.3.
and installation of prestressed spun
concrete piles,inclusive of pitching 10.4.3 Manufacture and Storage of
and driving, lengthening and cutting Prestressed Spun Concrete Piles
and preparation of pile heads, all in
accordance with this Specification 10.4.3.1 Casting
and to the details shown on the
Drawings. The length of piles to be cast
shall be as shown on the
10.4.2 Materials Drawings, subject to revision by
the S.O. Based on the results of
10.4.2.1 Concrete pile driving resistance and/or load
tests carried out on piles driven
Unless otherwise specified, on the site, the S.O. may from
ordinary Portland cement shall be time to time order the lengths of
used for the casting of piles. The piles to be modified.
materials and workmanship shall
be as specified under Section 9 Piles shall be hollow cylinders
of this Specification. The grade manufactured by the centrifugal
of concrete to be used shall be as casting process. Moulds shall be
shown on the Drawings. of metal, well braced and
stiffened against deformations
10.4.2.2 Reinforcement caused by the hydrostatic
pressure of the wet concrete
The prestressing tendons and the while spinning. The metal forms
non-prestressing reinforcement of shall have smooth joints and
the piles including workmanship inside surfaces. The forms shall
shall be as specified under be accessible for adequate
Sections 11 and 9 respectively of cleaning.
this Specification and to the
details as shown on the The spiral reinforcement shall be
Drawings. securely held to the longitudinal
reinforcement during casting and
10.4.2.3 End Plates spinning. Any welding used shall
not affect the strength of the pre
Details of end plates of each stressing tendons.
length of pile shall be as shown
on the Drawings. The pile shall not be removed
from the moulds until after the
Each end plate shall be machine- specified transfer strength is
finished and provided with a achieved.
chamfer to accommodate the
welding when two lengths of pile The external diameter and the
are jointed. thickness of the pile shall not be

less than that shown on the 10.4.4.2 Lengthening of Piles

Drawings and shall be constant
over the entire length of the pile Where lengthening of piles is
and coaxial with the end plate at required, the details of the joint
each end. shall be as shown on the
Drawings. When two lengths of
After a pile has been cast, the pile are jointed, the end plates
date of casting, reference number shall bear over their complete
and length shall be clearly areas. Shims for packing shall not
marked with indeletable marking be accepted.
on the top surface and on the
head of the pile. In addition, each 10.4.4.3 Cutting and Preparation of Pile
pile shall be marked at intervals Heads
of 0.5 m along its length before
being driven. When a pile has been driven to
the required set or depth, the
head of the pile shall be cut off to
10.4.3.2 Handling and Storage the level specified or shown on
the Drawings. The Contractor
The method and sequence of shall submit to the S.O. for
lifting, handling, transporting and approval, his proposed method
storing piles shall be such that for cutting of piles. Pile heads
piles are not damaged. Only the shall be constructed to details as
designed lifting and support shown on the Drawings.
points shall be used.
All piles within a stack shall be in

groups of the same length.
Packings of uniform thicknessess
shall be provided between piles at
the lifting points.
10.4.4 Installation of Prestressed Spun

Concrete Piles
10.4.4.1 Pitching and Driving of Piles
Pitching and driving of piles shall

be in accordance with Sub-
Sections 10.3.4.1 and 10.3.4.2.
Piles shall not be driven until the
concrete has achieved the
specified characteristic strength.

10.5 BORED CAST-IN-PLACE Bentonite shall be mixed

PILES thoroughly with clean fresh water
to make a suspension which will
maintain the stability of the pile
10.5.1 Description excavation for the period
necessary to place concrete and
This work shall comprise the boring complete construction.
or grabbing, with or without casing, Preparation of the suspension
and subsequently filling the hole shall comply with the
with plain or reinforced concrete to manufacturer's instructions.
form bored cast-in-situ piles, all in
accordance with this Specification Where saline or chemically
and to the details shown on the contaminated ground water
Drawings. occurs, special precautions shall
be taken to modify the bentonite
10.5.2 Materials suspension or prehydrate the
bentonite in fresh water to render
10.5.2.1 Concrete and Reinforcement it suitable in all respects for the
construction of piles.
The concrete and reinforcement
to be used and workmanship 10.5.3 Boring Operations
for bored cast-in-situ piles shall
be as specified under Section 9 10.5.3.1 Diameter of Piles
of this Specification. The grade
of concrete and the details of The diameter of piles shall not be
reinforcement to be used shall be less than the specified designed
as shown on the Drawings. diameter at any level throughout
its length.
10.5.2.2 Permanent Casings
10.5.3.2 Boring
Permanent casings which form
part of the designed pile shall be Boring shall be carried down to
as specified in the Drawings. the depth as required and
10.5.2.3 Drilling Fluid
When deemed necessary by the
Drilling fluid material, bentonite, S.O., the Contractor shall take
shall comply with Specification undisturbed soil samples while
No. DF CP4 of the Oil the pile is being bored. The
Companies Materials Association samples shall be taken to an
or its equivalent. A certificate approved Laboratory for testing.
shall be obtained by the
Contractor from the manufacturer Sampling and all subsequent
of the bentonite powder, showing handling and testing shall be
the properties of each carried out in accordance with
consignment delivered to the site. B.S.5930.
This certificate shall be made
available to the S.O. on request.

Piles shall not be bored close to In the event of a rapid loss of

other piles which have recently bentonite suspension or water
been cast and which contain from the piling excavation, the
workable or unset concrete, such excavation shall be backfilled
that a flow of concrete could be without delay and the instructions
induced from or damage caused of the S.O. shall be obtained prior
to any of the piles. to resuming boring at that
location.
10.5.3.3 Temporary Casings
10.5.3.5 Spillage and Disposal
Temporary casings of approved
quality or an approved alternative All reasonable steps shall be
method shall be used to maintain taken to prevent the spillage of
the stability of pile excavations bentonite suspension or water on
which might otherwise collapse. the site in areas outside the
immediate vicinity of the boring
Temporary casings shall be free operations. Discarded bentonite
from significant distortion. They water shall be removed from the
shall be of uniform cross-section site without delay. The disposal
throughout each continuous of bentonite water shall comply
length. During concreting they with the regulations of the Local
shall be free from internal Controlling Authorities.
projections and encrusted
concrete which might prevent the 10.5.3.6 Pumping of Boreholes
proper formation of the piles
being cast. Pumping from the borehole shall
not be permitted unless a casing
10.5.3.4 Stability of Piling Excavations has been placed into the stable
Using Drilling Fluid stratum to prevent the further
ingress of water in significant
Where the use of drilling fluid or quantities from other strata into
a column of water is approved for the boring, or, unless it can be
maintaining the stability of shown that pumping will not
boring, the level of fluid or have a detrimental effect on the
column of water in the surrounding soil or its properties.
excavation shall be maintained
such that the fluid pressure 10.5.3.7 Continuity of Construction
always exceeds the pressure
exerted by the soil and external A pile constructed in stable soil,
ground water and an adequate without the use of temporary
temporary casing shall be used in casings or other support, shall be
conjunction with the method to bored and concreted without
ensure the stability of the strata delay to ensure that the soil char
near ground level until concrete acteristics are not significantly
has been placed. The fluid water altered.
level shall be maintained at a
level not less than 1 metre above
the level of the external ground
water.

10.5.3.8 Enlarged Pile Bases of the reinforcement during the

construction of the pile and the
The enlarged pile base shall not spacing of the reinforcing bars
be smaller than the dimensions shall be maintained in such a way
specified and shall be concentric that proper concreting shall not
with the pile shaft diameter. A be impeded.
sloping surface of the frustum
forming the enlargement shall 10.5.4.2 Positions of Reinforcement
make an angle to the horizontal
of not less than 55º. Adequate spacer blocks, guide
tubes, and lifting wires shall be
10.5.3.9 Cleanliness of Pile Bases provided so as to maintain the
reinforcing steel in the positions
On completion of boring, loose, as specified.
disturbed or remoulded soil or
fragments of rock shall be Where temporary casings are
removed from the base of the employed, the longitudinal
pile. reinforcement shall extend at
least 1.0 metre below the bottom
10.5.3.10 Inspection of the casing so that movement of
the reinforcement during
For dry boreholes, each hole shall extraction of the casing is
be inspected prior to the placing minimised.
of concrete in it. The inspection
shall be carried out from the 10.5.5 Concreting Operations
ground surface in the case where
the borehole diameter is less than 10.5.5.1 Placing Concrete
750 mm. Where the borehole
diameter exceeds 750 mm, The method of placing and the
adequate equipment conforming workability of concrete shall be
to B.S. 5930 shall be provided to such that a continuous monolithic
enable the Contractor and the concrete shaft of the full cross-
S.O. to descend into the borehole section is formed.
for the purpose of inspection.
10.5.5.2 Workability of Concrete
For wet boreholes, i.e. holes
filled with drilling fluid or water, The workability of the concrete
a suitable probe shall be provided shall be determined by the slump
to ascertain the evenness and test as described in M.S. 26.
cleanliness of the pile base.
The suggested slump details for
10.5.4 Placing of Reinforcement typical concreting situations shall
be as specified in Table 10.1
10.5.4.1 Joints in Longitudinal Bars below. The slump shall be
measured at the time of
Reinforcement shall be such that discharge into the borehole.
the full strength of the bar is
effective across the joint and the
joint shall be made so that there
is no relative displacement

TABLE 10.1 - SLUMP RANGE FOR TYPICAL CONCRETING SITUATIONS
Typical Conditions Slump Range

of Use (mm)
Placed into water-free unlined bore.

Widely spaced reinforcement leaving
room for free movement between bars 75 to 125
Where reinforcement is not spaced widely

enough to give free movement between
bars.
Where casting level of concrete is within

the casing.
Where pile diameter is less than 600 mm. 100 to 175
Where concrete is to be placed by tremie

under water or drilling fluid. 150 to collapse
10.5.5.3 Compaction diameter, an enriched mix shall

be used in the first few batches of
Internal vibrators shall not be concrete to minimise segregation.
used to compact concrete unless
it can be satisfied that they will 10.5.5.5 Placing Concrete Under Water or
not cause segregation or arching Drilling Fluid
of the concrete.
Concrete to be placed under
10.5.5.4 Placing Concrete In Dry Borings water or drilling fluid shall be
placed by tremie unless otherwise
Approved measures shall be approved and shall not be
taken to avoid segregation and discharged freely into the water
bleeding and to ensure that the or drilling fluid.
concrete at the bottom of the pile
is not deficient in grout. Before placing concrete,
measures shall be taken to ensure
Where piles are vertical, concrete that there is no accumulation of
may be poured through a funnel silt or other material at the base
with a length of tube so that the of the boring.
flow is directed and does not hit
reinforcement bars or the side of
the hole. Chutes extending to
near the base shall be employed
for raking piles of large diameter.
For raking piles of small

The hopper and pipe of the 10.5.6.2 Concrete Level

tremie shall be clean and
watertight throughout. The pipe When the casing is being
shall extend to the base of the extracted, a sufficient quantity of
boring and a sliding plug or concrete shall be maintained
barrier shall be placed in the pipe within it to ensure that the
to prevent direct contact between pressure from external water,
the first charge of concrete in the drilling fluid or soil is exceeded
pipe of the tremie and the water and that the pile is neither
or drilling fluid. The tremie pipe reduced in section nor
shall at all times penetrate the contaminated.
concrete which has previously
been placed and shall not be No concrete shall be placed in the
withdrawn from the concrete boring once the bottom of the
until the completion of casing has been lifted above the
concreting. At all times, a top of the concrete; it shall be
sufficient quantity of concrete placed continuously as the casing
shall be maintained within the is extracted until the desired head
tremie pipe to ensure that the of concrete is obtained.
pressure from it exceeds that
from the water or drilling fluid. Adequate precautions shall be
taken in all cases where excess
The internal diameter of the heads of water or drilling fluid
tremie pipe shall not be less than could be caused as the casing is
150 mm for concrete made with withdrawn because of the
20 mm aggregate and not less displacement of water or fluid by
than 200 mm for concrete made the concrete as it flows into its
with 40 mm aggregate. The final position against the wall of
tremie pipe shall be so designed the pile shaft. Where double
that external projections are casings are used in the boring, the
minimised, allowing the tremie proposed method of working
pipe to pass through the shall be with the approval of the
reinforcing cage without causing S.O.
damage or uplifting. The internal
face of the tremie pipe shall be 10.5.6.3 Vibrating Extractors
from projections.
The use of vibrating extractors
10.5.6 Extraction of Casing shall be permitted subject to the
condition that work shall be
10.5.6.1 Workability of Concrete carried out in such a manner and
at such times as to minimise
Temporary casings shall be nuisance and disturbance.
extracted while the concrete
within them remains sufficiently
workable to ensure that the
concrete is not lifted.

10.5.7 Construction of Pile Heads 10.6.2 Materials
10.5.7.1 Water Levels All steel H-section piles shall

comply with B.S. 4 with regard to
In the event of the ground water sectional dimensions and the steel
level being higher than the shall comply with the requirements
required pile head casting level of B.S. 4360. The sections and
shown on the Drawings, the grades to be used shall be as
Contractor shall submit his specified or as shown on the
proposals for approval prior to Drawings.
placing concrete. The pile head
shall not be left below the ground 10.6.3 Manufacture and Storage of
water level unless approved Steel H-Section Piles
precautions are taken.
10.6.3.1 Manufacture
10.5.7.2 Cutting and Preparation of Pile
Heads Unless otherwise approved by the
S.O. the strengthening of the toe
The top of the pile shall be in lieu of a shoe or the
brought above the cut-off level of strengthening of the head of a
the pile to permit all laitance and pile shall be made from material
weak concrete to be removed and of the same grade as the pile and
to ensure that it can be properly to the details as shown on the
keyed into the pile cap. Pile Drawings.
heads shall be constructed to the
details shown on the Drawings. For standard rolled sections the
deviation from straightness in
10.5.7.3 Temporary Backfilling Above millimetres shall not exceed 1.04
Pile Casting Level (L-4.5) where L is the length of
the pile in metres.
After each pile has been cast, any
empty bore remaining shall be For proprietary sections made up
protected and shall be carefully from rolled sections the deviation
backfilled as soon as possible from straightness shall not exceed
with approved materials. 1/1000 of the length of the pile.
Each pile shall be clearly marked

10.6 STEEL H-SECTION PILES with white indeletable marking at
the flanged head showing its
reference number and overall
10.6.1 Description length. In addition, each pile
shall be marked at intervals of
This work shall comprise the supply 0.5 m along its length before
and installation of steel H-section being driven.
piles, inclusive of pitching and
driving, lengthening and preparation
of pile heads, all in accordance with
this Specification and to the details

The length of piles to be supplied 10.6.4.3 Cutting and Preparation of Pile

shall be as shown on the Heads
Drawings subject to revision by
the S.O. Based on the results of When a pile has been driven to
pile driving resistance and/or load the required set or depth and
tests carried out on piles driven before encasing in concrete, the
on the Site, the S.O. may from piles shall be cut to within 20
time to time order the lengths of mm of the levels shown on the
piles to be modified. Drawings. Pile heads shall be
constructed to the details as
10.6.3.2 Handling and Storage shown on the Drawings.
All operations such as handling The remaining section which can

and transporting of piles shall be be reused for lengthening of piles
carried out in such a manner that shall be stored and protected as
damage to piles and their directed by the S.O.
coatings is minimised. Piles
that are damaged during handling
and transporting shall be replaced 10.7 STEEL PIPE PILES
by the Contractor at his own
expense. All damaged and
rejected piles shall be removed 10.7.1 Description
from the Site forthwith.
Piles within a stack shall be in and installation of steel pipe piles,
groups of the same length and on inclusive of pitching and driving,
approved supports. lengthening and preparation of pile
heads, all in accordance with this
10.6.4 Installation of Steel H-Section Piles Specification and to the details
10.7.2 Materials
Pitching and driving of piles shall
be in accordance with Sub- All steel pipes shall comply with
Sections 10.3.4.1 and 10.3.4.2. B.S. 6323 with regard to sectional
dimensions and the steel shall
10.6.4.2 Lengthening of Piles comply with the requirements of
B.S. 4360.
Where lengthening of piles is
required, the piles shall be jointed 10.7.3 Manufacture and Storage of
by butt welding. Butt welded Steel Pipe Piles
joints shall be stiffened with
plates fillet welded on all four 10.7.3.1 Welding
sides as detailed on the Drawings.
All weldings shall be continuous Unless otherwise specified, all
and complying with B.S. 638, welds shall be full penetration
B.S. 5135 and B.S. 5950 for arc butt welds complying with the
welding and B.S. 4577 for requirements of B.S. 5153.
resistance welding as appropriate.
The type and size of weld shall
be as detailed on the Drawings.
10.7.3.2 Fabrication of Piles 10.7.3.4 Straightness of Piles
The root edge or root face lengths Unless otherwise approved, the
of piles that are to be butt welded deviation from straightness shall
shall not differ by more than 25% not exceed 1/600 of a length not
from the thickness of piles not exceeding 10 m. When two or
exceeding 12 mm in thickness; or more such lengths are joined, the
by more than 3 mm for piles deviation from straightness shall
exceeding 12 mm in thickness. not exceed 1/960 of the
When piles of unequal thickness completed length.
are to be butt welded together, the
thickness of the thinner material 10.7.3.5 Fabrication of Piles on Site
shall be the criterion.
When pile lengths are to be made
Pile lengths shall be set up so that up on Site, all test procedures and
the differences in dimensions are dimensional tolerances shall
matched as evenly as possible. conform to the Specification
for the supply of pipe materials.
The length of piles to be supplied Adequate facilities shall be
shall be as shown on the provided for supporting and
Drawings subject to revision by aligning the lengths of pile.
the S.O. Based on the results of
pile driving resistance and/or load 10.7.3.6 Handling and Storage
tests carried out on piles driven
on the Site, the S.O. may from All piles within a stack shall be in
time to time order the lengths of groups of the same length and on
piles to be modified. approved supports. All
operations such as handling,
10.7.3.3 Matching of Pile Lengths transporting and pitching of piles
shall be carried out in a manner
Longitudinal seam welds and such that damage to piles and
spiral seam welds of lengths of their coatings is minimised. Piles
pipe piles forming a completed that are damaged during handling
pile shall, whenever possible, be and transporting shall be replaced
evenly staggered. However, if in by the Contractor at his own
order to obtain a satisfactory expense. All damaged and
match of the ends of piles or the rejected piles shall be removed
specified straightness, the from the Site forthwith.
longitudinal seams or spiral
seams are brought closely to one 10.7.3.7 Marking of Piles
alignment at the joint, then they
shall be staggered by at least Each pile shall be clearly marked
100 mm. with white indeletable marking
showing its reference number and
overall length. In addition, each
pile shall be marked at intervals
of 0.5 metre along its length
before being driven.

10.7.4 Workmanship ii) for tubes of any wall

thickness, continuous
10.7.4.1 Welding Procedures ultra-sonic examination over
the whole weld, supplemented
The Contractor shall submit for where necessary by
approval, full details of the radiographs to investigate
welding procedures and defects revealed by the
electrodes with drawings and ultrasonic examination.
schedules as may be necessary.
Tests shall be undertaken as may 10.7.4.4 Acceptance Standards
be required by the S.O. and shall
be in accordance with the If the results of any weld test do
requirements of B.S. 4870. not conform to the specified
requirements, two additional
10.7.4.2 Welders' Qualifications specimens from the same length
of pile shall be tested. In the case
Only welders who are qualified of failure of one or both of
in the approved welding these additional tests, the length
procedure shall be employed. of pile covered by the test shall
Copies of certificates relating to be rejected.
welders' tests shall be made
available to the S.O. on request. 10.7.5 Protective Coatings
10.7.4.3 Radiographs If protective coatings are specified,

the preparation of surfaces and the
During production of welded application of the coatings shall be
tube piles, at least one radiograph carried out by skilled labour having
approximately 300 mm long shall experience in the preparation of the
be required on each completed coatings specified.
length as a spot check on weld
quality. This shall be taken on a 10.7.5.1 Surface Preparation
circumferential or longitudinal
weld and its position shall be as Unless otherwise specified, all
directed by the S.O. surfaces to be coated shall be
blast cleaned with an approved
For spirally welded piles, one of abrasive in accordance with B.S.
the following tests shall be 4232 or SIS 05 59 00 to remove
carried out :- rust, mill scale and other adhering
materials, to provide a finish to
i) for tubes of wall thickness 12 second quality (near white) of
mm or less, three spot check B.S. 4232 or SIS 05 59 00 grade
radiographs, one at each end Sa 2 1/2.
of each length of the tube as
manufactured and one at a 10.7.5.2 Application and Type of Primer
position to be chosen at the
time of testing by the S.O.; Immediately after surface
and spot check radiographs as preparation, the surface shall be
required by the S.O. on the coated with an approved primer
weld joints between strip or the specified coating to avoid
lengths; recontamination. No coat shall be

applied to a metal surface which 10.7.6 Installation of Steel Pipe Piles

is not thoroughly dry.
The primer shall be compatible
with the specified coating. Pitching and driving of piles shall
be in accordance with Sub-
10.7.5.3 Part to be Welded Sections 10.3.4.1 and 10.3.4.2.
The coating within 200 mm of a 10.7.6.2 Lengthening of Piles

weld shall be applied after
welding. Unless otherwise approved,
where lengthening of piles is
10.7.5.4 Thickness, Number and Colour required, the piles shall be jointed
of Coats by butt welding along the entire
periphery as detailed on the
The minimum dry film thickness Drawings.
of the finished coating, including
the minimum dry film thickness 10.7.6.3 Cutting and Preparation of
of each coat and the minimum Pile Heads
number of coats that are to be
applied, shall be as specified and When a pile has been driven to
shown on the Drawings. the required set or depth and
Coatings shall be applied in before encasing in concrete, the
accordance with the pile shall be cut to within 20 mm
manufacturer's instructions. of the levels shown on the
Drawings and protective coatings
10.7.5.5 Inspection of Coatings and shall be removed from the
Acceptibility surfaces of the pile head 100 mm
above the soffit of the concrete.
The finished coating shall be Pile heads shall be constructed to
generally smooth, of a dense and details as shown on the
uniform texture and free from Drawings.
sharp protuberances or pin holes.
10.7.6.4 Concreting of Pile Shaft
Any coat damaged by subsequent
processes or which has If concreting is specified or
deteriorated to an extent such that shown on the Drawings after the
proper adhesion of the coating pile has been cut off to the
may not be obtained or specified level, the shaft shall be
maintained, shall be recleaned to filled with concrete in a
the original standard and recoated continuous operation. The
with the specified sequence of method of placing shall be
coats. approved by the S.O.
The completed coating shall be The reinforcement cage in the

checked for thickness and pile shall be made sufficiently
continuity by an approved rigid and kept in its correct
magnetic gauge or detector. Areas position during concreting.
where the thickness is less than
that specified shall receive
approved additional treatment.
The length of the reinforcing bars 10.8.3 Drilling Operations

projecting above the pile cut off
level shall be as shown on the 10.8.3.1 Diameter of Piles
Drawings.
The diameter of piles shall not be
less than the specified/designed
10.8 MICROPILES diameter at any level throughout
its length.
10.8.1 Description 10.8.3.2 Drilling
This work shall comprise the drilling The Contractor shall submit to
of a hole, placing of reinforcement the S.O. details of drilling
unit and subsequently filling the hole equipment and drilling procedure
with grout to form micropiles, all in for approval before
accordance with this Specification commencement of works.
and to the details shown on the Drilling operations shall be
Drawings. carried out in accordance with the
relevant requirements of Sub-
10.8.2 Materials Section 10.5.3.
10.8.2.1 Reinforcement Unit 10.8.4 Grouting Operations
The type of reinforcement unit to 10.8.4.1 Mixing and Placing Grout

be used, the diameter and/or
thickness, grade, yield strength The Contractor shall provide
and working stress shall be as details of the method and
specified or as shown on the equipment used in grout mixing.
Drawings. Further information such as
grouting pressure, grouting
10.8.2.2 Grout procedure, grouting equipment
and techniques employed in
Unless otherwise specified, the grouting underwater shall also be
grout shall be non-shrink cement furnished for approval.
grout. The grout mix design such
as the water-cement ratio, the Grout shall be mixed on Site and
minimum cement and grout shall be free from segregation,
strength at 7 and 28 days shall be slumping and bleeding. Grout
as specified and shown on the shall be pumped into its final
Drawings. position in one continuous
operation as soon as possible and
If admixtures are used, details of in no case more than half an hour
admixtures shall be submitted to after mixing.
the S.O. for approval before
commencement of works. The 10.8.4.2 Testing Grout
use of the admixture shall fully
comply with the manufacturer's Grout shall be tested in
instructions. accordance with B.S. 1881 and
B.S. 4550.

10.8.5 Construction of Pile Heads Pressure-treated timber piles shall

conform to M.S. 822 and shall be
10.8.5.1 Lengthening of Piles approved by SIRIM.
Where lengthening is required, 10.9.3 Manufacture and Storage of

the pile reinforcement unit shall Pressure-Treated Timber Piles
be connected on Site to the
details shown on the Drawings. 10.9.3.1 Manufacture
Other means of jointing Before commencement of work

reinforcement shall be to the the Contractor shall notify the
approval of the S.O. S.O. of the name of the supplier
and manufacturer for approval.
10.8.5.2 Cutting and Preparation of Pile The method of preservative

Heads treatment for timber piles shall be
the full-cell process as described
Pile heads shall be constructed to in M.S. 360. The preservative
the details as shown on the used shall comply with M.S. 733.
Drawings. The depth of penetration of
preservative shall be a minimum
of 25 mm and the net dry salt
10.9 PRESSURE-TREATED TIMBER retention in the treated part of the
PILES timber shall be a minimum of 16
kg/cu.m.
10.9.1 Description Piles shall be within -2 mm and

+6 mm of their specified cross-
This work shall comprise the supply sectional dimensions. The
and installation of pressure-treated centroid of any cross-section of a
timber piles, inclusive of pitching pile shall not deviate by more
and driving, lengthening and than 25 mm from the straight line
preparation of pile heads, all in connecting the centroids of the
accordance with this Specification end faces of the pile.
and to the details shown on the
Drawings. The timber terms used in Before the treated timber pile is
this Specification shall have the accepted for the work the
meanings assigned to them in M.S. Contractor shall obtain from the
229. manufacturer of the treated piles
a warranty on an approved form
10.9.2 Materials which provides, that for a ten
year period, the treated piles shall
Unless otherwise approved by the be free from fungus and insect
S.O., Kempas (Koompassia attack.
Malaccensis) shall be used and this
shall not be of a lesser quality than
the grading specified in Appendix A
of M.S. 822.

Each treated pile shall be The length of piles to be supplied

permanently marked with shall be as shown on the
identifications which indicate that Drawings subject to revision by
they comply with this the S.O. Based on the results of
Specification, manufacturer's pile driving resistance and/or load
trade mark, type of treatment, tests carried out on piles driven
charge number and date of on the Site, the S.O. may from
treatment and the length of the time to time order the lengths of
pile. The end plates of each pile piles to be modified.
shall have SIRIM Control Labels.
10.9.4 Installation of Pressure-Treated
The S.O. may require inspection Timber Piles
and testing at the treatment plant
to observe and ensure that the 10.9.4.1 Pitching and Driving of Piles
manufacturing process and
control testings of the piles are Pitching and driving shall be in
carried out in accordance with accordance with Sub-Sections
this Specification. Records of the 10.3.4.1 and 10.3.4.2.
actual treatment schedule shall be
kept during the treatment process, Piles shall be provided in one
and the Contractor shall furnish single length of 6.0 m each unless
such records for the piles otherwise approved. Any pile
supplied when requested by the driven to the required set at a
S.O. depth of 6.0 m or less shall be in
one continuous length.
10.9.3.2 Delivery and Storage
The pile head shall be adequately
The Contractor shall notify the protected during driving, so that
S.O. of the delivery of timber brooming and splitting do not
piles to the Site, and provide the occur. The pile head shall be
necessary facilities to enable the fitted with toothed metal plates as
S.O. to inspect each pile and take approved by the S.O. during
random sampling for normal driving.
determination of depth of
penetration and the net dry salt In the case of hard driving, unless
retention. otherwise approved by the S.O., a
metal helmet shall be fitted to the
Accepted piles shall be marked top of the pile. The top of the
and stacked in lengths on drained pile shall first be trimmed to fit
hard ground. Each pile shall be closely into the recess of the
stacked clear of the ground and underside of the helmet. A hard
have an air space around it. The wood dolly and, if necessary, a
piles shall be separated by sticks packing piece shall be used above
or blocks placed vertically one the helmet.
above the other and closely
spaced horizontally to avoid If during driving the head of the
sagging of the piles. All rejected pile becomes excessively
piles shall be removed from the broomed or otherwise damaged,
Site forthwith. the damaged part shall be cut off
and the helmet refitted.

When fissures appear in a pile i) the cut-offs or bored holes

during driving, which in the shall be given two flood coats
opinion of the S.O. will affect its of 10% m/v solution of the
strength, the pile shall be rejected preservative, or as specified in
and replaced at the Contractor's accordance with M.S. 360,
expense. allowing each application to
soak thoroughly into the cut
10.9.4.2 Lengthening of Piles or bored surface;
If jointing is required, pile joints ii) immediately after the

shall be made by using Mild preservative solution has
Steel Welded Boxes 450 mm dried, the pile heads shall be
long fabricated from 5 mm thick heavily coated with a
plates unless otherwise shown on bituminous compound which
the Drawings. Joint boxes shall conforms to B.S. 3416 for the
be painted with red lead paint or whole depth that the pile is to
otherwise protected against be enclosed in the pile cap.
corrosion to the satisfaction of the
S.O. The internal dimensions of
the box shall be 3 mm undersize 10.10 BAKAU PILES
of the pile cross-sectional
dimensions. The joint and the
ends of the piles to be jointed 10.10.1 Description
shall be constructed so that the
necessary strength and stiffness This work shall comprise the
are developed at the joint. supply and installation of bakau
piles, inclusive of pitching and
driving, lengthening and
10.9.4.3 Cutting and Preparation of Pile preparation of pile heads, all in
Heads accordance with this
Specification and to the details
When a pile has been driven to shown on the Drawings.
the required set or depth, the head
of the piles shall be cut off square 10.10.2 Materials
to sound wood and treated with
an approved preservative and a Unless otherwise approved by the
waterproof coating all in S.O. only Bakau Minyak
accordance with M.S. 822. The (Rhizophora Apiculapa) or Bakau
pile head shall be embedded for a Kurap (Rhizophora Mucronata)
depth of not less than 150 mm in shall be used. Bakau piles shall
the concrete cap which shall be at be provided in one single length
least 150 mm thick round the of not less than 5.0 m each. The
piles. diameter of piles at the small end
shall not be less than 75 mm
When piles are cut-off at the pile unless otherwise specified.
cap level, all cut-offs and bored
holes shall be treated as follows :-

All bakau piles shall be free from Unless otherwise approved,

rot, fungal or pest attack and any bakau piles shall be driven by
other defects. The piles shall be means of a drop hammer of at
reasonably straight and circular in least 250 kg in mass, suspended
cross-section with all branch from a shear-leg or approved
joints trimmed off to the general pile-frame.
outline of the piles but leaving
the bark intact on the piles. Piles shall be driven in an
approved sequence to minimise
10.10.3 Delivery and Inspection of Bakau the detrimental effects of heave
Piles and lateral displacement of the
ground. When required, levels
The Contractor shall notify the and measurements shall be taken
S.O. of the delivery of piles to the to determine the movement of the
Site and provide labour and ground or any pile resulting from
facilities to enable the S.O. to the driving process. If any pile
inspect and measure each pile at rise occurs as a result of adjacent
the time of unloading. Accepted piles being driven, the Contractor
piles shall be stacked on an shall submit to the S.O. for
approved surface in an approved approval, his proposals for
area and kept constantly in a correcting this and to avoid the
damp condition. Rejected piles same in subsequent work.
shall be removed from the Site
forthwith. The pile head shall be flat and at
right angles to the axis of the pile,
10.10.4 Installation of Bakau Piles its edges chamfered to minimise
splitting during driving. The
10.10.4.1Pitching of Piles Contractor shall take precautions
to avoid damage to the pile head
Piles shall be pitched accurately during hard driving by providing
in the positions and at spacings as a suitable metal helmet. A hard
shown on the Drawings or as wood dolly and, if necessary, a
approved by the S.O. packing piece shall be used above
the helmet. If during driving the
10.10.4.2Driving of Piles head of the pile becomes
excessively broomed or
The length of piles to be driven otherwise damaged, the damaged
shall be as shown on the part shall be cut off, the head
Drawings. Based on the results retrimmed and the helmet
of pile driving resistance and/or refitted.
load tests carried out on piles
driven on the site, the S.O. may,
from time to time order the
lengths or spacing of piles to be
modified.

10.10.4.3 Lengthening of Piles 10.11.2 Preliminary Pile Load Tests
Where a pile has to be jointed, Preliminary pile load tests shall be

it shall be to the details as carried out before the S.O. issues to
shown on the Drawings. Only the Contractor, in writing,
one joint shall be allowed. instructions on the pile length and
The two pile ends to be pile length combinations for the
jointed shall be of the same manufacture and supply of the piles.
diameter and each shall be cut The Contractor shall not proceed to
at right angles to its axis to manufacture or supply the piles until
make contact over the whole he has received instructions in
cross-section when the two writing to do so from the S.O.
timbers are co-axial. A mild
steel tube connector of No. 9 The lengths of the piles for the
gauge to B.S. 6323 shall be preliminary load tests shall be
used to join the two pile ends. determined by the S.O.
The steel tube connector shall
be painted with red lead paint 10.11.3 Production Pile Load Tests
or otherwise protected against
corrosion all to the Load tests shall also be carried out
satisfaction of the S.O. The during the installation of piles for the
pile ends shall be trimmed or permanent Works. Such pile load
packed in the connector to tests shall be referred to as
provide a tight fit. production pile load tests.
10.10.4.4 Cutting and Preparation of 10.11.4 Testing Procedure

Pile Heads
10.11.4.1Preparation of Test Pile
When the piles have been
driven to the required depth, The pile head shall be cut off or
the top of the piles shall be built up to the necessary elevation
cut off to a uniform level. and shall be capped appropriately
The cut-off level shall be to produce a bearing surface
below the lowest dry season perpendicular to the axis of the
ground water level as shown pile. The arrangement shall be
on the Drawings or as such that none of the test load is
approved by the S.O. carried by the ground under the
cap.
10.11 PILE TESTING
10.11.4.2Method of Loading
10.11.1 Test Piles
The test load shall be applied in
In order to determine the required one of the following ways :-
length of pile at each location, the
Contractor shall drive test piles as i) by means of a jack which
shown on the Drawings and/or as obtains its reaction from
instructed by the S.O. Test piles kentledge heavier than the
shall be driven with the same required load;
hammer that is used for driving
foundation piles.

ii) by means of a jack which wires. The reference beam

obtains its reaction from supports shall be located at least
tension piles or other suitable 3 m from the load test pile,
anchors. reaction pile or piles supporting
reaction loads. The reference
The load shall be measured beams or wires shall be protected
using a calibrated load gauge from the effects of temperature
and also a calibrated pressure changes.
gauge in the hydraulic system.
The jack and load gauge shall 10.11.5 Method of Testing
be carefully aligned so that
the load applied is co-axial 10.11.5.1General
with the pile.
Maintained Load Tests shall be
When method (i) is used, care conducted on test piles as
shall be taken to ensure that selected by the S.O. The
the centre of gravity of the loading tests shall be carried out
kentledge is on the axis of the in accordance with Sub-Section
pile. The nearest edge of the 10.11.5.2.
crib supporting the kentledge
stack shall not be closer than When instructed or approved by
1.3 m to the surface of the test the S.O., Constant Rate of
pile. Kentledge shall not be Penetration Tests shall also be
used for testing raked piles. conducted on other piles. The
tests shall be carried out in
When method (ii) is used, all accordance with Sub-Section
anchor piles shall be at a 10.11.5.3.
distance of at least three (3)
pile shaft diameters from the Prior to the performance of any
test pile, centre to centre, and load test, the Contractor shall
in no case shall they be less submit to the S.O. for his
than 2 m from the test pile. approval, working drawings
showing the method and
If the anchor piles are to be equipment he proposes to use in
permanent working piles, the performance of the load test
their levels shall be observed and the measurement of
during application of the test settlements. Such submission
load to ensure no residual shall include design calculations
uplift occurs. of lateral supports or other
methods to be used in ensuring
10.11.4.3Measurement of Settlement against buckling. Horizontal
supports to ensure buckling
Settlements shall be measured by stability shall be provided to the
use of a reference beam or wire pile to be loaded whenever the
supported independantly of the ratio of the unsupported height to
load test pile, reaction pile or the least cross-sectional
piles supporting reaction loads. dimension is 20 or more.
Settlements shall be measured to Horizontal supports shall provide
the nearest 0.1 mm for reference full support without restraining
beams or 0.5 mm for reference the vertical movement of the pile
in any way.
10.11.5.2Maintained Load Test corresponding loads shall be

made in the loading process.
The Maintained Load Test shall
be carried out as follows :- After attaining a test load equal to
twice the design load, the load
i) the full test load on a pile shall gradually be released and at
shall be twice the design load least four readings of settlement
noted on the Drawings and it and their corresponding loads
shall be applied in twelve shall be made during the
equal increments. At least two unloading process. The
hours shall elapse between the settlement obtained when the
addition of each load load has been completely
increment, i.e. until the rate of released shall also be recorded.
settlement is reduced to less An interval of at least 15 minutes
than 0.25 mm/hour and shall elapse before the next CRP
slowing down; test is commenced.
ii) the full test load shall be 10.11.6 Submission of Results

maintained on the pile for at
least 48 hours and settlements Full test data and results shall be
shall be recorded at jointly signed by the S.O.'s
intervals of not more than 12 representative and the Contractor's
hours. The test pile shall authorised agent immediately upon
then be unloaded in four completion of the test, and shall
equal increments at one hour consist of the following :-
intervals until the full load
is removed. Settlement
readings shall be made i) for the Maintained Load Test, for
immediately after and before each stage of loading, the period
every load increment is for which the load was held, the
applied or removed. load and the maximum
settlement. These are to be
10.11.5.3Constant Rate of Penetration plotted as time-settlement graphs.
(CRP) Test
ii) for the CRP test, the maximum
For each pile load test, three load reached and a graph of load
cycles of pile loading test at a against penetration;
constant rate of penetration shall
be carried out to a full test load 10.11.7 Interpretation of Test Results
equal to twice the design load.
The S.O.'s interpretation and
The rate of loading shall be such conclusions on the test results shall
that a constant rate of penetration be final. Unless otherwise specified,
is maintained throughout the test the pile so tested shall be deemed to
insofar as is practicable. The rate have failed if :-
of movement of each pile to be
tested shall be agreed upon with i) the residual settlement after
the S.O. prior to the start of the removal of the test load exceeds
test. At least twelve readings of 6.50 mm; or
settlements and their

ii) the total settlement under the Bakau piles shall be tested to
Working Load exceeds 12.50 failure by the Maintained Load
mm; or Test as described hereinbefore.
The load on the pile group shall
iii) the total settlement under be applied in 2 to 4 equal
twice the Working Load increments as directed by the
exceeds 38.0 mm, or 10% of S.O. until the failure load is
pile diameter/width whichever reached. The failure load (i.e.
is the lower value. ultimate load) is that load at
which the piles continue to settle
10.11.8 Load Testing of Bakau Piles at a constant rate without further
increase of applied load.
In general, all relevant Sub-Sections
stated hereinbefore shall apply to the For each increment of load, the
load testing of bakau piles, except settlement readings shall be
that what is understood as single test recorded at 15 minute intervals
piles in these Sub-Sections shall until the rate of settlement is less
mean a group of test piles for bakau than 0.25 mm per hour. The load
piles. at each increment shall be
maintained at a constant value
The load testing of bakau piles shall throughout the test.
be carried out on a group of nine
bakau piles, made up of three rows Graphs of time-settlement, load-
of piles, three in a row. time and load-settlement, to a
suitable scale, shall be plotted
An approved reinforced concrete pile and submitted to the S.O. with all
cap with a loading pedestal shall be records of the readings.
cast centrally over the group of piles
to be tested. The loading pedestal
shall be short to ensure stability, and
it shall have an approved mild steel
bearing plate cast on top. The load
shall be applied centrally on to the
steel plate.

Standard Specification JKR Road

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What are the specifications for road signage?

What are the specifications for road signage?

What tests are done on piles?

What tests are done on piles?

FOR INTERNAL USE ONLY

Standard Specification For Road Works

CAWANGAN JALAN KETUA PENGARAH KERJARAYA

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 1

Mix Type Wearing Course Binder Course

Mix ACW 20 ACB 28

B.S Sieve % Passing by weight

28.0 mm 100 80 - 100

ACW 20 - Wearing Course 4.5 - 6.5 %

ACW 28 - Binder Course 4.0 - 6.0

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 2

6.2.5.5 Sign Faces

All retro-reflective sheeting used on the same

The edges of all the retro-reflective sheeting

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 3

6.2.6.1 FLUORESCENT ORANGE WIDE ANGLE PRISMATIC RETRO-

6.2.6.1.1 Description 6.2.6.1.2 Requirements

The flurescent orange wide angle prismatic i) Photometric - Coefficient of

Minimum Coefficient of Retroreflection RA

Observation Angle ( ° ) Entrance Angle ( ° ) Orange

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 4

iii) Nighttime Color.

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 5

iv) Resistance to Accelerated Weathering. vi) Resistance to Heat.

The retro-reflective surface of the sheeting The retroreflective sheeting, applied to a

The retroreflective sheeting applied

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 6

STANDARD SPECIFICATION FOR ROADS WORKS

SECTION 1 General S1-11 to S1-31

SECTION 2 Earthworks S2-1 to S2-20

SECTION 3 Drainage Works S3-1 to S3-31

SECTION 4 Flexible Pavement S4-1 to S4-55

SECTION 5 Portland Cement Concrete Pavement S5-1 to S5-21

SECTION 6 Road Funiture S6-1 to S6-22

SECTION 7 Street Lighting S7-1 to S7-19

SECTION 8 Traffic Signals S8-1 to S8-33

SECTION 9 Concrete S9-1 to S9-39

SECTION 10 Piling Works S10-1 to S10-35

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 7

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 8

1.1 GENERAL DESCRIPTION OF THE PROJECT S1-11

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 9

APPENDIX 1A GENERAL DESCRIPTION OF PROJECT S1-22

APPENDIX 1B SCOPE OF WORKS S1-23

APPENDIX 1C VEHICLES FOR S.O. AND HIS STAFF S1-24

APPENDIX 1D LIST OF LABORATORY EQUIPMENT

(a) Soil Testing Equipment S1-25

APPENDIX 1E SURVEY EQUIPMENT S1-30

FIGURE 1-1 APERTURE CARD FOR MICROFILM S1-31

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 10

SECTION 1 - GENERAL iv) The terms "Engineer" and

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 11

1 inch = 25.40 millimetres Should the Contractor require additional

1.4 PROGRAMME OF WORKS Areas or area to be rendered as part of

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 12

1.9 DIMENSIONS AND LEVELS 1.11 DESIGN OF TEMPORARY