Series 600 Specification For Highway Works Earthworks: 613 Sub-Formation and Capping
Series 600 Specification For Highway Works Earthworks: 613 Sub-Formation and Capping
Series 600 Specification For Highway Works Earthworks: 613 Sub-Formation and Capping
Series 600
Specification for Highway Works Earthworks
(x) Vibro-tampers are machines in which an engine-driven reciprocating mechanism acts on a spring system
through which oscillations are set up in a base-plate.
(xi) Power rammers are machines which are actuated by explosions in an internal combustion cylinder, each
explosion being controlled manually by the operator.
(xii) Dropping weight compactors are machines in which a dead weight is dropped from a controlled
height using a hoist mechanism and they include self-propelled machines with mechanical traversing
mechanisms capable of compacting soil in trenches and close to structures.
(xiii) In the case of power rammers and dropping-weight compactors one pass will be considered as made
when the compacting shoe has made one strike on the area in question.
(xiv) For items marked * in the Method 3 column of Table 6/4 the roller shall be towed by track-laying
tractors. Self-propelled rollers are unsuitable.
(xv) Where combinations of different types or categories of plant are used, the following shall apply:
(a) the depth of layer shall be that for the type of plant requiring the least depth of layer; and
(b) the number of passes shall be that for the type of plant requiring the greatest number of passes.
(02/16) End-product Compaction
11 (02/16) Where end-product compaction is required it shall comply with sub-Clauses 12 to 15 of this Clause.
12 (02/16) The Contractor shall at least 7 days before commencement of end-product compaction make available
the following to the Overseeing Organisation:
(i) the values of maximum dry density and the optimum moisture content obtained in accordance with
BS 1377: Part 4 using the 2.5 kg rammer method or vibrating hammer method as appropriate for each of
the fills he intends to use which meet the requirements of the permitted Class or Classes (where within
any Class of material the fill contains material having different maximum dry densities and optimum
moisture contents the Class shall be further sub-divided, by extending the identification system, in order
to monitor the compacted density);
(ii) a graph of density plotted against moisture content from which each of the values in (i) above of
maximum dry density and optimum moisture content were determined and, for Class 7A material, a plot
of the 5% air voids curve for each sub-division.
13 (02/16) Once the information contained in sub-Clause 12 of this Clause has been made available to the
Overseeing Organisation it shall form the basis for compaction.
14 (02/16) Fill compacted to end-product requirements shall have a field dry density, measured in accordance with
sub-Clause 15 of this Clause, equal to or greater than the percentage given in Table 6/1 of the maximum dry density
for the relevant Class of fill previously made available to the Overseeing Organisation in accordance with sub-
Clause 12 of this Clause.
15 (02/16) The field dry density referred to in sub-Clause 14 of this Clause shall be measured in accordance with
BS 1377: Part 9, except that nuclear methods shall only be used where required or permitted in contract specific
Appendix 6/3. Where nuclear methods are used, the gauge shall be calibrated in accordance with BS 1377: Part 9.
3 (02/16) Unless otherwise described in contract specific Appendix 6/7, capping shall either consist of one Class
of capping material throughout its depth laid in one or more layers of compacted thickness complying with Clause
612, or be formed of not more than two elements of different capping materials. Each element shall be formed of
one or more layers of the same capping material, each of compacted thickness complying with Clause 612. Class
9D or 9E stabilised capping material shall not be placed or constructed above
Class 6F granular capping material or Class 6S granular filter layer material.
4 (02/16) Where required in contract specific Appendix 6/7, before commencing the construction of capping in
the permanent works, the Contractor shall demonstrate the methods, equipment and materials he proposes to use by
constructing an area, or areas as appropriate, of capping on a typical prepared sub-formation to the same thickness as
required in the permanent works. The area of each capping construction demonstration shall be not less than 700 m².
5 (02/16) The materials placed during the demonstration may form part of the permanent works, provided they
meet the requirements of the contract, or be carried out elsewhere on the site where this is detailed in contract
specific Appendix 6/7. After completion of each demonstration area the Contractor shall within a period of not
greater than 5 days and before commencing the main construction of the appropriate capping in the permanent
works, carry out tests on each demonstration area and provide the Overseeing Organisation with records
substantiating compliance with the stipulated criteria of contract specific Appendix 6/7. Where required by contract
specific Appendix 6/7 the Contractor shall provide sheeting, to protect the demonstration area.
6 (02/16) The demonstration area shall, if it does not meet the requirements for the permanent works or is located
elsewhere on site, be removed and the area reinstated in accordance with contract specific Appendix 6/7.
7 (02/16) The methods and materials used in the accepted demonstration shall not be changed during the course of
the works without the construction of a further demonstration where such demonstrations are required by contract
specific Appendix 6/7.
8 (02/16) Unless otherwise stated in contract specific Appendix 6/7, the sub-formation shall have the same
longitudinal gradient, crossfall and surface level tolerances as the formation.
9 (02/16) The Contractor shall limit any unprotected area of sub-formation, which is to receive capping to suit the
output of the plant in use and the rate of deposition of capping.
10 (02/16) No unprotected sub-formation which is to receive capping shall remain continuously exposed to rain
causing degradation, nor be left uncovered overnight.
11 (02/16) In cuttings the Contractor shall, as permitted or required in contract specific Appendix 6/7 carry out one
of the following procedures:
(i) for Class 6F granular capping material or Class 6S granular filter layer material, excavate below
formation level to a depth to accept the capping, trim the surface to form the sub-formation and
immediately compact with one pass of a smooth-wheeled roller having a mass per m width of roll
not less than 2,100 kg or a vibratory roller having a mass per m width of roll not less than 700 kg or
a vibrating plate compactor having a mass per m² of not less than 1,400 kg, except that only smooth
wheeled rollers shall be used on Class 3 chalk material, and immediately deposit and compact above it a
capping in Class 6F granular capping material or Class 6S granular filter layer material; or
(ii) for Class 9A, 9B, 9C, 9D, 9E or 9F capping material construct the capping by stabilising the intact
material, providing it complies with Class 6E, 6R 7E, 7F, 7G or 7I material requirements, immediately
below formation to form Class 9A, 9B, 9C, 9D, 9E or 9F material, respectively; or
(iii) excavate below formation to sufficient depth to enable stabilisation of intact Class 6E, 6R, 7E, 7F, 7G
or 7I material to be carried out, to produce Class 9A, 9B, 9C, 9D 9E or 9F material forming the lower
element of the capping (after stabilisation of this element, the capping shall be completed by depositing
a further layer or layers of Class 6E, 6R 7E, 7F, 7G, or 7I material and stabilising it to form Class 9A,
9B, 9C, 9D, 9E or 9F capping or depositing and compacting Class 6F granular capping material to form
the upper element of the capping); or
(iv) excavate to sub-formation level and deposit material complying with Classes 6E, 6R, 7E, 7F, 7G, or 7I
to be stabilised to form a capping of Class 9A, 9B, 9C, 9D, 9E or 9F layers.
Where a stabilised layer is directly overlain by Class 6F granular capping material the stabilised layer shall be
compacted as for a sub-formation in 11(i) above.
12 (02/16) On embankments and other areas of fill the Contractor shall, as permitted or required in contract specific
Appendix 6/7 carry out one of the following procedures:
(i) complete the embankment to form the sub-formation or remove any protection layer and trim the surface
to form the sub-formation, and in both cases compact with one pass of a smooth-wheeled roller having
a mass per m width of not less than 2,100 kg or a vibratory roller of not less than 700 kg per m width or
a vibrating plate compactor having a mass per m² of not less than 1,400 kg, (except that only smooth-
wheeled rollers shall be used on Class 3 chalk material) and immediately construct above it, in one or
more layers, Class 6F granular capping material or Class 6S granular filter layer material; or
(ii) construct the embankment to sufficient height and carry out stabilisation to form a capping of Class 9A,
9B, 9C, 9D, 9E or 9F material in one or more layers utilising where appropriate any protection layer
previously constructed; or
(iii) for multi-element capping, incorporating stabilised material, construct the embankment to sufficient
height to carry out the work described in 12(ii) above and immediately construct above it one or more
layers of Class 6F granular capping material.
Where a stabilised layer is directly overlain by Class 6F granular capping material the stabilised layer shall be
compacted as for a sub-formation in 12(i) above.
13 (02/16) For Class 6F3 material Optimum Moisture Content shall be determined according to BS 1377: Part 4
Method 3.7 (vibrating hammer test). Measurements of moisture content both for control purposes and for optimum
moisture content determination shall be according to BS 1377: Part 2 Method 3 (oven dry method) but using an
oven on a reduced temperature setting of 45 to 50°C.
14 (02/16) Filter layers constructed of Class 6S granular filter layer material shall be protected from damage
by traffic and construction plant. The Contractor shall so organise work that only the traffic directly engaged in
depositing, spreading and compacting the filter layer shall be permitted access to the surface of this layer. At no
time shall the Contractor permit the leading edge of the filter layer to extend more than 100 metres beyond the
leading edge of the succeeding layer of subbase.
6 (02/16) The Contractor shall not carry out cement stabilisation when the shade temperature is below 3°C unless
on a rising thermometer above 0°C. Cement stabilisation shall not be carried out during periods of rain or when rain
is imminent. When cement is spread on material likely to cause premature hydration, processing in accordance with
sub-Clause 7 of this Clause shall follow immediately.
7 (02/16) Unless indicated otherwise by contract specific Appendix 6/7, Class 6E, 7F or 7G material forming the
layer to be stabilised shall be processed by pulverising and mixing in the cement by means of a sufficient number
of passes of a suitable mobile stabilising machine until 95% of the silt and clay fraction is reduced to particles or
lumps passing a BS 28 mm sieve after dry sieving and the pulverisation complies with Table 6/1.
8 (02/16) During processing, sufficient water shall be available in the material to hydrate the cement and enable
satisfactory mixing and compaction to be achieved. Any added water shall be through an integral spray-bar on the
stabilising machine. Any added water shall have a sulfate content not exceeding 1400 mg/l as SO4, when tested in
accordance with BS EN 1744-1 clause 10.
9 (02/16) The stabilising machine shall be equipped with a device for controlling the depth of processing which
shall be maintained at the correct setting at all times. An overlap of 150 mm shall be made between adjacent passes
of the stabilising machine. Where a subsequent layer of material is placed on a layer previously stabilised the tines
or blades of the stabilising machine shall be set so that they cut into the previously stabilised layer below by at least
20 mm.
10 (02/16) Each layer of Class 9A, 9B or 9C processed material shall be compacted as soon as possible after the
final pass of the stabilising machine. Compaction shall be completed within 2 hours following the mixing of the
cement into the material to be stabilised. Immediately before compaction Class 9B processed material shall have a
Moisture Condition Value (MCV) of not greater than 12 nor less than the figure stated in contract specific Appendix
6/1 for Class 9B cement stabilised material, both as determined in accordance with Clause 632. Water shall be
added if necessary in a uniform manner to enable this MCV requirement to be met. Any added water shall have a
sulfate content not exceeding 1400 mg/l as SO4 when tested in accordance with BS EN 1744-1 clause 10.
11 (02/16) The compaction of each layer of Class 9A or 9B material shall comply with Clause 612, Table 6/4
Method 6 or Method 7 respectively, except that if layers of Class 9A or 9B greater than 250 mm thickness are to be
constructed, the number of passes of the compaction plant shall be determined from the results of a demonstration
area as detailed in contract specific Appendix 6/7.
12 (02/16) The compaction of Class 9C material shall comply with Clause 612, end product compaction, to satisfy
the compaction requirements given in Table 6/1 of this Class.
13 (02/16) Class 9A, 9B and 9C materials shall be cured in accordance with Clause 1035. During periods when the
air temperature is forecast to drop below 3°C or when ground frost is forecast Class 9A, 9B and 9C material shall
be protected, to prevent freezing, for a period of 7 days from the time of completion of compaction. Such protection
shall be sealed to prevent the ingress of moisture.
14 (02/16) Class 9A, 9B and 9C materials shall not have other material deposited or compacted above them until
such time as the required bearing ratio in contract specific Appendix 6/1 has been achieved. The relaxation allowed
in sub-Clause 617.2 shall not apply before this time.
4 (02/16) The Contractor shall carry out testing of the lime as installed for available lime in accordance with
Clause 641 at weekly intervals unless otherwise required in contract specific Appendix 6/7 during periods when
lime stabilisation is carried out. The results shall be reported to the Overseeing Organisation. The available lime
shall meet the requirements stated in contract specific Appendix 6/7 and the values stated in the Declaration of
Performance.
5 (02/16) Class 7E material to be stabilised shall have added to it, at any point, the percentage of its dry weight
of lime, as determined on the demonstration area, to meet the required bearing ratio in contract specific Appendix
6/1, subject to a minimum of 2½% by weight of ‘available lime’ as a percentage of the dry weight of the Class 7E
material.
6 (02/16) Lime of quantity complying with sub-Clause 5 of this Clause shall be uniformly spread by a suitable
spreading machine on top of the layer to be stabilised. Using a collecting tray and balance the Contractor shall
check the rate of spread by weight, once for every 500 m² of lime spread or a different rate of testing for the rate of
spread as described in contract specific Appendix 6/7. At the same time the Contractor shall collect samples of lime
deposited on the tray and test them for available lime content in accordance with Clause 641.
7 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material shall be stabilised in a single
layer if its compacted thickness is 250 mm or less. If its compacted thickness is greater, the material shall be
stabilised in layers not less than 130 mm and not more than 250 mm thick, including any cutting-in required by
sub-Clause 12 of this Clause.
8 (02/16) Unless indicated otherwise in contract specific Appendix 6/7 lime stabilisation shall be carried out only
during the months of March to September inclusive and when the shade temperature is not below 7°C. Only when
the specified bearing ratio is attainable at a shade temperature less than 7°C, may lime stabilisation be carried out at
such lower temperature. Lime stabilisation shall be suspended if rainfall will have an adverse effect on the material
being stabilised. The spreading of lime shall not be carried out in a manner or under conditions that will result in
lime being blown from the site onto adjacent land or property.
9 (02/16) Unless indicated otherwise in contract specific Appendix 6/7, the material forming the layers to be
stabilised shall be processed by pulverising and mixing in the lime by means of sufficient number of passes of a
suitable mobile stabilising machine until 95% of the Class 9D processed material passes a BS 28 mm sieve after
dry sieving and the pulverisation complies with Table 6/1.
10 (02/16) During processing sufficient water shall be available in the material to slake the quicklime (if used) and
to enable satisfactory mixing and compaction to be achieved. Any added water shall be through an integral spray-
bar on the stabilising machine. Any added water shall have a sulfate content not exceeding 1400 mg/l as SO4 when
tested in accordance with BS EN 1744-1 clause 10.
11 (02/16) The layer shall receive at least two passes of the stabilising machine to pulverise and mix the lime and
soil, after which the processing shall be interrupted by a period of not less than 24 hours and not greater than 72
hours, to enable the lime to react with the soil. Before this period commences the surface of the layer shall be
sealed with one pass of a smooth wheeled roller having a mass per metre width of roll of not less than 2700 kg or
a pneumatic tyred roller of not less than 1000 kg per wheel. At the end of this period the layer shall receive one
further pass of the stabilising machine or more if required to enable the material to comply with sub-Clauses 9 and
13 of this Clause, adding water uniformly if necessary. Any added water shall have a sulfate content not exceeding
1400 mg/l as SO4 when tested in accordance with BS EN 1744-1 clause 10.
12 (02/16) The stabilising machine shall be equipped with a device for controlling the depth of processing which shall
be maintained at the correct setting at all times. An overlap of 150 mm shall be made between adjacent passes of the
stabilising machine. Where a subsequent layer of material is placed on a layer previously stabilised the tines or blades
of the stabilising machine shall be set so that they cut into the previously stabilised layer below by at least 20 mm.
13 (02/16) Each layer of Class 9D processed material shall be compacted as soon as possible after the final pass of
the stabilising machine. Immediately before compaction the processed material shall have a Moisture Condition
Value (MCV) of not greater than nor less than the figures stated in contract specific Appendix 6/1, for Class 9D
lime stabilised material, both as determined in accordance with Clause 632.
14 (02/16) If there is a delay following the final pass and before commencement of compaction the surface shall be
sealed by not less than 2 passes of a smooth-wheeled roller having a mass per metre width of not less than 2,700 kg or
of a pneumatic tyred roller of not less than 1,000 kg mass per wheel. On recommencement and before compaction the
layer shall be re-processed without the addition of lime, by a sufficient number of passes of the stabilising machine to
meet the MCV requirements of sub-Clause 13 of this Clause adding water uniformly if necessary.
15 (02/16) The compaction of each layer shall comply with Clause 612, Table 6/4 Method 7 except that if layers
more than 250 mm thick are constructed the number of passes of the compaction plant shall be those determined
from results obtained on a demonstration area as detailed in contract specific Appendix 6/7.
16 (02/16) Class 9D material shall not have other material deposited or compacted above it until such time as the
required bearing ratio in contract specific Appendix 6/1 has been achieved. The relaxation allowed in sub-Clause
617.2 shall not apply before this time.
(ii) where the rock surface is tabular it shall be regulated by depositing and compacting cement bound
material as described in contract specific Appendix 6/7, complying with the 1000 Series, or ST1 concrete
to Clause 2602.
5 (02/16) The Contractor shall limit any areas of completed formation to suit the output of plant in use and the rate
of deposition of sub-base. No formation of cohesive material Classes 2 and 7 shall remain continuously exposed to
rain causing degradation or be left uncovered overnight.
6 (02/16) The preparation of formation on existing sub-base material shall be completed as described in contract
specific Appendix 6/7.
(ii) have stones and other debris removed and disposed off site which have:
(a) dimensions greater than 100 mm equivalent diameter, unless otherwise permitted in contract
specific Appendix 6/8; and
(b) dimensions greater than 50 mm equivalent diameter which lie within 50 mm of the surface;
(iii) be graded to smooth contours, eliminating all mounds and depressions where water may collect;
(iv) not have stones or other debris protruding above the surface by more than 30 mm, and comply with the
further requirements of Clauses 3004 and 3005.