PROJECT QUALITY PLAN 746525-D

A - Z IDAMAN SDN BHD

MENAIKTARAF JALAN MASUK KE KAMPUNG JERAM
Ref. No. : AZISB-PQP-JDJL.061.1212
PANJANG, DAERAH JEMPOL, NEGERI SEMBILAN

CONSTRUCTION METHOD STATEMENT

WORKS : INSTALLATION OF ASPHALTIC PLUG JOINT AT BRIDGE

1. Pengesahan Tapak
i) Pemasangan Asphaltic Plug Joint akan dilaksanakan mengikut lokasi yang ditetapkan
dalam Lukisan Rekabentuk Pembinaan dan disahkan oleh Pegawai Penguasa iaitu :-
a) Deck Slab antara span 20m A dan Span 40m (pada kedudukan Pier A)
b) Parapet Wall – di kedudukan Abutment A, Pier A, Pier B dan Abutment B .

ii) Semua dokumen berkaitan persediaan dan perlaksanaan kerja mengikut SPK JKR
perlu dilengkapkan.

2. Tenaga Kerja

Kategori Pekerja Bilangan Catatan

Jurutera / Pengurus Projek 1

Juruteknik / Foreman 1

Penyelia Tapak 1

Pekerja Mahir (Pemasang APJ) 3

Operator Jentera 2

Pekerja Am / Buruh 4

3. Jentera Dan Alat Kelengkapan

Jentera / Kelengkapan Bil. / Set Catatan

Survey Levels Equipment 1

Air Blower & Hot Air Burner 1

Diamond Saw Cutter 1

Mechanical Compactor 1

Probe Thermometer 1

Lorry 2
 PROJECT QUALITY PLAN 746525-D
A - Z IDAMAN SDN BHD
MENAIKTARAF JALAN MASUK KE KAMPUNG JERAM
Ref. No. : AZISB-PQP-JDJL.061.1212
PANJANG, DAERAH JEMPOL, NEGERI SEMBILAN

ASPHALTIC PLUG JOINT

ESOFLEX
‘W’

‘D’ Premix Premix

Plate Pin
Caulking

Concrete Deck Concrete Deck

Construction Gap

Design Detail
Product Horizontal Vertical Standard Joint Size Construction
Name Movement Movement ‘W’ x ‘D’ Gap

ESOFLEX 50 ± 1.5 500 x 75 25

Note : All dimensions in mm

PRODUCT DESCRIPTION

ESOFLEX Joint System is an asphaltic plug joint which is suitable for low to medium movement
capacity expansion joints on highway bridges and other selective structures. The design movement
for this joint are 50mm horizontally and ±1.5mm vertically.

ESOFLEX Joint System extends to the full depth of surfacing and is installed after the carriageway and
verge construction has been completed. It performs by elastic and plastic deformation of the binder
matrix through a combination of bridge deck movement factors and the nature of the traffic using
the structure

ESOFLEX Joint System when installed will accommodate bridge deck movement factors. The normal
movement capacity is attained in joint size at 400mm wide and not less than 50mm deep.
Two sizes of aggregate, 6mm – 10mm and 14mm – 19mm are used for ESOFLEX Joint System from
basalt granite and dolerite groups has been shown to be satisfactory in exhibiting excellent
resistance to crushing, impact, abrasion, polishing and flakiness.

The types of aggregate recommended as follows :

Aggregate Abrasion Value (A.A.V.) max 5.0

Polished Stone Value (P.S.V.) max 62
Aggregate Impact Value (A.I.V.) min 16
Aggregate Crushing Value (A.C.V.) 10 to 25%
 PROJECT QUALITY PLAN 746525-D
A - Z IDAMAN SDN BHD
MENAIKTARAF JALAN MASUK KE KAMPUNG JERAM
Ref. No. : AZISB-PQP-JDJL.061.1212
PANJANG, DAERAH JEMPOL, NEGERI SEMBILAN

ASPHALTIC PLUG JOINT

FEATURES

 Perfect Waterproof Properties

 Smooth and Comfortable Riding
 Excellent Durability
 Fast Installation
 Easy Maintenance
 Flexible and Fast-Cure Compound

INSTALLATION

 Premix Marking and Saw Cut to the required joint dimension

 Hacking and Cleaning by Air Blower and Hot Air Burner.
 Removing all Laitance and Sub-Standard Material
 Applying Binder into the prepared trench
 Installing Plate with nail over the gap
 Applying Mixture into the prepared trench
 Compaction of Joint with Mechanical Compacter
 Lay and Trowel of Binder for Finishing Layer
 Completed Joint System can be Trafficked within 1 – 2 Hours.
 PROJECT QUALITY PLAN 746525-D
A - Z IDAMAN SDN BHD
MENAIKTARAF JALAN MASUK KE KAMPUNG JERAM
Ref. No. : AZISB-PQP-JDJL.061.1212
PANJANG, DAERAH JEMPOL, NEGERI SEMBILAN

ASPHALTIC PLUG JOINT

METHOD STATEMENT

1. The width of joint is first mark out on the asphalt surface and saw cut to provide a trench in
the carriageway of width and depth as specified in the contract.

2. The excavated area is cleaned and dried the recess in the verge with a compressed air and
wire brush.

3. The prepared area is wire brushed to remove loose asphalt and concrete material. Other fine
loose are remove by air blowing.

4. The expansion gap is caulk with expanded polyethylene foam or mayan rope and the M.S
plate will be nailed centrally. The vertical and horizontal surface is primed with the binder.

5. After completion of the tanking procedure, the joint is constructed in layer.

6. The aggregates are dried and cleaned in a mixer drum by heating.

7. The temperature of the aggregate shall be checked by a good operator with experience will
be able to attain the correct temperature. It is important that the stone is heated
throughout.

8. Heated binder (200 ± 20˚C) is added to the aggregate in the approximate proportions of the
mixing guide below and when the mix is homogeneous, the material is poured into the
trench and raked level. Further binder is then slowly poured into the trench, fully saturating
the matrix. Air will continue to escape from the matrix and the correct appearance will be
with the aggregate partially raised above the binder level. It is important that this flooding is
carried out before the joint appreciably cools, without flooding other parts of the open
trench.

A typical mixing guide is shown below when using a mini-mixer, modified to withstand high
temperatures:-
Aggregate Heat Binder

First layer 60 kg 25 kg
Second layer 60 kg 25 kg
Final layer 50 kg 10 kg

The above guide is suitable for joint depth at 100mm and above installed in three layers. For
joint depth below 100mm, only first layer and final layer is necessary.

The above is an approximate guide, which may be adjusted accordingly. Too much binder to
the mix initially may cause segregation in the trench and lead to an undesirably “soft” joint.
The desired volume ratio of aggregate and binder is typically 75 ± 5% Aggregate : 25 ± 5%
Binder.
 PROJECT QUALITY PLAN 746525-D
A - Z IDAMAN SDN BHD
MENAIKTARAF JALAN MASUK KE KAMPUNG JERAM
Ref. No. : AZISB-PQP-JDJL.061.1212
PANJANG, DAERAH JEMPOL, NEGERI SEMBILAN

9. The temperature of the binder is checked at regular intervals using the probe thermometer.

10. The second layer of joint construction may proceed in a similar manner to the first, as soon
as the lower layer has been fully saturated with binder.

11. The final layer is constructed by adding binder to the heated aggregate as indicated in the
mixing guide above. The aggregate is brought approximately 5mm above the road surface
and compacted to surface level using a vibrating plate before the layer is flooded.

12. The first application of binder to the compacted layer should be screed flush with the top of
the joint, masking into the carriageway each side of the saw cut to provide on aesthetically
pleasing finish.

13. The joint is allowed to cool to ambient temperature and may be trafficked in 1 – 2 hours.