Republic of the Philippines

CAGAYAN STATE UNIVERSITY

Carig Campus
College of Engineering and Architecture
Gmelina Road, CSU Carig compound, Carig Sur
Tuguegarao City, 3500, Cagayan

HIGHWAY
AND
RAILROAD
ENGINEERING
Engr. Ralph S. Reyes, CE
Instructor, CSU Carig Campus
College of Engineering and Architecture
Unit 3
HIGHWAY DEVELOPMENT
AND PLANNING
Lesson 1

MATERIAL TESTING , ROAD

COMPONENTS AND
SPECIFICATIONS
GENERAL DISCUSSION ON DEFINITION AND TERMS

RELATED TO MATERIALS TESTING AND

QUALITY CONTROL
IN ENGINEERING POINT OF VIEW, MATERIALS
QUALITY CONTROL HAS TWO ASPECTS
NAMELY :

• MATERIALS TESTING

• QUALITY CONTROL
WHAT IS MATERIALS TESTING ?

 is the basic means or a tool by which an engineer

or an inspector can be used to determined whether
the materials should be allowed to be incorporated
or be rejected into the work.

 It is a documented proof of the quality of materials

indicating it meets or it fails the desired properties
as called for in the specifications requirements of an
approved contract.

 There can be no quality assurance without adequate quality

control at the source or manufacturer or at construction,
therefore testing is a tool for measuring quality control
in project implementation.
 WHAT IS THE IMPORTANCE OF MATERIALS
TESTING

Engineers do not guess !!!

Testing is an important complement of quality

control in engineering works

Materials testing is not done by sight or other means without

the benefit of laboratory tests. If it is done by sight, it is pure
and simple guessing.

So without testing even in the field or in the laboratory,

no one can state definitely if the quality of materials is
satisfied or not, even the expert.
WHY WE NEED TO KNOW & LEARN TESTING
- Project Engineers, Materials Engineers and Laboratory Technicians
who are involved in the implementation of various infrastructures
needs to learn & know testing technology in construction materials to
enhance and strength their capabilities in the implementation of
Quality Assurance Program in a project.
WHAT BENEFITS WILL YOU ACQUIRED IN
LEARNING MATERIALS TESTING

 Recognize the basic technologies in testing of

construction materials.

• Identify and familiarize the required tests on specific

construction materials

• Identify and understand the basic properties of materials

• Understand the significance of tests on the materials

• Aware of the importance of materials testing in project

implementation
 Perform effectively field/laboratory sampling and testing of
construction materials in accordance with the standard
methods/procedures.

• Familiarize in the application of the proper method of sampling

of materials in the field and laboratory

• Identify and familiarize in all laboratory testing apparatus /

equipment for materials sampling and testing

• Learn and familiarize standard methods and procedures of

laboratory testing of various construction materials

• Learn to check the accuracy and proper maintenance of

laboratory testing apparatus/equipment
 Evaluate, analyze and interpret test results of
construction materials for the purpose of acceptance and
rejection.
• Learn proper computation and check result of
tests performed

• Know the proper reporting system of test reports

• Understand the application of materials standard

specifications based on the result of tests

• Learn how to analyze and evaluate result of

tests indicated on official test reports from testing
laboratories

• Learn the proper recommended measures in the

acceptance or rejection of materials
 HOW MATERIALS IS REPRESENTED
BY A TEST

The usual procedure is to make a test for a certain quantity of materials

representing the quantities to be incorporated into the work or in
accordance with the minimum testing requirements prescribed in each
project. The requirements specify the kind and number of tests for
each items of works.

It should be emphasized that what are specified are the minimum number
of testing only. Additional number of test can be require to the materials
if the owner/inspector is in doubt of the quality of materials or the
finished structure.
When the Testing of Materials be Conducted

An aspect of testing which is very important and most often

overlook is when testing should be conducted.

Testing of material is conducted prior to incorporation into the

work.

If the test is not conducted at the proper time, there is no quality control
since it will then be too late to correct anything that is defective.

If someone will attempt to evaluate the quality of materials without testing

he is taking a big risk because he is guessing.
• STANDARD SPECIFICATIONS FOR HIGHWAYS AND BRIDGES
( MATERIALS AND QUALITY CONTROL REQUIREMENTS )
• Earthworks
Item 102 -- Excavation
Item 104 – Embankment
Item 105 – Subgrade Preparation
Item 106 – Compaction Equipment and Density Control
• Subbase and Base Course
Item 200 – Aggregate Subbase Course
Item 201 - Aggregate Base Course
Item 202 – Crushed Aggregate Base Course

• Surface Courses
Item 300 – Aggregate Surface Course
Item 301 – Bituminous Prime Coat
Item 302 - Bituminous Tack Coat
Item 307 - Bituminous Plant Mix Surface Course-General
Item 310 – Bituminous Concrete Surface Course, Hot Laid
Item 311 – Portland Cement Concrete Pavement
• Bridge Construction
Item 404 – Reinforcing Steel
Item 405 – Structural Concrete
Item 406 – Prestressed Concrete Structures
Item 407 – Concrete Structures
Item 411 – Paints
• Drainage and Slope Protection Works
Item 500 – Pipe Culverts and Storm Drains
Item 505 – Riprap and Grouted Riprap
Item 506 – Stone Masonry
Item 507 - Rubble Concrete
Item 511 – Gabions and Mattresses

* Miscellaneuos Materials
Item 603 – Guardrail
Item 704 – Concrete Masonry Blocks
Main Road Components

 Subgrade
 Aggregate sub-base course
 Aggregate base course
 Surface course
 Drainage structures
 Slope protection/retaining structures
 Miscellaneous Works
Main Road Components
 Main Road Components

 Subgrade- is the upper layer of natural soil which may be the undisturbed
local materials, or soil excavated elsewhere placed as fill. In either case, it is
compacted during construction for road stability.
 Aggregate Subbase and Base Courses - are individual stabilizing layers of
selected material and designed thickness placed on top of the subgrade to
distribute the load transmitted from the surface course.
 Surface Course - is the uppermost structural component of the roadway,
which provides resistance to wear and shearing stress due to traffic load. It
also provides an even skid resistance surface with comfortable durability and
is appropriately crowned to prevent rain water from penetrating into the
subgrade.
Main Road Components

 Shoulders - are located beside the carriage way which is the total width
available for passing vehicles, and is used to receive lateral clearance to
protect major structures on the roadside, to secure safety and comfort of
both motorists and pedestrians and for emergency stopping purposes.
 Drainage Structures - are located beneath or alongside the roadway used
in collecting, transporting and disposing of surface water originating in or
near the road right-of-way.
 Types of Drainage - can be lateral drainage such as a U-shaped, V-shaped
lined canal (side ditch) or perforated drain canal. It can also be transverse
or cross drainage such as a box culvert or a pipe culvert.
Main Road Components

 Slope Protection Structures - are constructed along the side of

the roadway to stabilize the slopes.
 Retaining Walls - are constructed along the side of the
roadway if there are space constrictions. Erosion and sediment
controls are constructed to prevent detrimental effects.
 STANDARD SPECIFICATIONS
FOR HIGHWAYS AND BRIDGES

( MATERIALS AND QUALITY CONTROL REQUIREMENTS

 TYPICAL CROSS – SECTION OF A ROADWAY

Y
MASONR
P
RA

- STONE
ITEM 311 - PCCP
RIP
ED

ITEM 201 – Aggregate Base Course

T
OU

6
GR

ITEM 200 – Aggregate Subbase Course

ITEM 50
05
M5

Item 104 - Embankment

ITE

SUBGRADE or NATURAL GROUND

ITEM 102 – EXCAVATION
 ITEM 102 – EXCAVATION
• This item shall consists of roadway, drainage and borrow excavation
and the disposal of material in accordance with specification and in conformity with
the lines, grades and dimensions shown on the Plans.
• Roadway excavation includes excavation and grading for roadways,
parking areas, intersections, approaches, slope rounding, benching,
waterways and dtches; removal of unsuitable material from the roadbed and beneath
embankment areas; and excavating selected material found
in the roadway for specific use in the improvement.
• Classification of Roadway Excavation
1. Unclassified Excavation - it consist of the excavation and disposal of all
materials regardless of its nature, not classified
and included in the Bill of Quantities

2. Rock Excavation – it consist of igneous, sedimentary and metamor-

phic rock which cannot be excavated without blasting
or the use of rippers, and all boulders or other detached
stones each having a volume of 1 cubic meter or more
 • Classification of Roadway Excavation
3. Common Excavation - it consist of all excavation not included in the Bill of
Quantities under Rock Excavation or other pay items.

4. Muck Excavation - it consist of the removal and disposal of deposits of saturated or

unsaturated mixtures of soils and organic matter not suitable for
foundation material regardless of moisture content.

• Borrow Excavation - consist of the excavation and utilization of

approved material required for the construction of embankments
or for other portions of the work and shall be obtained from
approved sources in accordance with the following:

• Borrow, Case 1 - will consist of material obtained from sources

designated on the Plans or in the Special Provision

• Borrow, Case 2 - will consist of material obtained from sources

provided by the contractor.
 Construction/Quality Control Requirements:

• All excavation shall be finished to reasonably smooth and uniform

surfaces. No materials shall be wasted without the authority of the
Engineer.

• Prior to excavation, all necessary clearing and grubbing in that area shall have
been performed in accordance with Item 100, Clearing and Grubbing

• All suitable materials removed from the excavation shall be used in

the formation of the embankment, subgrade, shoulders, slopes, bedding, and
backfill for structures and for other purposes shown on the Plans or as directed.

• All excess material, including rock and boulders that cannot be used in the
embankments shall be disposed off as directed.
ITEM 104 - EMBANKMENT
 ITEM 104 - EMBANKMENT
• an earth material placed on top of subgrade in order to distribute the wheel
load transmitted to the subgrade. It is commonly used as fill materials to a
roadway construction where it needs to upgrade the existing grade elevation
to suit to actual field conditions when required in the plans.

MATERIALS REQUIREMENT :
Embankments shall be constructed of suitable materials, in consonance
with the following definitions:

1. Suitable Material – material which is acceptable in accordance with the

contract and which can be compacted in the manner specified. It can be
common material or rock.

Selected Borrow , for Topping – soil of such gradation that all particles
will pass sieve with 75 mm ( 3 inches ) and not more than 15 mass
percent will pass the 0.075 mm ( N0. 200 ) sieve. The materials shall have
a plasticity index of not more than 6 and a liquid limit of not more than
30
2. Unsuitable Material - material other than suitable materials such as:
a. Materials containing detrimental quantities of organic materials,
such as grass, roots and sewerage.
b. Organic soils such as peat and muck.

c. Soils with liquid limit exceeding 80 and/or plasticity index exceeding

55
d. Soils with a natural water content exceeding 100%

e. Soils with very low natural density, 800 kg/m3 or lower

f. Soils that cannot be properly compacted as determined by Engineer

CONSTRUCTION / QUALITY CONTROL REQUIREMENTS :

 The surface of the existing ground shall be compacted to a depth of

150 mm ( 6 in. ) and the top portions of the roadbed in both cuts and
fill of embankments shall consist of selected borrow for topping from
excavations.
 Roadway embankment of earth material shall be placed in horizontal
layers not exceeding 200 mm ( 8 inches ), loose measurement, and shall
be compacted before the next layer is placed.
 Thicker layer may be placed if vibratory roller with high compactive
effort is used provided that density requirement is attained and as
approved by the Engineer.

Compaction Trials
Before commencing the formation of embankments, compaction trials
on areas not less than 10 m wide and 50 m long shall be carry-out to
determine the relationship between types of compaction equipment and
the number of passes required and the method of adjusting moisture
content.
 The embankment material shall be compacted in layers until a uniform
density of not less than 95 mass percent of the maximum dry density is
attained as determined by AASTHO T 99 Method C

 At least one group of three in-situ density tests shall be carried out
for each 500 m2 of each layer of compacted fill.
ITEM 105 - SUBGRADE PREPARATION
This item shall consist of the preparation of the subgrade for the support of
overlying structural layers and should extend to full width of the roadway.
MATERIALS REQUIREMENT :
Unless otherwise stated in the Contract and except when the subgrade is
in rock cut, all materials below subgrade level to a depth of 150 mm or to
such greater depth shall meet the requirements of Item 104 - Embankment

CONSTRUCTION / QUALITY CONTROL REQUIREMENTS :

The finished compacted surface of the subgrade shall conform to the
allowable tolerances:

Permitted variation from design Level of Surface + 20 mm

- 30 mm
Permitted Surface Irregularity measured by 3m
Straight Edge 30 mm

Permitted Variation from Design Cross Fall or

Camber ± 0.5%

Permitted Variation from Design Longitudinal

Grade over 25 m length ± 0.1%
ITEM 106 - COMPACTION EQUIPMENT and DENSITY
CONTROL STRIPS
This item is a control procedure used to determine density requirements
of selected embankments, subgrade, bases and bituminous concrete. The
procedure will consist of control strip construction to establish target
densities for the specified course plus uce of sand-cone method of density
testing equipment to determine in-place densities obtained during the
construction process.

CONSTRUCTION / QUALITY CONTROL REQUIREMENTS :

Minimum requirements for compaction equipment:

1. Sheepsfoot, tamping or grid rollers shall be capable of exerting a force
of 45 newton/mm (250 lbs/in.) of length of roller drum
2. Steel-wheel rollers other than vibratory shall be capable of exerting force
of not less than 45 newton/mm (250 lbs/in.) of width of the compression
roll or rolls
3. Vibratory steel-wheel rollers shall have a minimum mass of 6 tonnes.
The compactor shall be equipped with amplitude and frequency controls
and specifically designed to compact the material on which is used.
4. Pneumatic-tire rollers shall have a smooth tread tires of equal size that will
provide a uniform compacting pressure for the full width of the roller and
capable of exerting a ground pressure of at least 550 kpa (80 lbs/in2).

5. Heavier compacting unit may be required to achieve the specified

density of the embankment

To determine target density, a control strip shall be constructed at the

beginning of work each course material to be compacted. A control
strip shall an area of approximately 335 sq.m.

The target density shall be the mean density of the control strip by
averaging the results of ten in-place density tests taken at randomly
selected sites within the control strips

If the mean density of the control strips is less than 98 percent of the
density of laboratory compacted specimens as determined by testing
procedures appropriate for the material being placed, another control
strip shall be constructed.
ITEM 200 – AGGREGATE SUBBASE COURSE
 ITEM 200 – AGGREGATE SUBBASE COURSE
• The subbase is a structural layer which accepts greater compressive stress
than the subgrade and thus reduces the deformation of the pavement under
traffic loading.

• Made of economical materials with a relatively low load bearing capacity

which are place on top of subgrade or an embankment materials in order to
distribute the wheel load transmitted to the subgrade.

Materials Requirements:

Subbase materials shall consist of hard, durable particles or fragments of

crushed slag, or crushed natural gravel and filler of natural or crushed sand
or other finely divided mineral matter shall be free from vegetable matter and
lumps or balls of clay.
Grading Requirements:

The subbase materials should be well graded and should conform to

the following grading requirements as tested by ASSHTO T 11 and T 27

Sieve Designation Mass % Passing

Mm Inches
50 2 100
25 1 55 – 85
9.5 3/8 40 – 75
0.075 No. 200 0 - 12
Liquid Limit: (Tested by AASHTO T 89)

- The fraction passing 0.425 mm (No. 40) sieve shall have a Liquid
Limit of not greater than 35

Plasticity Index: (Tested by AASHTO T 90)

- The fraction passing the 0.425 mm (No. 40) sieve shall have a
plasticity index (PI) of not greater than 12

Abrasion Loss or Mass Percent Wear: (Tested by AASHTO T

96)
- The coarse portion, retained on a 2.0 mm (No. 10) sieve shall have a
mass percent of wear not exceeding 50 by the Los Angeles
Abrasion Tests.

CBR Value: (Tested by AASHTO T 193)

- The material shall shall have a soaked CBR value of not less than
25%. This value shall obtained at the maximum dry density
(MDD) as determined by ASSHTO T 180, Method D)
Construction/Quality Control Requirements:
Spreading and Compacting
- where the required thickness is 150 mm or less, the material may be
spread and compacted in one-layer.

- where the required thickness is more than 150 mm, the aggregate
subbase shall be spread and compacted into two (2) or more layers
of approximately equal thickness and the maximum compacted
thickness of any one (1) layer shall not exceed 150 mm

- compaction of each layer shall have a field density of at least 100

percent of the maximum dry density determined in accordance with
AASHTO T-180, Method D

- before subbase construction is started, a trial section shall be

conducted in order to check the suitability of the materials and the
efficiency of the equipment and construction method which is
proposed to be used by the contractor.

- one trial section of about 500 m2 shall be made for every type of
material and/or construction equipment/procedure propose for use.
 Allowable Tolerances to the Designed Level and
Transverse Slopes for a Compacted Aggregate Subbase

Permitted variation from design

Thickness of Layer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  20 mm

Permitted variation from design + 10 mm

Level of Surface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 mm

Permitted Surface Irregularity

Measured by 3-m straight edge - - - - - - - - - - - - - - - - - - - - - - - - - 20 mm

Permitted variation from design

Crossfall or Camber - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ± 0.3%

Permitted variation from design

Longitudinal Grade over 25 m length - - - - - - - - - - - - - - - - - - - - ± 0.1%
ITEM 201 – AGGREGATE BASE COURSE

The base reduces the vertical compressive stress induced by traffic

in the subbase and the subgrade.

Made of high quality material with a high load bearing capacity and lies
close under the surfacing course material. It provides a relatively non-
frost material on which to provide support for surface course and
sometimes to carry traffic temporarily.

Materials Requirements:

The fraction passing the 0.075 mm (No. 200 sieve shall not be
greater than 0.66 (two thirds) of the fraction passing the 0.425 mm
(No. 40 sieve)
Materials Requirements

The base course materials should conform to one of the following

grading requirements:

Sieve Designation Mass % Passing

mm inches Grading A Grading B
50 2 100
37.5 1–½ - 100
25.0 1 60 – 85 -
19.0 ¾ - 60 – 85
12.5 ½ 35 – 65 -
4.75 No. 4 20 – 50 30 – 55
0.425 No. 40 5 – 20 8 – 25
0.075 No. 200 0 - 12 2 – 14
CONSTRUCTION / QUALITY CONTROL REQUIREMENTS
Spreading and Compaction
The same as construction procedure as in Item 200 – Aggregate Subbase
Course
Allowable Tolerances to the Designed Level and
Transverse Slopes for a Compacted Aggregate Subbase

Permitted variation from design

Thickness of Layer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  10 mm

Permitted variation from design + 5 mm

Level of Surface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 mm

Permitted Surface Irregularity

Measured by 3-m straight edge - - - - - - - - - - - - - - - - - - - - 5 mm
Permitted variation from design
Crossfall or Camber - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ± 0.2%
Permitted variation from design
Longitudinal Grade over 25 m length - - - - - - - - - - - - - - - - ± 0.1%
 ITEM 202 – CRUSHED AGGREGATE BASE COURSE
Either a natural or manufactured base course material where granular
component are made of crushed gravel, crushed stone or crushed rock and
of much superior quality than an ordinary base course and not less than 50
mass percent shall have at least one (1) fractured surface.

This material requires a soil binder to have plasticity for proper bonding of
aggregates and use to provide support for surface course of a roadway.

Material Requirements

Crushed Aggregates

shall consist of hard, durable particles or fragments of stone or gravel

crushed to the size and shall be clean and free from vegetable matters,
lumps or balls of clay and other deleterious substances. The material
shall be of such nature that it can be compacted readily to form a
firm, stable base.
GRADING REQUIREMENTS

The base material shall conform to one of the following grading

requirements, whichever is called for in the Bill of Quantities.

Sieve Designation Mass Percent Passing

Std., mm Std., inch Grading A Grading B
37.5 1 – 1/ 2 100
25 1 - 100
19 3 /4 60 - 85 -
12.5 1/ 2 - 60 - 90
4.75 No. 4 30 - 55 35 - 65
0.425 No. 40 8 - 25 10 - 30
0.075 No. 200 2- 14 5 - 15
ITEM 300 - AGGREGATE SURFACE COURSE
This Item consist of a wearing course or top course composed of gravel
or crushed aggregate and binder material constructed on a prepared base.

Materials Requirement :
Shall consist of hard, durable particles or fragments of stone or gravel and
sand or other fine mineral particles free from vegetable matter and lumps
or balls of clay and it can be compacted readily to form a firm, stable layer.
Grading Requirements

Sieve Designation Mass Percent Passing

Standard Alternate Grading Grading Grading Grading
mm US Std. A B C D

25 1” 100 100 100 100

9.5 3/8 50 – 85 60 – 100 - -
4.75 No. 4 35 – 65 50 – 85 55 – 100 70 - 100

2.00 No. 10 25 – 50 40 – 70 40 – 100 55 – 100

0.425 No. 40 15 – 30 25 – 45 20 – 50 30 – 70
0. 075 No. 200 5 – 20 5 – 20 6 – 20 8 - 25
CONSTRUCTION / QUALITY CONTROL REQUIREMENTS :
Placing, Compacting Requirements and Trial Sections shall be in
accordance with the requirements of Item 201, Aggregate Base Course.

Surface Course Thickness and Tolerances

Permitted variation from design + 15 mm
Thickness of Layer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 mm
-

Permitted variation from design + 15 mm

Level of Surface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 mm

Permitted Surface Irregularity

Measured by 3-m straight edge - - - - - - - - - - - - - - - - - - - - 5 mm
Permitted variation from design
Crossfall or Camber - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
+ 0.2%
Permitted variation from design
Longitudinal Grade over 25 m length - - - - - - - - - - - - - - - -
+ 0.1%
ITEM 301 - BITUMINOUS PRIME COAT

This item consists of preparing and treating an aggregate base course

with bituminous material preparatory to the construction of bituminous
surface course.

Materials Requirement :

Bituminous material shall be either Rapid Curing (RC) or Medium Curing

(MC) Cut-Back Asphalt

Rapid Curing Liquid Asphalts shall conform to the requirements of

AASHTO M 81

Medium Curing Liquid Asphalts shall conform to the requirements of

AASHTO M 82
Construction / Quality Control Requirements :

Prime coat shall be applied only to surfaces which are dry or slightly
moist. No prime coat shall be applied when the weather is foggy or
rainy.

The bituminous material shall be sprayed by means of a pressure

distributor of not less than 1000 liters capacity mounted on pneumatic
tires with a heated temperature of 180 deg. centigrade

The rate of application of the bituminous material shall be within the

range of 1 to 2 liters/m2

The prime coat shall be left undisturbed for a period of at least 24

hours and shall not be opened to traffic until it has penetrated and
cured sufficiently.
ITEM 302 - BITUMINOUS TACK COAT

This item consists of preparing and treating an existing bituminous

or cement concrete surface with bituminous material preparatory to
the construction of bituminous surface course.

Materials Requirement :

Bituminous material shall be either Rapid Curing (RC) Cut-Back or

Emulsified Asphalt

Rapid Curing Liquid Asphalts shall conform to the requirements of

AASHTO
M 81

Emulsified Asphalt shall conform to the requirements of AASHTO M140

(Anionic) or AASHTO M 208 (Cationic)
Construction / Quality Control Requirements :

Tack coat shall be applied only to surfaces which are dry or slightly
moist. No tack coat shall be applied when the weather is foggy or
rainy.

Before applying the tack coat , the full width of the surface to be
treated shall be cleaned of loose and foreign materials by means of
power broom or blower and supplemented as necessary by hand
sweeping.

The rate of application of the bituminous material shall be within the

range of 0.2 to 0.7 liters/m2
ITEM 310 - BITUMINOUS CONCRETE SURFACE COURSE,
HOT LAID

 This is Item shall consist of constructing a bituminous concrete surface

course composed of aggregates, mineral filler, and bituminous material
mixed in a central plant , constructed and laid hot on the prepared base.

Materials Requirements :
Composition and Quality of Bituminous Mixture
( Job Mix Formula )

• Each job-mix formula shall propose definite single values for :

1. The percentage of aggregate passing each specified sieve size

2. The percentage of bituminous material to be added.

3. The temperature of the mixture delivered on the road

4. The kind and percentage of additive to be used

5. The kind and percentage of mineral filler to be used

 Standard Tolerances for the Job - Mix Formula

Passing No. 4 and larger sieves + 7 percent

Passing No. 8 to No. 100 sieves ( inclusive ) + 4 percent

Passing No. 200 sieve + 2 percent

Bituminous Material + 0.4 percent

Temperature of Mixture + 10 deg. Centigrade

 The mixture shall have a minimum compressive strength of 1.4 Mpa
( 200 psi )

 The mixture shall have a mass percent air voids with the range of 3 to 5

 The mixture shall also have an index of Retain Strength of not less than
70 when tested by AASTHO T 165

 The proportion of bituminous material, on the basis of total dry aggregate

shall be from 5.0 to 8.0 mass percent

 Hydrated lime shall be added to the mixture during the mixing operation
in the amount of one-half to one ( 0.5 to 1.0 ) mass percent by dry
aggregate basis.
Construction / Quality Control Requirements :

 Weather Limitations : Bituminous mixtures shall not be placed on any

wet surface, or when weather conditions would be prevent
the proper handling or finishing of the material.

 The mixture shall be placed at a temperature not less than 107 deg.
Centigrade as measured in the truck just prior to dumping into the
spreader.

 The mixture shall be rolled/compacted by a paver until the marks roller

marks are eliminated and a minimum of 97 mass percent of the density
of the laboratory compacted specimens prepared in accordance with
AASTHO t 166 has been obtained.
Acceptance, Sampling and Testing

 Samples shall be cut at full depth of the finished pavement for testing
by sawing or core drilling. Sawed and cored samples shall be squared
at least 150 mm x 150 mm or 100 mm diameter, respectively.

 At least one, but not more than three (3) samples shall be taken for each
full day’s operation.

 If no core samples were taken during the day’s operation, core samples
shall be taken from the completed pavement for every 100 lm. per lane.
no acceptance and final payment shall be made on completed asphalt
pavement unless core test for thickness determination is conducted.
 The compacted pavement shall have a density equal to, or greater than 97
mass percent of the density of a laboratory specimen. The asphalt
pavement represented by the cores shall not accepted if the deficiency in
density is more than 2 %.

 The compacted pavement shall have a thickness tolerances of (-) 5 mm.

Thickness in excess of the specified thickness shall not be considered in
the payment of asphalt pavement.

 The asphalt pavement represented by the individual core shall not be

accepted if the deficiency in the core thickness is more than 5 mm.
Averaging of the density and thickness of asphalt cores is not permitted.

 If the deficiency in the core thickness is more than 5 mm, additional layer
may be permitted in order to meet the designed thickness, however, the
minimum additional asphalt overlay thickness should be dependent on the
minimum capacity of asphalt paver but it should not be less than 50 mm
( 2 inches ).
 ITEM 311 - PORTLAND CEMENT C0NCRETE PAVEMENT

This item consist of pavement of Portland Cement Concrete, with or without

reinforcement, constructed on the prepared base in accordance with
specification and in conformity with lines and grades, thickness and
typical cross-section of the plans.
Materials Requirements:

1. Portland Cement
Only Type I Portland Cement shall be used unless otherwise provided for
in the Special Provisions.

Different brands or the same brands from different mills shall not be mixed

nor shall they be used alternately unless the mix is approved by the
Engineer.
The use of Portland Pozzolan Cement Type IP meeting the requirements
of AASTHO M 240 / ASTM C 695 shall be allowed, provided that the trial
mixes shall be done and that the mixes meet the concrete strength
requirements.
2. Fine Aggregate

• material passing the 0.075 mm ( No. 200 sieve ) shall not contain
more than (3) mass percent by washing nor more than (1) mass
percent each of clay lumps or shale.

• when subjected to five (5) cycles of the sodium sulfate soundness

test, the weighted loss, shall not exceed 10 mass percent

• if subjected to the calorimetric test for organic impurities and a color

darker than the standard is produced, it shall be rejected.

* when tested for the effect of organic impurities of strength of mortar,

the fine aggregate may be used if the relative strength at 7 and 28
days is not less than 95 mass percent
 Grading Requirements for Fine Aggregates

Sieve Designation Mass Percent Passing

9.5 mm ( 3/8 in. ) 100

4.75 mm ( No. 4 ) 95 - 100

2.36 mm ( No. 8 ) -

1.18 mm ( No. 16 ) 45 - 80

0.600 mm ( No. 30 ) -

0.300 mm ( No. 50 ) 5 - 30

0.150 mm ( No. 100 ) 0 - 10

3. Coarse Aggregate

• contain not more than one (1) mass percent of material passing the 0.074
mm ( No. 200 sieve ) by washing nor more than 0.25 mass percent of clay
lumps, nor more than 3.5 mass percent of soft fragments.

• if subjected to five (5) cycles of the sodium sulfate soundness test, the
weighted loss shall not exceed 12 mass percent.

• shall have a mass percent of wear not exceeding 40 when tested to Los

Abrasion machine.
 Grading Requirement For Coarse Aggregate

Sieve Designation Mass Percent Passing

Standard Alternate Grading Grading Grading

mm U.S. Std. A B C

75 3 in. 100 - -

63 2 – ½ in. 90 – 100 100 100

50 2 in. - 90 – 100 95 - 100

37. 5 1 – ½ in. 25 – 60 35 – 70 -
25 1 in. - 0 – 15 35 – 70
19 ¾ in. 0 – 10 - -

12.5 ½ in. 0–5 0–5 10 – 30

4.75 No. 4 - - 0–5

5. Reinforcing Steel

• tie bars shall be deformed bars that are to bent and re-straightened
during construction and shall conform to the requirements of AASTHO M 31 or
M42

• dowel bars shall be plain round bars where one-half of the length shall
be painted with one coat of approved lead or tar paint and shall conform to
the requirements of AASTHO M 31 or M42.

• sleeves for dowel bars shall be metal of approved design to cover

50 mm ( 2 inches ) of the dowel with a closed end, and with suitable
stop to hold the end of the sleeve at least 25 mm (1 inch ) from the end
of the dowel.
PROPORTIONING, CONSISTENCY AND STRENGTH OF CONCRETE
Cement Factor, Min. :
- to meet the minimum strength requirements for paving concrete, it is
required to have at least 364 kg. of cement per cubic meter of concrete or
a cement content of 9.1 bags/cu.m. of concrete on a 40 kg. per bag of
cement

Slump Requirements :
- if vibrated, a slump between 37.5 – 75 mm ( 1-1/2 – 3 inches )

- if not vibrated, a slump between 12.5 – 37.5 mm ( ½ - 3 inches )

Strength Requirements :
- flexural strength @ 14 days of 3.8 Mpa ( 550 psi ), when tested by the
third point method or 4.5 Mpa ( 650 psi ), when tested by mid-point
method

- compressive strength @ 14 days of 24.1 Mpa ( 3500 psi ) for cores taken

and tested in accordance with AASTHO T 24

CONSTRUCTION / QUALITY CONTROL REQUIREMENTS
Preparation of Grade
• the prepared base shall be checked of the required density, surface
imperfections and finished grade elevation.

• the prepared base shall be extended and compacted at least 60 cm.

beyond the edge of the proposed concrete pavement to ensure that the density
of the base at the edge of pavement is the same as on its carriageway that can
support the paving machine when it is used.

Setting of Forms
• forms shall be of steel and of equal depth equal to the thickness of the
pavement at the edge and provided with adequate devices for secure
setting.

• any roadbed, which at the form line is found below established grade,
shall be filled with approved granular materials to grade in lifts of 3 cm.
or less, and thoroughly re-rolled or tamped.
Mixing of Concrete

• the concrete may be mixed at the site of the work, in a central-

mix plant, or in truck mixers

• concrete mix when supplied by a batching plant, shall only be

allowed in the DPWH projects provided it is duly accredited
by the BRS ( DO # 253, S. of 2003 ).

• batching plants installed/used in the DPWH contract projects

shall also be required to be accredited prior to supply the
concrete mix.

• concrete when mixed at the site or in a central mixing plant, the

mixing time shall not be less than 50 seconds nor more than 90
seconds
 Mixing of Concrete

• the time elapsed from the time the water is added to the mix until the
concrete is deposited in place at the site, shall not exceed 45 minutes
when concrete is hauled in non agitating trucks, nor 90 minutes when hauled in
truck mixers.

• when volumetric measurements are authorized for small project requiring

less than 75 cu.m. of concrete per day of pouring, the weight proportions
shall be converted to equivalent volumetric proportions. Use of chute is
allowed provided that a weighing scales for determining the batch weight
will be used.

• retempering concrete by adding water or by other means shall not be

permitted, except that when concrete is delivered in truck mixers, provided
all these operations are performed within 45 minutes after the initial mixing
operation and the water-cement ratio is not exceeded.
Limitation of Mixing

• concrete not in place within 90 minutes from the time the ingre-
dients were charged into the mixing drum or that has developed
initial set shall not be used.

• retempering of concrete or mortar which has partially hardened

that is remixing with or without additional cement,aggregate or
water, shall not be permitted.

Placing of Concrete
• if only finishing equipment is carried on the newly paved lane,
paving in adjoining lanes may be permitted after 3 days.
• concrete shall be thoroughly consolidated by means of a vibrator
inserted in the concrete in a vertical position and should not be
operated longer than 15 seconds in any one location.

• vibrators shall operate at a frequency of 8,300 to 9,600 impulses

per minute under load and the space interval of inserting
vibrators should be between 50 cm to 60 cm.
Placing of Concrete

• vibrators shall be used for consolidation only, and not be used for
moving concrete horizontally along the forms.

• a well consolidated concrete is 20 % to 25 % higher in strength than that

of concrete which is not thoroughly consolidated

• concrete not in-place within 90 minutes from the time the ingredients
were charged into the mixing drum or that has develop initial set shall
not be used.

Test Specimens
• as work progresses, at least one (1) set consisting of three (3) concrete
beam test specimens, 150 mm x 150 mm x 525 mm or 900 mm shall be
taken from each 330 m2 of pavement, 230 mm depth, or fraction thereof
placed each day.
Joints in Portland Cement Concrete Pavement

Longitudinal Joints

• deformed steel tie bars of specified length, size,spacing shall be placed

perpendicular to the longitudinal joints and may be bent at right angles
against the form of the first lane constructed and straightened into final
position before the concrete of the adjacent lane is placed.

• when shown on the plans and when the adjacent lanes of pavement are
constructed separately, joint steel side forms shall be used which will
form a keyway along the construction.
Transverse Contraction Joint/ Weakened Joint

• consists of planes of weakness created by forming or cutting

grooves in the surface of the pavement and shall include transfer
assemblies.

• the depth of the weakened plane joint should at all times not less
than 50 mm and width should not be more than 6 mm.

Longitudinal joints
width = 6mm, min.

Depth = 50mm min.

 Types of Contraction/Weakened Joint
1. Transverse Strip Contraction Joint
- can be formed by installing a parting strip to be left in place

2. Formed Groove Contraction Joint

- shall be made by depressing an approved tool or device into the
plastic concrete and shall remain in place unti the concrete has
attain its initial set and shall then be removed without disturbing the
adjacent concrete, unless the device is designed to remain in the
joint.
3. Sawed Contraction Joint
- created by sawing grooves in the surface of the pavement of the width
not more than 6 mm and depth of not less than 50 mm and at the
spacing and lines as shown on the plans.
- sawing of the joints shall commence as soon as the concrete has
hardened sufficiently to permit sawing without excessive ravelling,
usually 4 to 24 hours.

- sawing of any joint shall be omitted if cracks occurs at or near the joint
location prior to the time of sawing.
Transverse Construction Joint

• shall be constructed when there is an interruption of more than

30 minutes in the concreting operations.

• no transverse joint shall be constructed within 1.50 m of an

expansion joint, or plane of weakness.

• if sufficient concrete has been mixed at the time of interruption

to form a slab of at least 1.5 m long, the excess concrete from
the last preceding joint shall be removed and disposed off as
directed.
Load Transfer Device

• dowel bar of specified size, length and spacing is used in

transverse contraction joint as load transfer device to the
succeeding plane of weakness and shall be held in position
parallel to the surface and center line of the slab that is
left in the pavement.

• the portion of each dowel shall be painted with one coat of lead
or tar and be thorouhly coated of an approved lubricant to
prevent the concrete from binding to that portion of the dowel.

• dowel bar shall be provided with metal sleeves designed to cover

50 mm plus or minus 5 mm of the dowel , with a watertight
closed end and with a suitable stop to hold the end of the
sleeves at least 25 mm from the end of the dowel.
Final Finish

• brooming operation should be executed that the corrugations

produced in the surface shall be uniform in appearance and
not more than 1.5 mm in depth.

• the hardened surface of the finished pavement shall have a

coefficient of friction less than 0.25 or more. Completed
pavement that is found to have a coefficient of friction less
than 0.25 shall be grounded or scored by the contractor at
his own expense to provide the required coefficient of friction.
 Surface Test

• the hardened finished pavement shall be tested with a 3-m

straight-edge or other specified device.

• areas showing high spots of more than 3 mm but not exceeding

12 mm shall be marked and immediately ground down with an
approved grinding tool to an elevation where there area or spot
will not show surface deviations in excess of 3 mm when tested
with 3 m straight

• areas showing high spots of more than 12 mm, the pavement

shall be removed and replaced by and at the expense of the
contractor.

• any area or section to be removed shall not be less than 1.5 m

in length and not less than the full width of the lane involved.

• any remaining portion of the slab to be removed and replaced

adjacent to the joints that is less than 1.5 m in length, shall also
be removed and replaced.
Curing
Immediately after the finishing operations have been completed and
the concrete has sufficiently set, the surface of the newly placed
concrete shall be cured for a period of 72 hours, with any of the
following methods:

1. By covering the pavement with cotton or burlap mats saturated with

water.

2. By thoroughly wetting the pavement and covering its top surface

and sides with waterproof paper.

3. By ponding which involves maintaining a layer of water on the

surface of the pavement by means of earth or sand dikes.

4. By spraying uniformly with white pigmented curing compound

( Impervious Membrane Method ) immediately after finishing of the
surface and before the set of concrete has taken place.
 Removal of Forms

• forms for concrete shall remain in place undisturbed for not

less than24 hours after concrete pouring.

• in case portions of the concrete are spalled during the removal

of forms, they shall be immediately repaired with fresh mortar
mixed in the proportioned of one part of Portland Cement and
two parts of fine aggregates.

• in case major honeycombs occurs on sides of the pavement, it

shall be removed and replaced at the expense of the contractor.
Item 505 - RIPRAP AND GROUTED RIPRAP
- A structure which is built of stone only or stone, cement, fine
aggregates and water, with or without filter backing which is
commonly used in slope protection works, drainage canals and other
places as called for in the plans, and constructed on the prepared
foundation bed in accordance with the lines and grades, sections and
dimensions shown on the plans.

Materials Requirements
Stones – consist of rock as nearly rectangular in section as is
practical,except that riprap of Class A may consist of round
natural stones. The stones shall be sound, tough, durable,
dense, resistant to the action of air and water, and suitable
in all respects for the purpose intended.

- Sound pieces of concrete obtained from the removal of

bridges, culverts and other structures may be substituted
for stone with the approval of the Engineer.
Classes of Stones Intended for Riprap

Class A - Stones ranging from a minimum of 15 kg to a maximum of

25 kg., with at least 50 percent of the stones weighing more
than 20 kg.

Class B - Stones ranging from a minimum of 30 kg to a maximum of

70 kg. with at least 50 percent of the stones weighing more
than 50 kg.

Class C - Stones ranging from a minimum of 60 kg to a maximum of

100 kg with at least 50 percent of the stones weighing more
than 80 kg.

Class D - Stones ranging from a minimum of 100 kg to a maximum of

200 kg with at least 50 percent of the stones weighing more
than 150 kg.
 Mortar

• shall consists of sand, cement and water conforming to the

requirements under Item 405 – Structural Concrete.

• shall be mixed in the proportion of one part cement to three parts

sand by volume and sufficient water to obtain the required
consistency

• Portland Cement Type I conforming to the requirements of

AASHTO M 85 (ASTM C 150) shall be used.

• Use of Portland Pozzolan Type IP meeting the requirements of

AASHTO M 240 (ASTM C 595) Specifications for Blended
Hydraulic Cement shall be allowed, provided that trial mix shall be
done and that the mixes meet the strength requirement.
• Fine aggregates shall conform to the requirements as specified in
Item 405, Structural Concrete and have the following grading
requirements:

Grading Requirements for Structural Concrete

Sieve Designation Mass Percent Passing

9.5 mm ( 3/8 ) 100

4.75 mm ( No.4 ) 95 - 100

2.36 mm ( No. 8 ) -
1.18 mm ( No.16 ) 45 - 80

0.600 mm ( No. 30 ) -

0.300 mm ( No. 50 ) 5 - 30
0.150 mm ( No. 100 ) 0 - 10
 Mortar
• the horizontal and vertical contact surface between stones shall be
embedded by cement mortar having a minimum thickness of 20 mm.

• sufficient mortar shall be used to completely fill all voids leaving the
face of the stones exposed.

Filter Materials

• when required, the riprap shall be placed on a filter layer to prevent fine
embankment materials to be washed out through the voids of the faces of
stones.

• the grading of the filter material shall be specified on the Plans or in the
Special Provisions.

• if not so specified, fine aggregate passing the grading requirements for

Item 405, Structural Concrete, will satisfy for the filter materials.
Construction / Quality Control Requirements

• the bed for riprap shall be excavated to the required depths

and properly compacted, trimmed and shaped.

• stones placed below the water line shall be distributed so that

the minimum thickness of the riprap is not less than that of
the specified.

• stones above the water line shall be placed by hand or

individually by machines and they shall be laid with close,
broken joints and shall be firmly bedded into the slope and
against the adjoining stones.

• Stones shall be laid with its larger axis perpendicular to the

slope in close contact with each adjacent stone.

• For dry riprap, interstices between stones shall be filled with

small broken fragments firmly rammed into place
• the surface of riprap shall not vary from the theoretical surface
by more than 100 mm at any point.
• Grouted riprap shall be cured for a period of at least three (3)
days.
• For grouted riprap, spaces between the stones shall be filled
with cement mortar throughout the thickness of the riprap and
sufficient mortar shall be used to completely fill all voids
except that the face surface of the stone shall be left exposed.

• Riprap shall have the following minimum thickness, measured

perpendicular to the slope

Class A - 300 mm

Class B - 500 mm

Class C - 600 mm

Class D - 800 mm
• Weepholes shall be placed horizontally at the lowest points
where free outlets for water can be obtained and shall spaced
at not more than 2 meter center to center in a staggered
manner.

• All faces of stones shall be thoroughly cleaned of mortar stains

immediately after stones are laid and while the mortar is fresh.
 ITEM 506 - STONE MASONRY
This item consist of stone masonry in minor structures, in headwalls for
culverts, in retaining walls at the toes of slopes, and at other places called
for on the Plans.

Materials Requirements

Stone - unless otherwise shown on the Plans, stones shall have a thickness
of not less than 150 mm, and widths of not less than one and one-half
times their respective thickness, and lengths of not less than one and
one-half times their respective widths. Stones shall be clean, hard,
durable and of good shape and free of depressions and projections
that might weaken or prevent it from being properly bedded. Adobe
stones shall not be used unless otherwise specified.
Mortar
- shall consists of sand, cement and water conforming to there
requirements under Item 405 – Structural Concrete except as to
the of fine aggregate which shall all pass the 2.36 mm (No.8)
sieve, not less than 15 nor more than 40 percent shall pass the 0.3
mm (No. 50) sieve, and not more than 10 percent shall pass the 0.15
mm (No. 100) sieve.
 • shall be mixed in the proportion of one part cement to three parts sand by
volume and sufficient water to obtain the required consistency that can be
handled easily and spread with the trowel.

• Mortar that is not used within 90 minutes after the water has been added shall be
discarded. Retempering of mortar will not be permitted.

Construction / Quality Control Requirements

• Stones shall be laid with their longest faces horizontal in full beds of mortar and
joints shall be flushed with mortar. Large stones shall be used in the corners.
• The exposed faces of individual stones shall be parallel to the faces of the walls
in which the stones are set.

• Weepholes shall be placed horizontally at the lowest points where free outlets
for water can be obtained and shall spaced at not more than 2 meter center to
center in a staggered manner. Other provision of weepholes shall conform to the
requirements of Item 405, Riprap and Grouted Riprap.

• All faces of stones shall be thoroughly cleaned of mortar stains immediately after
stones are laid and while the mortar is fresh.
• The stone masonry shall be protected from the hot or dry weather and
shall be cured by keeping wet for a period of at least three (3) days after
completion.

• Weepholes shall be placed horizontally at the lowest points where free

outlets for water can be obtained and shall spaced at not more than 2
meter center to center in a staggered manner.

• The length of the weepholes shall not be less than the thickness of the
walls of the abutment and shall be at least 50 mm diameter PVC or other
pipe material accepted by the Engineer.

• Cleaning of exposed faces of stones shall be immediately done after

being laid and while the mortar is still fresh. All face of stones shall be
thoroughly cleaned of mortar stains and shall be kept clean until the
work is completed.

• Curing of the completed stone masonry shall be satisfactory protected

from the sun and shall be kept wet for a period of at least three (3) days
after completion.
ITEM 507 - RUBBLE CONCRETE
This item consist of the construction of rubble concrete in accordance
with the specification and in conformity with the lines, grades, slopes and
dimension shown in the Plans.

Materials Requirements
Stone - the stone shall be cleaned, hard, and durable and shall be
subject to the Engineer’s approval. Adobe stone shall not be used
unless otherwise specified. Stones to be used shall be more than
0.015 cubic meter in volume and not less than 75 percent of the
total volume of rock embankment and shall consist of stones 0.03
cubic meter in volume.

Concrete Class “B”

- It shall be in accordance with Item 405, Structural Concrete with
16.50 Mpa ( 2400 psi ) minimum compressive strength @ 28 days
Construction / Quality Control Requirements

Placing of Concrete:
- One layer of concrete Class “B” shall be placed at the prepared
base prior to placing of stones. Clearance between stones shall
not be less than 2-1/2 inches or the maximum size of concrete
aggregates for Class “B”.

- Concrete Class “B” shall be placed after each layer of stone and shall
be thoroughly consolidated by means of a vibrator inserted in each
in each layer of concrete. In no case shall the vibrator be operated
longer than 10 seconds in any location.

Weepholes
• Weepholes shall be placed horizontally at the lowest points where
free outlets for water can be obtained and shall spaced at not more
than 2 meter center to center in a staggered manner. Other provision
of weepholes shall conform to the requirements of Item 405, Riprap
and Grouted Riprap.
Item 511 – Gabions and Mattresses

M
a
t
t
r
Gabions e
s Gabions
s
 GABIONS

- is a restraint structure used to control landslide or erosion. It is free

draining, heavy monolithic gravity structure consisting of wire
baskets filled with non-degrable rocks.

- gabions are flexible enough to cope with differential settlement and

they have excellent permeability to drain the restrained material. Less
lateral space is needed as compared to the rock buttress, and much
preferred where the space is limited.

- it is made of zinc-coated steel wire and range in size from 1.0 x 1.0 x 1.0
m to 1.0 x 1.0 x 3.0 m. Each basket is secured to an adjacent basket
with a tie wire and is loaded in place with selected rocks ranging from
200 mm to 400 mm in size.
Gabion structures can be subject to various stresses and they must be able to
settle, twist and conform to channel and foundation shifts and changes. At the
same time, gabions must have sufficient strength to contain the weight of the
rocks with which they are filled and of additional filled gabions that may be
placed upon them, as well as to resist the impact force of high velocity
currents and soil pressure. 

Applications:

• Mass gravity retaining structures 

• Mechanically stabilized earth walls (MSE walls) 

• Vegetated slope reinforcement

• Slope Stabilization 

• Slope reinforcement 

• Slope & Bank protection 

• Shore Protection 

• Culvert Outlet scour pads & headwalls 

• Bridge abutments 

• Erosion Control
Gabions shall be constructed of wire mesh and shall be supplied in
various lengths and heights. A double twisted wire mesh
container of various sizes, uniformly partitioned into internal
cells , interconnected with other units and filled with stones to
form flexible, permeable, monolithic structures such as retaining
walls, spur dikes, sea walls, revetments and channel linings for
erosion control.

The lengths shall be multiples of 2,3 or 4 times the width of the gabion
and height shall be 0.50 m to 1.00 m and the horizontal width shall
not be less than one-meter.

Mattresses are double twisted wire mesh container uniformly partitioned into
internal cells with relatively small height in relation to other
dimensions, having smaller mesh openings than the mesh used for
gabions. It is generally used for river bank protection and channel
linings.

The length shall be 3.00 m to 6.00 m, the width shall be 2.00 m

and the height shall be 0.17 m, 0.23 m 0r 0.30 m or as shown
on the Plans.
Materials Requirements
Wire - the wire used in the manufactured of double-twisted mesh for use in
gabions and mattresses shall conform to the specifications for the
style ordered as shown below:

Style 1 - double-twisted mesh shall be manufactured from zinc-

coated steel wire conforming to the specification
requirements of ASTM A 641, Class 3 coating, soft temper

Style 2 - double-twisted mesh shall be manufactured from Zn-

5A1-MM- coated steel wire conforming to the
specification requirements of ASTM A 856/ A 856 M,
Class 3 coating, soft temper

Style 3 - double-twisted mesh shall be manufactured from the

same type of metallic coated steel wire as Style 1 with
an additional PVC coating extruded into the metallic-
coated steel wire.

Style 4 - double-twisted mesh shall be manufactured from

aluminum- coated steel wire conforming to the
specification requirement of ASTM A 809, soft temper
The minimum size of the galvanized and PVC coated wire to be used in the
fabrication of the gabion and mattresses shall be as follows:

Diameter, mm, min.

Gabion Mattress
Metallic PVC Metallic PVC
Coated Coated Coated Coated
Body Wire 3.05 2.70 2.20 2.20
Selvedge or Perimeter Wire 3.80 3.40 2.70 2.70
Tying & Connecting Wire 2.20 2.20 2.70 2.20

• Diameter Tolerances for Galvanized Wire to be used in the fabrication of gabion

and mattresses shall be ± 0.10 mm

• The nominal and the minimum thickness of PVC coating shall be 0.50 mm and
0.38 mm, respectively

• The PVC coating shall not show cracks or breaks after the wires are twisted in the
fabrication of the mesh.
Lacing Wire and Stiffener - shall be made of wire having the same
coating material as the double-twisted wire mesh
conforming to Specification requirements of ASTM 641, A
856/A 856 M or A 809

Dimension Requirements of Gabion and Mattresses

Diameter, mm, min.

Gabion Mattresses
Metallic PVC Metallic PVC
Coated Coated Coated Coated

Body Wire 3.05 2.70 2.20 2.20

Selvedge or Perimeter Wire 3.80 3.40 2.70 2.70

Tying and Connecting Wire 2.20 2.20 2.70 2.20

Tensile Strength of Zinc-Coated Wire for Fabrication of
Gabion and Mattresses

Strength, min., MPa

Gabion Mattresses
Body Wire 485 515

Selvedge or Perimeter Wire 485 485

Tying and Connecting Wire 515 515

Weight of Zinc Coating Per Unit Area of Uncoated Wire Surface

Wire Diameter, mm Class 3 or A Coating, g/m2

Over 1.90 to 2.30 220
Over 2.30 to 2.70 230
Over 2.70 to 3.10 240
Over 3.10 to 3.50 260
Over 3.50 to 3.90 270
Rockfill

• Rock used in the gabions and mattresses shall consist of hard, durable
rock pieces that will not deteriorate when submerge to water or exposed
to severe weather conditions.

• Rock pieces shall be generally uniformly graded in sizes ranging from

100 mm to 200 mm ( 4 to 8 inches).

• Filled gabions shall have a minimum density of 1,400 kg/m3. Voids

shall be evenly distributed

• No rock size shall exceed 2/3 the mattress depth and at least 85% by
weight of the stone shall have a size greater than 80 mm. No stones
shall be able to pass through the mesh.

• Rock shall have a sodium sulfate soundness loss of not more than 9%
after five (5) cycles.
Construction / Quality Control Requirements

• Gabion shall be assembled by binding together all vertical edges with

wire ties on approximately 152 mm (6 inches) spacing or by continuous
piece of connecting wire stitch around the vertical edges with a coil
every 102 mm (4 inches).

• Before laying/placing of the mattress and gabion, the subgrade or base

shall be properly compacted to a depth of 150 mm.

• The gabions shall be filled with stone carefully placed by hand or

machine to assure alignment and avoid bulges with a minimum voids.
properly compacted to a depth of 150 mm.
ITEM 704 – MASONRY UNITS
 STANDARD SPECIFICATIONS FOR
CONCRETE MASONRY UNIT

ITEM 704 – Masonry Units

Concrete Masonry Blocks

ASTM C – 90 - Load Bearing Concrete Masonry Units

ASTM C – 129 - Non Load Bearing Concrete Masonry

Units

Concrete Solid Blocks

ASTM C – 139 or ASTM 145, Grade as specified

ASTM C – 90 - Load Bearing Concrete Masonry Units

Strength Requirements

Individual : 5.5 Mpa ( 800 psi )

Average : 6.9 Mpa ( 1000 psi )

ASTM C – 129 - Non Load Bearing Concrete Masonry Units

Strength Requirements

Individual : 3.45 Mpa ( 500 psi )

Average : 4.14 Mpa ( 600 psi )