TABLE OF CONTENTS

SECTION 1

EXCAVATION AND BACKFILL..................................................1-1

SECTION 1.1 : 1.1.1 1.1.2

CLEARING AND GRUBBING......................................................1-1 Description......................................................................................1-1 Preservation of Property..................................................................1-1

SECTION 1.2 : 1.2.1

REMOVAL OF EXISTING STRUCTURES..................................1-4 Description......................................................................................1-4

SECTION 1.3 : 1.3.1 1.3.2

ROADWAY EXCAVATION..........................................................1-5 Description......................................................................................1-5 Materials.........................................................................................1-5

SECTION 1.4 :

EXCAVATION AND BACKFILL FOR STRUCTURES......................................................................1-8

1.4.1 1.4.2

Description......................................................................................1-8 Materials.........................................................................................1-8

SECTION 1.5 : 1.3.1 1.3.2

EMBANKMENT..........................................................................1-14 Description....................................................................................1-14 Materials.......................................................................................1-14

SECTION 2

SUBBASE AND BASE COURSES................................................2-1

SECTION 2.1 : 2.1.1 2.1.2

SUBBASE......................................................................................2-1 Description.....................................................................................2-1 Materials.........................................................................................2-1

MWS 1 - 1

SECTION 2.2 : 2.2.1 2.2.2

BASE..............................................................................................2-6 Description......................................................................................2-6 Materials.........................................................................................2-6

SECTION 3

ASPHALTIC AND CONCRETE PAVEMENTS...........................3-1

SECTION 3.1 :

GENERAL REQUIREMENTS FOR ASPHALTIC SURFACING..................................................................................3-1

3.1.1 3.1.2

Description......................................................................................3-1 Materials.........................................................................................3-3

SECTION 3.2 : 3.2.1 3.2.2

BITUMINOUS MATERIALS......................................................3-20 Description....................................................................................3-20 Materials.......................................................................................3-20

SECTION 3.3 : 3.3.1 3.3.2

ASPHALTIC PRIME COAT........................................................3-24 Description....................................................................................3-24 Materials.......................................................................................3-24

SECTION 3.4 : 3.4.1 3.4.2

ASPHALTIC TACK COAT..........................................................3-28 Description....................................................................................3-28 Materials.......................................................................................3-28

SECTION 3.5 : 3.5.1 3.5.2

ASPHALTIC SURFACE TREATMENT......................................3-30 Description....................................................................................3-30 Materials.......................................................................................3-30

MWS 1 - 2

SECTION 3.6 : 3.6.1 3.6.2 3.6.3

ASPHALTIC CONCRETE SURFACING.....................................3-39 Description....................................................................................3-39 Asphaltic Concrete Wearing Course...............................................3-39 Asphaltic Concrete Basecourse......................................................3-48

SECTION 3.7 :

PORTLAND CEMENT CONCRETE PAVEMENT............................................................3-54

3.7.1 3.7.2 3.7.3

Description....................................................................................3-54 Materials........................................................................................3-54 Equipment and Tools.....................................................................3-57

SECTION 4

STRUCTURES..............................................................................4-1

SECTION 4.1 :

PORTLAND CEMENT CONCRETE STRUCTURES.........................................................4-1

4.1.1 4.1.2 4.1.3

Description.....................................................................................4-1 Materials........................................................................................4-10 Equipment and Tools.....................................................................4-12

SECTION 4.2 : 4.2.1 4.2.2

REINFORCEMENT FOR STRUCTURES....................................4-31 Description....................................................................................4-31 Materials.......................................................................................4-31

SECTION 4.3 : 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5

PILING.........................................................................................4-37 Description....................................................................................4-37 Submittals......................................................................................4-37 Pilot Piles.......................................................................................4-38 Precast Concrete and Timber Piles-Materials..................................4-38 Precast Concrete and Timber Piles-Construction Methods...............4-44

MWS 1 - 3

4.3.6 4.3.7 4.3.8

Bored Cast-in-Place Piles...............................................................4-47 Testing..........................................................................................4-54 Piling Records................................................................................4-65

SECTION 4.4 : 4.4.1 4.4.2

PRESTRESSED CONCRETE.......................................................4-67 Description....................................................................................4-67 Materials........................................................................................4-68

SECTION 4.5 : 4.5.1 4.5.2 4.5.3

PRECAST CONCRETE SEGMENTAL WORK...........................4-86 General..........................................................................................4-86 Precast Segment Manufacture........................................................4-86 Precast Segment Erection Works...................................................4-95

SECTION 4.6 : 4.6.1 4.6.2

POROUS BACKFILL MATERIAL.............................................4-100 Description..................................................................................4-100 Materials.....................................................................................4-100

SECTION 4.7 :

DAMP PROOFING AND MEMBRANE WATER PROOFING.................................................................4-102

4.7.1 4.7.2

Description.................................................................................4-102 Materials....................................................................................4-102

SECTION 4.8 :

JOINT SEALERS AND BRIDGE EXPANSION JOINTS..............................................................4-108

4.8.1 4.8.2 4.8.3

Description................................................................................4-108 Materials...................................................................................4-108 Bridge Expansion Joints............................................................4-109

MWS 1 - 4

SECTION 5.5 : 5.5.1 5.5.2

DRAINAGE STRUCTURES.....................................................5-13 Description.................................................................................5-13 Materials.....................................................................................5-13

SECTION 5.6 : 5.6.1 5.6.2

CONCRETE SIDEWALK..........................................................5-15 Description..................................................................................5-15 Materials......................................................................................5-15

SECTION 5.7 : 5.7.1 5.7.2

ROAD MARKINGS....................................................................5-16 Description...................................................................................5-16 Materials.......................................................................................5-16

SECTION 5.8 : 5.8.1 5.8.2 5.8.3

ROAD SIGNS...............................................................................5-21 Description....................................................................................5-21 Materials........................................................................................5-21 Design and Construction................................................................5-25

SECTION 5.9 :

PROVISIONS FOR STREET LIGHTING AND TRAFFIC SIGNALS.....................................................................5-35

5.9.1 5.9.2

General..........................................................................................5-35 Materials........................................................................................5-36

SECTION 6

STEEL STRUCTURES.................................................................6-1

SECTION 6.1 : 6.1.1 6.1.2

GENERAL.....................................................................................6-1 Scope..............................................................................................6-1 Shop Drawings................................................................................6-1

SECTION 6.2 :

MATERIALS..................................................................................6-2

MWS 1 - 5

SECTION 6.3 :

INSPECTION AND TESTING......................................................6-3

SECTION 6.4 :

STORAGE OF MATERIALS........................................................6-3

SECTION 6.5 : 6.5.1 6.5.2

FABRICATION.............................................................................6-4 General...........................................................................................6-4 Quality of Workmanship and Inspection..........................................6-4

SECTION 6.6 :

ASSEMBLY...................................................................................6-6

SECTION 6.7 :

CONNECTIONS USING HIGH-TENSILESTRENGTH BOLTS.......................................................................6-6

SECTION 6.8 :

CONNECTION BY WELDING....................................................6-11

SECTION 6.9 : 6.9.1 6.9.2 6.9.8

PROTECTIVE TREATMENT OF STEEL WORK.......................6-13 General..........................................................................................6-13 Coating Systems............................................................................6-13 Material Identification and Quality Control....................................6-18

SECTION 6.10 :

FABRICATION OF STAINLESS STEEL....................................6-19

SECTION 6.12: 6.12.1 6.12.2 6.12.3 6.12.4 6.12.5

ERECTION.................................................................................6-20 Delivery Storage and Handling.....................................................6-20 Erection of Structural Steelwork..................................................6-20 Alignment....................................................................................6-21 Accuracy of Construction............................................................6-21 Erection Tolerances.....................................................................6-21

MWS 1 - 6

6.12.6 6.12.7 6.12.8 6.12.9 6.12.10

Connection to Concrete Elements................................................6-21 Column Bases.............................................................................6-22 Plumbing and Alignment of Columns...........................................6-22 Position in Plan of Members.......................................................6-22 Levels.........................................................................................6-22

SECTION 6.13 : 6.13.1 6.13.4

SUPPORTS AND FOUNDATIONS...........................................6-23 Positioning and Setting of Foundation Bolts.................................6-23 Encasing Steelwork in Foundations..............................................6-24

SECTION 7

RAILING.....................................................................................7-1

SECTION 7.1 :

DESCRIPTION............................................................................7-1

SECTION 7.2 :

MATERIALS...............................................................................7-1

SECTION 8

BRIDGE AND VIADUCT BEARING..........................................8-1

SECTION 8.1 : 8.1.1

DESCRIPTION.............................................................................8-1 Indicated Bearings..........................................................................8-1

SECTION 8.2 : 8.2.2

ELASTOMERIC BEARINGS.......................................................8-2 Manufacture and Design of Elastomeric Bearings...........................8-2

SECTION 8.3 : 8.3.2

MECHANICAL BEARING...........................................................8-4 Manufacture and Design of Mechanical Bearings............................8-4

SECTION 8.4 :

CONSTRUCTION METHODS......................................................8-7

MWS 1 - 7

SECTION 10 :

GUARD RAILS AND CONCRETE PARAPETS.........................10-1

SECTION 10.1 :

DESCRIPTION............................................................................10-1

SECTION 10.2 :

MATERIALS...............................................................................10-1

SECTION 10.3 :

CONSTRUCTION METHODS....................................................10-2

SECTION 11:

PAINTING METAL STRUCTURES............................................11-1

SECTION 11.1 :

DESCRIPTION.............................................................................11-1

SECTION 11.2 :

GENERAL....................................................................................11-1

SECTION 11.3 :

MATERIALS................................................................................11-1

SECTION 11.4 :

CONSTRUCTION METHODS.....................................................11-3

SECTION 12 :

SETTLEMENT AND SURVEY....................................................12-1

SECTION 12.1 :

SETTLEMENT CONTROL INSTRUMENTATION.................................................................12-1

12.1.1 12.2.2

Description....................................................................................12-1 Materials........................................................................................12-1

SECTION 12.2 : 12.2.1 12.2.2

SETTLEMENT TABLETS...........................................................12-3 Description....................................................................................12-3 Materials........................................................................................12.3

MWS 1 - 8

SECTION 12.3 : 12.3.1 12.3.2

RIGHT OF WAY MONUMENTS................................................12-4 Description....................................................................................12-4 Materials........................................................................................12-4

SECTION 12.4 : 12.4.1 12.4.2

PERMANENT REFERENCE POINTS.........................................12-5 Description....................................................................................12-5 Materials........................................................................................12-5

SECTION 13 :

WATER WORK............................................................................13-1

SECTION 13.1 :

GENERAL....................................................................................13-1

SECTION 13.2 :

SHOP DRAWINGS.......................................................................13-1

SECTION 13.5 : 13.5.1

CATHODIC PROTECTION.......................................................13-63 Cathodic Protection Terminals.....................................................13-63

SECTION 13.6 : 13.6.1 13.6.2 13.6.3 13.6.4

TRENCH EXCAVATION AND BACKFILL..............................13-67 Trench Excavation.......................................................................13-67 Trench Pipe Bedding....................................................................13-68 Backfilling and Compaction..........................................................13-68 Sheeting and Bracing....................................................................13-68

SECTION 13.8 :

MISCELLANEOUS WORK FOR WATER MAINS.........................................................................13-79

13.8.1

General........................................................................................13-79

MWS 1 - 9

SECTION 1 : EXCAVATION AND BACKFILL

SECTION 1.1 : CLEARING AND GRUBBING

1.1.1

DESCRIPTION This work shall consist of all clearing and grubbing necessary for the performance of the Work covered by the Contract in accordance with the Contract Specification. The areas to be cleared or cleared and grubbed shall be the areas designated by staking or designated on the drawings or designated in the Contract Documents. The clearing and grubbing shall consist of clearing the designated areas of all trees, down timber, snags, vegetation, rubbish and objectionable material and shall include grubbing stumps and roots and disposing of all material resulting from the clearing or grubbing. It shall also include the demolition, removal and disposal of structures that obtrude into or encroach upon or obstruct the Work except where provided for otherwise.

1.1.2

PRESERVATION OF PROPERTY Attention is directed to the Contractor's obligations under law and under the Contract with regard to damage, particularly with regard to protection of property, forest, and landscape and to responsibility for damage claims. Existing highways, improvements, facilities, adjacent property, utilities, services and trees and plants designated for preservation shall be protected from injury or damage which could result from the Contractor's operations.

SECTION 1.2 : REMOVAL OF EXISTING STRUCTURES

1.2.1

DESCRIPTION This item shall consist of satisfactory removal and disposal or salvage, wholly or in part, of all the existing structures, substructures, buildings, culverts, walls, fencing, etc., as required.

MWS 1 - 10

SECTION 1.3 : ROADWAY EXCAVATION

1.3.1

DESCRIPTION The Work shall consist of all the required excavation within the limits of right of way except excavation otherwise classified. It shall include the removal, hauling and proper utilization or disposal of all excavated materials and shaping of excavation and preparation of exposed surfaces of excavation on the entire length of the roadway and approaches, in accordance with these Specifications and the lines, levels, grades, dimensions and cross sections shown on the drawings. Roadway excavation shall include the following : (a) All excavated materials indicated on the drawings within the faces of the cross sections, excavation of all materials for approach streets, and intersections. All topsoil required to be salvaged within the limits of the right of way in accordance with Section 1.6 Topsoil. The removal and disposal of existing surfacing, including flexible pavement, reinforced concrete pavement, sidewalks, curb or curb and gutter within the limits of construction. The demolition, removal and disposal of all foundations, foundation walls, basement or ground level floors, timber, rubble, masonry pipe, pipe structure and pipe culverts within the limits of construction and not otherwise provided for in the Contract. Excavation for removal of slides, breakages and cave-ins. Excavation for stream and channel changes. Excavation required in cuts or under embankments below the lowest normal limit of excavation indicated on the drawings or below ground line, for the removal of unsuitable material, and below the ground line under embankments where benching is required, or as otherwise directed.

(b) (c)

(d)

(e) (f) (g)

1.3.2 1.3.2.1

MATERIALS Classification Excavation shall be termed unclassified and shall include all materials to be excavated in accordance with the Specifications.

1.3.2.2

Unsuitable Materials

MWS 1 - 11

Material encountered in cut areas and in the foundation of the embankment that is unsuitable for the planned use shall be excavated and disposed of outside the site. Backfill as necessary shall be with suitable material. Highly organic clays and silts, peat, soils containing large amounts of roots, grass and other vegetable matter are to be considered unsuitable. Materials that are soft or unstable merely because they are too wet or dry are not to be classified as unsuitable. 1.3.3 CONSTRUCTION METHODS (a) All roadway excavation and embankment construction shall be performed as specified herein and in Section 1.5 Embankment, and the completed roadway shall conform to the required alignment, levels, grades, and cross sections. Where provided for, the topsoil shall be removed and stored in piles at locations in accordance with the requirements of Section 1.6 Topsoil. The top of any dike which comes within 1.2 meters of the design profile grade shall be cut down and the materials shall be disposed. (b) All materials within the right of way area have been classified unsuitable for embankment construction. Excavated materials shall be utilized, in so far as is practicable, in constructing other parts of the roadway such as landscaping and verges. Unsuitable material and required roadway excavation in excess of that needed for construction shall be known as waste. Waste shall be removed and disposed of at designated areas in such manner as to present a neat appearance and not to obstruct drainage to any highway nor to cause injury to highway works or property. (c) Unsuitable material shall be excavated below subgrade level in cut and below embankment foundation level to the depth shown on the drawings. Where unsuitable material is excavated below the normal subgrade level or below embankment foundations or for benching under embankments the excavation shall be backfilled with material and in a manner that conforms with Section 1.5 density as determined by AASHTO Designation T180. All slopes shall be finished in a neat and workmanlike manner and to an accuracy appropriate to the material, and care shall be taken that no material is loosened below the required slopes. Breakages and slides shall be removed and disposed of as directed. During construction the roadbed and ditches shall be maintained in such condition as to ensure proper drainage at all times. Ditches and channels shall be so constructed and maintained as to avoid damage to the roadway section.

(d)

MWS 1 - 12

(e)

In cut areas, the top of the subgrade on which base or subbase is to be placed shall be compacted to a minimum depth of 150 mm to not less than 95 percent of the maximum dry density as determined by test, AASHTO Designation T 180. Where the required density cannot be obtained, the material shall be excavated to the depth of 300 mm. The material thus excavated shall be disposed of. The excavated area above described shall be backfilled with suitable material and placed in accordance with the compaction requirement for "Embankment". In cut areas where subgrade materials having a CBR value less than the design value are found, the material shall be excavated to the depth required on the drawings. The excavated area shall be backfilled with the required embankment material, and placed in accordance with the compaction requirement for "Embankments". In cut areas where the replacement of the subgrade materials are not required the top of the subgrade shall be compacted to a minimum depth of 200 mm and to not less than 95 percent of the maximum dry density as determined by AASHTO Designation T180.

(f)

The surface of the finished subgrade shall be neat and workmanlike and shall have the required form, superelevation, levels, grades and cross section. The surface shall be constructed to sufficient accuracy to permit the construction of subsequent layers of material to the thickness, cross section, surface tolerance, and compaction specified.

SECTION 1.4 : EXCAVATION AND BACKFILL FOR STRUCTURES

1.4.1

DESCRIPTION This work shall consist of excavation for the foundation of underdrains and structures, other than pipe culverts, not otherwise provided for by the Specifications, constructing and removing cofferdams and sheeting, pumping, dewatering and bailing, backfilling of completed structures and disposal of excavated material. Storm sewers and pipes shall be excavated and backfilled in accordance with Section 5.1 Reinforced Concrete Pipe.

1.4.2 1.4.2.1

MATERIALS Foundation Filled Material Material for foundation fill shall consist of suitably graded sand, gravel, stone or concrete as shown on the drawings.

1.4.2.2

Concrete for Foundation Fill Concrete shall conform to the general requirements of Section 4.1. Concrete to be used as foundation fill in dry excavations shall be made with an aggregate and

MWS 1 - 13

cement conforming to the requirements of Section 4.1 and shall be mixed and placed in accordance with Section 4.1 except that minimum cement content shall be 250 kilograms per cubic meter of concrete. Material belonging to the Groups A7 and A8 of AASHTO M145 shall be classified as unsuitable material for backfill 1.4.2.3 Backfill Material Backfill shall be approved compactible material. It shall be obtained from the structure excavation if such material is suitable. Any additional material needed shall be obtained from roadway or borrow excavation. Material belonging to the Groups A7 and A8 of classified as unsuitable material for backfill. AASHTO M145 shall be

SECTION 1.5 : EMBANKMENT

1.5.1

DESCRIPTION This work shall consist of the construction of embankments and backfill not specified elsewhere by furnishing, placing, compacting and shaping suitable material of acceptable quality obtained from approved sources in accordance with these Specifications, and to the lines, grades, dimensions, and cross sections shown on the drawings.

1.5.2

MATERIALS Materials for embankments shall consist of river or beach sand or land deposit sand of equivalent physical property. The maximum percentage of material passing the 75 micron sieve shall be 10 percent in the initial 600 mm thick working blanket and 20 percent in the successive layers of embankment. The maximum dry density shall not be in excess of 2000 kg/m3. Materials for earthfill, landscaping and islands shall consist of clay, laterite, land deposit sand or river or beach sand as shown on the drawing.

MWS 1 - 14

SECTION 2 : SUBBASE AND BASE COURSES

SECTION 2.1 : SUBBASE

2.1.1

DESCRIPTION This work shall consist of furnishing, placing and compacting subbase material on a prepared and accepted subgrade in accordance with these Specifications, and the lines, levels, grades, dimensions and cross sections shown on the drawings.

2.1.2 2.1.2.1

MATERIALS Materials for Sub-base The material for upper subbase and lower subbase shall conform to the requirements for embankment material and also shall conform to the requirements for one of the following types.

2.1.2.2

Sub-base for Rigid Pavements Material shall be natural or artificial mixture of hard durable particles of mineral aggregate, free from vegetable matter, soft particles and excess clay. (a) Grading : The grading shall conform to grading envelopes A or B in Table 2.1-1. The fraction passing the 75 micron sieve shall be not greater than two thirds of the fraction passing the 425 micron sieve. Plasticity : The portion passing the 425 micron sieve shall, if it is plastic, have a liquid limit not greater than 25 and a plasticity index not greater than 6. CBR : The material shall have a soaked CBR value not less than 80% when compacted to 95% of maximum dry density as determined by AASHTO Test Method T 180. Percentage of Wear : The coarse part of the material sampled and tested in accordance with AASHTO Test Method T 96 shall have a percentage of wear not greater than 50. Soundness : The material shall not include any fraction that breaks up when alternately wetted and dried.

(b)

(c)

(d)

(e)

15

2.1.2.3

Sub-base for Flexible Pavements Material shall be soil aggregate material, free from vegetable matter, soft particles and excess clay. (a) Grading : The grading shall conform to grading envelopes A, B, C, D, E or F in Table 2.1-1. The fraction passing the 75 micron sieve shall be not greater than two thirds of the fraction passing the 425 micron sieve. Plasticity : The portion passing the 425 micron sieve shall, if it is plastic, have a liquid limit not greater than 25 and a plasticity index not greater than 6. CBR : The material shall have a soaked CBR value not less than 30% when compacted to 95% of maximum dry density as determined by AASHTO Test Method T 180. Percentage of Wear : The coarse part of the material sampled and tested in accordance with AASHTO Test Method T 96 shall have a percentage of wear not greater than 50.

(b)

(c)

(d)

TABLE 2.1-1 Grading Requirements for Sub-base Material U.S. Sieve Grading Designation 50 mm 25 mm 9.5 mm 4.75 mm 2.00 mm 425 micron 75 micron Percentage by Weight Passing Square Mesh Sieves Grading Grading Grading Grading Grading Grading A B C D E F 100 100 75 - 95 100 100 100 100 30 - 65 40 - 75 50 - 85 60 - 100 25 - 55 30 - 60 35 - 65 50 - 85 55 - 100 70 - 100 15 - 40 20 - 45 25 - 50 40 - 70 40 - 100 55 - 100 8 - 20 15 - 30 15 - 30 25 - 45 20 - 50 30 - 70 2-8 5 - 20 5 - 15 5 - 20 6 - 20 8 - 25

SECTION 2.2 : BASE

2.2.1

DESCRIPTION This work shall consist of a base, composed of crushed aggregate material placed and compacted on a prepared and accepted subgrade, subbase or

16

other base course in accordance with these Specifications and the lines, levels, grades, dimensions and cross sections shown on the drawings.

2.2.2

MATERIALS The materials shall meet the requirements for subbase provided for in Section 2.1, sub-base for rigid pavement, except where otherwise herein indicated. The portion of aggregate passing the 425 micron sieve shall if it is plastic, in all cases, have a liquid limit not more than 25 and a plasticity index not more than 6. The material shall conform with the grading requirements listed in Table 2.1-1, Section 2.1. The material shall have a CBR value, after the specified compaction, as indicated on the drawings or, if not indicated, not less than 80. The coarse part of the material sampled and tested in accordance with AASHTO Test Method T96 shall have a percentage of wear not greater than 40. If no grading is indicated on the drawings grading A or B shall be used.

17

SECTION 3 : ASPHALTIC AND CONCRETE PAVEMENTS

SECTION 3.1 : GENERAL REQUIREMENTS FOR ASPHALTIC SURFACING

3.1.1

DESCRIPTION This work shall cover the general requirements that are applicable to all types of asphaltic surfacing irrespective of gradation of mineral aggregate, kind and amount of asphaltic material, or use. Deviations from these general requirements are indicated in the specific requirements as set forth in the respective sections for each type. The work shall consist of one or more courses of plant-mixed asphaltic mixtures constructed on a prepared and accepted, sub-base, base or other roadbed in accordance with these Specifications and specific requirements of the type under Contract, and in conformity with the required lines, levels, grades, dimensions and typical cross section.

3.1.1.1.

General Composition of Mixtures The asphaltic mix shall be composed basically of coarse mineral aggregate, fine mineral aggregate, and combined, in such proportions that the resulting blend meets the grading requirements for the specific type under the Contract. To such composite blended aggregate shall be added asphalt within the percentage limits set in these Specifications for the specific type.

3.1.1.2

Formulae for Job Mix Before starting work, the Contractor shall submit to the Employer proposed job mix formula, in writing, for the mixtures to be supplied for the project. The formula so submitted shall stipulate for the mixture a single definite temperature at which the mixtures are to be emptied from the mixer, and, for mixtures to be laid hot, a single definite temperature at which the mixtures are to be delivered on the road, all of which shall fall within the ranges of the general composition and temperature limits. In setting the job mix, the Contractor at his discretion may use the submitted formula, in whole or in part. In any event, the job mix formula for the

18

mixture shall fix a single percentage of aggregate passing each required sieve size, a single percentage of asphalt to be added to the aggregate, a single temperature at which the mixture is to be emptied from the mixer, and a single temperature at which the mixture is to be delivered on the road. The requirements for Asphaltic Concrete Surfacing are given in Section 3.6. 3.1.1.3 Applications of Job Mix Formula and Allowable Tolerances All mixture furnished shall conform to the job mix formula, within the ranges of tolerance given below. For Base Course Passing sieves 9.5 mm and larger Passing sieves between 9.5 mm and 75 micron ................ Passing 75 micron Asphalt Temperature of mixture when emptied from mixer........... Temperature of mixture at delivery on road

7% 4% 1% 0.30% 11C 11C

For Surface Courses Tolerances shall be as specified in Section 3.6. Each day samples of the materials and mixture shall be taken and tested for checking the required uniformity of the mixture. When unsatisfactory results or changed conditions make it necessary, the Contractor shall establish a new job mix. Should a change in a material be encountered or should a change in a source of material be made, a new job mix formula shall be submitted and approved before the mixture containing the new material is delivered. Job materials shall be rejected if they are found to have voids or other characteristics requiring, for a balanced mix, an asphalt content greater or less than the specified range. The temperature of the mix shall at all stages of production, delivery and placement, comply with the limits of temperature. Where the maximum limit of the production temperature has been exceeded, all materials in the batch will be rejected. Any truck load delivered with the material at a temperature below the minimum limit will also be rejected. All materials rejected shall be disposed of, and the Employer shall be notified of its disposal.

19

3.1.2 3.1.2.1

MATERIALS Coarse Mineral Aggregate The portion of the aggregate retained on the 4.75 mm sieve shall be known as coarse aggregate and shall be crushed stone, or crushed gravel. Crushed stone, and crushed gravel shall consist of clean, tough, durable material free from vegetable matter, soft particles, and other objectionable matter, and shall have a percentage of wear of not more than 30 at 500 revolutions as determined by AASHTO Test Method T-96. Crushed stone and crushed gravel, when subjected to five alternations of the sodium sulphate soundness test, using AASHTO Test Method T-104, shall have a weighed loss not greater than 12%. When crushed gravel is used, not less than 75% by weight of the particles retained on a 4.75 mm sieve shall have at least one fractured face.

3.1.2.2

Fine Mineral Aggregate The portion of the aggregate passing a 4.75 mm sieve shall be known as fine mineral aggregate, and shall consist of natural sand, stone screenings, or a combination of each. Fine aggregate shall be composed of clean, hard durable particles, rough surfaced and angular, free from vegetable matter, soft particles, clay balls or other objectionable material. Stone screenings shall be produced from stone meeting the requirements for coarse mineral aggregate in Sub Section 3.1.2.1.

3.1.2.3

Mineral Filler Mineral filler where required shall consist of limestone dust, dolomite dust, or similar rock dust, portland cement, hydrated lime, silica cement or other mineral matter. It shall be dry and free from foreign or other objectionable material. It shall dry and free from lumps and when tested by means of laboratory sieves shall meet the following grading requirements : -

20

Percentage by weight passing square mesh sieves (AASHTO Test Method T 37) Sieve designation 600 micron 300 micron 75 micron 100 95 - 100 70 - 100

Mineral filler shall be considered to include any mineral dust naturally present in the asphalt. 3.1.2.4 Asphaltic Materials Asphaltic materials shall conform to the requirements of Section 3.2. 3.1.2.5 Sources of Supply Approval of sources of supply of asphaltic material, aggregate and mineral filler shall be obtained prior to delivery of the material. Samples of each shall be submitted as directed at least ten days in advance of its use. No asphaltic material other than that represented by the test sample shall be used by the Contractor. The material used shall comply in all respects with the requirements herein. Blending of asphaltic materials from different refineries shall not be permitted.

SECTION 3.2 : BITUMINOUS MATERIALS

3.2.1

DESCRIPTION This Section specifies the bituminous materials to be used in the Work.

3.2.2

MATERIALS The materials shall be of the kind required, or indicated in this Specification and/or the drawings. If material to be used is not completely described, the precise kind used shall be a kind suitable for the purpose and in accordance with generally recognized good practice. Material shall meet the requirements for one of the following types.

21

3.2.2.1

Asphalt Cement Asphalt cement shall conform to the requirement (for the appropriate grade) given in AASHTO Standard Specification for Asphalt Cement, Designation M 20-70 or TIS 851. Asphalt cement shall be intended when material is referred to as straight run bitumen, penetration grade bitumen or by its penetration value (as for example 60 - 70 pen).

3.2.2.2

Cut Back Asphalt Cut back asphalt shall be of the rapid curing type, or the medium curing type, and shall conform to the requirements (for the appropriate grade of cut back asphalt) given in whichever of the following AASHTO Standard Specifications may apply.

Cut back Asphalt (Rapid curing type) Cut back Asphalt (Medium curing type)

Designation M 81-70. Designation M 82-73.

Cut back asphalt shall be intended when material is referred to as cut back bitumen or described by one of the grades given in the above named Standard Specifications, as for example R.C. 2 (Approximately R.C.250). 3.2.2.3 Emulsified Asphalt Emulsified asphalt shall be of the anionic type unless the cationic type is explicitly required. Anionic emulsified bitumen shall conform to the requirements for the appropriate grade, given in Table 3.2-1 or with AASHTO Designation M 140-82. Cationic emulsified asphalt, shall conform to the requirements for the appropriate grade, given in Table 3.2-2. Emulsified Asphalt shall be intended when material is referred to as bitumen emulsion.

SECTION 3.4 : ASPHALTIC TACK COAT

3.4.1

DESCRIPTION

22

This work shall consist of furnishing and applying asphaltic material to a previously prepared roadbed, in accordance with these Specifications.

3.4.2

MATERIALS Asphaltic material shall be either rapid curing cut back or rapid setting emulsion of the type and grade called for in the Contract Documents and shall conform to the requirements of the Specifications Section 3.2.

3.4.3 3.4.3.1

CONSTRUCTION METHODS Equipment The equipment shall be as specified in Section 3.3 Prime Coat.

3.4.3.2

Cleaning Surface

When it is necessary, the full width of surface to be treated shall be cleaned with a power broom or power blower to remove loose dirt and other objectionable material. The surface to be treated shall be dry. 3.4.3.3 Application of Bituminous Material Immediately after cleaning the surface, asphaltic material shall be applied by means of a distributor at the predetermined rates but not exceeding 0.45 litre per square metre and at the temperature within the range called for in Section 3.3 for the particular material being used. The tack coat shall be applied only when the surface is dry. The surfaces of structures, curbs and trees adjacent to the areas being treated shall be protected in such manner as to prevent their being spattered or marred. No asphaltic material shall be discharged into borrow pits or gutters. Emulsions may be diluted with clean water in order to control the rate of spread. This shall be done at the Contractor's expense. The surface course shall not be placed over the tack coat until it is in a proper condition of tackiness to receive it. Tack coat shall be applied only so far in advance of surface course placement as is necessary to obtain this proper condition of tackiness. Until the surface course is placed the Contractor shall protect the tack coat from damage.

SECTION 3.5 : ASPHALTIC SURFACE TREATMENT

3.5.1

DESCRIPTION

23

Asphaltic Surface Treatment shall consist of one or more applications of asphaltic material and cover aggregate to a primed non-plastic surface or to a previously constructed asphaltic surface in accordance with these Specifications and to the area shown on the drawings. 3.5.2 3.5.2.1 MATERIALS Asphaltic Materials Asphaltic materials shall be either RC 800 or RC 3,000 cut back asphalt, rapid setting emulsion or conforming to the requirements of Section 3.2 of these Specifications. 3.5.2.2 Asphalt Additive Adhesion and Anti-stripping Agent shall be added to the asphaltic material where so specified. The additive shall be of the suitable type and the required percentage of additive shall be thoroughly mixed with the asphaltic material in accordance with the manufacturers instructions for such time as is necessary to produce a homogeneous mixture. 3.5.2.3 Aggregates Aggregates shall consists of clean, hard, dry, tough, sound, crushed stone or crushed gravel of uniform quality, free from dust, clay, dirt and other deleterious matter and from excess of flat or laminated pieces. Aggregate shall be of such a nature that when thoroughly coated with the asphaltic material proposed for the work, the coating shall not be removed upon contact with water. The aggregate shall have a percentage of wear not exceeding 40 when tested for abrasion resistance by AASHTO Test Method T-96 and when subjected to five alternations of the sodium sulphate test for soundness, AASHTO Test Method T-104, shall have a weighted loss not greater than 12%. The flakiness index as determined in accordance with B.S. 812 shall not exceed 25%. If satisfactory test and service records of the aggregate are not available the contractor shall carry out other tests to determine its acceptability for surface treatment. When crushed gravel is used, not less than 90% by weight of the particles retained on a 3.35 mm sieve shall have at least one fractures face. The grading of the aggregates shall fall within the limits specified in Table 3.5-1 for the appropriate nominal size called for elsewhere in the Contract Documents. 3.5.2.4 Pre-Coated Aggregate

24

When so indicated in the Contract Documents aggregates shall be precoated with asphaltic material to improve the adhesion to the asphalt. Precoating shall be carried out in all cases where penetration grade asphalt is used. Pre-coating material shall be thinly and evenly applied by means of a fine pressure spray to a moving stream of aggregate or by mixing with the aggregate in an approved mixing plant so that all particles are fully coated but do not contain excess material. The coating shall be such that no material shall drip from a particle of aggregate suspended between the fingers. TABLE 3.5-1 Grading Requirements for Cover Aggregate for Asphaltic Surface Treatment Nominal Size mm. 25.00 19.00 12.50 9.50 4.75 Percentage by weight passing Square Mesh Sieves to AASHTO Test Method T027 19 mm. 12.5 mm. 9.5 mm. 0 - 45 0 - 10 0-5 90 - 100 0 - 30 0-8 100 90 - 100 0 - 40 100 90 - 100 100

Note : on Table 3.5-1 1. 2. 3. For single Surface Treatment either 19, 12.5 or 9.5 mm nominal size may be specified. For Double Surface Treatment the first course may be either 19 mm or 12.5 mm followed by a second course of 9.5 mm nominal size. For Shoulders : A single course of 12.5 mm nominal size shall be applied. The chipping shall be of a contrasting colour to the carriageway material.

Aggregate shall not contain sufficient moisture to cause uneven distribution of the pre-coating material and shall not be used in the Work until the moisture has evaporated and the pre-coating material has adhered effectively to the aggregate. Pre-coating of aggregate shall not be carried out when rain is imminent unless the aggregate is adequately covered or unless a suitable adhesion agent is added to the pre-coating material in accordance with the manufacturers instructions.

25

In areas subject to dusty conditions, pre-coated aggregate shall not be stockpiled for any period longer than is necessary for moisture to dry out. When there is a visible coating of dust on the particles the Contractor shall carefully consider its suitability prior to use. 3.5.2.5 Stockpiling of Aggregates A separate stockpile shall be made for each nominal size of aggregate at each location. The site of the stockpile shall be cleared of all vegetation and debris, graded and drained and where necessary the area shall be surfaced with a 100 mm layer of stone or rock. Each stockpile shall be built at least 2 meters high by tipping in layers not more than one meter deep over the whole area of the stockpile. The Contractor shall supply any planking or other material required in connection with movement of vehicles over and about the stockpiles. The bottom 50 mm layer of aggregate or any contaminated aggregate shall not be used in the work.

TABLE 3.5-2 Approximate Quantities of Materials for Surface Treatment per Square Meter

Nominal Size of Aggregate mm. 19.0 12.5 9.5

Rate of Application Kilograms Aggregate Liters Asphaltic Material 20 - 30 1.2 - 2.2 12 - 18 0.8 - 1.5 8 - 12 0.7 - 1.2

26

Notes : on Table 3.5-2 1. The quantities shown above are a guide only and shall vary considerably according to the type and condition of the surface, the grading, type, shape and absorbency of the aggregate, the weather conditions and the traffic. The asphaltic material may be asphalt cement, cut back asphalt or emulsified asphalt as specified elsewhere in the Contract Documents. For seal coats, emulsions may be diluted with clean water in order to control the rate of application. This shall be done at the Contractors expense. In the case of multiple surface treatments a considerable variation of the quantities shown above for asphaltic materials may be found necessary or desirable. The first application of asphalt material may be reduced and subsequent applications increased if this provides a better result.

2.

3.

SECTION 3.6 : ASPHALTIC CONCRETE SURFACING

3.6.1 3.6.1.1

DESCRIPTION General This work shall consist of a surfacing of dense graded asphaltic concrete, constructed on a prepared base in accordance with these Specifications and the lines, levels, grades, dimensions and typical cross sections shown on the drawings. This work shall also consist of constructing asphaltic concrete overlays of one or multiple layers on a previously tack-coated existing bituminous surface as well as providing a bituminous leveling course where necessary. All the provisions of Section 3.1, General Requirements for Asphaltic Surfacing shall form a part of these Specifications unless otherwise stipulated herein. The surfacing shall consist of one or two layers of the thickness shown on the drawings. The top layer shall be denoted as the wearing course and the lower layer as the basecourse.

3.6.2

ASPHALTIC CONCRETE WEARING COURSE

27

Asphaltic concrete wearing course shall be made and constructed in accordance with the following requirements, and Schedule 3.6-1 3.6.2.1 Materials (a) Coarse Aggregate - Coarse aggregate shall be hard, unweathered, durable, clean and crushed rock. When tested in accordance with the methods described in B.S. 812 it shall have the following properties. Aggregate Crushing Value Flakiness Index Water Absorption not more than 30% not more than 35% not more than 2%

The Contractor shall inform the Employer of the group to which the rock belongs as classified in Appendix B to B.S. 802. (b) Fine Aggregate - Fine aggregate shall be clean natural bank, river, dune or pit sand or quarry sand produced in a secondary plant. It shall consist of hard non-absorbent sharp grains and be free from clay, loam, loosely bonded aggregations and other foreign matter. Other sources of fine aggregate shall be subjected to approval. Mineral Filler - Mineral filler where required shall consist of limestone dust, dolomite dust, portland cement, hydrated lime, silica cement or other suitable mineral matter. It shall be free from foreign or other objectionable material. It shall be dry and free from lumps and when tested by means of laboratory sieves shall meet the following grading requirements : Percentage by Weight Sieve Designation 0.600 mm. 0.150 mm. 0.075 mm. AASHTO Test Method T-37 100 95 - 100 65 - 100

(c)

Mineral filler shall be considered to include any mineral dust naturally present in the asphalt. (d) Asphaltic materials shall conform to the requirementsof Section 3.2. Asphalt cement of 60/70 penetration shall be used.

3.6.2.2

Laboratory Design of Mixture

28

The Contractor shall first design the mix in accordance with the Marshall procedure as given herein. The figure given in the Schedule 3.6-1 shall be used as a guide. Mixes shall be made not only at but also above and below the binder contents shown. The mixes shall be made and compacted at the temperatures indicated in the schedule. In determining the optimum binder content a number of test specimens shall be prepared as follow : Four consistent specimens are required at each binder content within the range 4.0% to 7.0% at increments of 0.5% thus : Four specimens at 4.0% Four specimens at 4.5% Four specimens at 5.0% Four specimens at 5.5% and so on up to 7.0%

All binder contents shall be weight of the total moisture. The specimens detailed above shall be manufactured in accordance with AASHTO Designation T 245-90. As many as eight specimens at each binder content may have to be made up to achieve consistency. The compacted samples shall then be weighted in air and water so that the density and voids may be calculated. After immersion in a water bath thermostatically controlled at 60 for 45-60 minutes, the samples shall be tested for measurement of the Marshall Stability and Flow Value in accordance with AASHTO Designation T 245-74. Curves shall be plotted, using the mean values obtained from each group of four specimens, for Marshall Statility, Compacted Density, Voids, Voids in Mineral Aggregate and Flow Value all against binder content. The mean optimum binder content shall be determined as follows : (a) (b) (c) (d) Stability 1 - Peak of the Stability Curve Density - Peak of the Density Curve Voids in the total mixture - 4.0% Voids Filled with binder - 79%

The maximum of the range of binder to be examined is to be extended if necessary to ensure that the curves for stability and density, when plotted against the percentage of binder, show optimum values. An optimum binder content below the specified minimum shall not be approved.

29

Where the stability/binder curve exhibits more than one peak the binder content chosen for the determination of the mean optimum binder content shall be the one which most nearly satisfies the voids requirements. It is sometimes necessary, where no peak stability is shown, to prepare and test supplementary mixtures at intervals of 0.25% binder content on either side of the expected optimum. With absorbent aggregates some difficulty in determining maximum density may occur. In such cases the binder content at which the increase in density shows a marked falling off should be adopted. The individual test values at the mean optimum binder content shall be assessed from the plotted curves and compared with the criteria in Schedule 3.6-1 The curves shall be submitted to the Employer with the Contractors recommendation for binder content of the proposed mixture, which must meet the requirements of the Marshall Stiffness (Stability/Flow). It may be necessary to adjust the grading until the requirements are met. The following principles may be used for adjusting mixes : (a) (b) Voids in Mix low and Stability satisfactory - reduce bitumen content or filler content; modify aggregate grading to give more voids. Voids in Mix low and Stability low - increase filler content; reduce bitumen content; increase stone content and angularity of stone. Voids in Mix satisfactory and Stability low - increase filler content; reduce bitumen content or filler content; increase stone content or angularity of stone. Voids in Mix high and Stability satisfactory - increase bitumen content or filler content; modify grading to give less voids. Voids in Mix high and Stability low - increase filler content; increase bitumen content; modify grading to give less voids.

(c)

(d) (e)

When all the values fall within the limits stated in Schedule 3.6-1, the mixture at mean optimum binder content and parameters shall be designated the Laboratory Design Mixture and shall be used for Job Standard Mixture. 3.6.2.3 Trial Areas A trial area having a length of at least 30 metres shall be constructed by the Contractor, at the beginning of the work. The surfaces of the trial areas shall be in accordance with Sub Section 3.6.2.11. At least two samples of compacted material from the trial area shall be taken in accordance with B.S. 598 and shall be analyzed and the aggregate grading

30

and binder content determined. The findings shall be recorded. Trial area may be located inside the actual asphaltic concrete pavement work. 3.6.2.4 Job Standard Mixture If the Laboratory Design Mixture after passing through the mixing plant and after being laid and compacted, fails to produce a satisfactory trial area the grading and mixture proportions may be modified as necessary and within the requirements of Schedule 3.6-1, to produce a mixture of satisfactory workability and acceptable surface finish. After a satisfactory trial area is completed this mixture shall be designated the Job Standard Mixture. The Contractor shall report in writing to the Employer, before general mixing or laying proceeds, the combined aggregate grading, the mixture proportions and the values for stability flow, unit weight and voids (means values from four specimens) of the Job Standard Mixtures, which shall not be changed thereafter. The Job Standard Mixture shall be used for the density control specimens referred to hereafter. The series of mixtures from the mixing plant during normal production shall be designated the Plant Mixtures and the limits governing permissible variations between the Plant Mixtures and the Job Standard Mixture are given in Schedule 3.6-1. Throughout the Contract any variations outside these limits shall be investigated and corrected. If for any reason the quality, grading or supply source of aggregates is changed, or if at any time the cause of variations outside the permissible limits cannot be corrected for reasons beyond the control of the Contractor, the Contractor shall make new Laboratory Design Mixture or Job Standard Mixture, depending on the extent of change or variation. 3.6.2.5 Sampling and Testing Samples of the mixed materials shall be taken in the first two hours and every two hours thereafter to determine aggregate grading and binder content. If any of these tests show results which are not in accordance with the job standard mix, within permissible variation, suitable adjustments shall immediately be made to ensure compliance therewith. Samples of the mixed material shall be taken once per day or for each 500 tonnes whichever is greater, for making Marshall specimens to determine stability, flow and unit weight. All sampling and testing required under this paragraph shall be undertaken by the Contractor who shall keep records of these tests results. 3.6.2.6 Job Standard Mixture Density The density of the compacted wearing course shall be related to the Job Standard Mixture Density. The Job Standard Mixture Density, shall be determined by making, from samples of the approved Job Standard Mixture, six standard Marshall specimens and by determining the

31

apparent specific gravity of each and comparing them with the mean value of the six. Any individual result which differs from the mean by more than 1.5 percent shall be rejected and, provided not more than two results are so rejected, the mean of the remaining results, converted to kilograms per cubic meter, shall be designated the Job Standard Mixture Density. 3.6.2.7 Trial Areas to Establish Rolling Method After the Job Standard Mixture is designated a further trial area shall be laid using this mixture to establish the rolling method required to produce the specified filed density. Three pairs of samples shall be taken from the compacted trial area and the mean density of each pair shall be not less than 99 percent of the Job Standard Mixture Density. If the required field density is not obtained the rolling procedure shall be adjusted and further trial areas shall be laid and tested until satisfactory results are obtained. These shall be recorded. 3.6.2.8 Field Density Control Twin samples shall be taken from every 1,000 square metres of wearing course, or every 2 hours whichever is the more frequent, and their densities determined by the Contractor. The samples shall be 100 mm diameter cores cut by the Contractor using an suitable coring machine. The mean value obtained from the twin samples from the same area shall be taken as the field density of the compacted course. The field density is to be such that of twenty consecutive mean values, not more than three results are to be below 98 percent of the Job Standard Mixture Density. Material which does not meet this requirement shall be cut out and replaced. The samples may also be used to determine the course thickness. 3.6.2.9 Heating and Mixing Aggregates, including filler, shall be thoroughly dry immediately before mixing. The aggregates and binder shall be heated separately to the specified temperatures after which they shall be thoroughly and intimately mixed together in the correct proportions for at least 1 minutes and until every particle of aggregate is completely coated. Filler may be added before or after the binder but mixing shall continue for at least 1 minute after the addition of the filler. The total mixing is being obtained. Where the extracted dust is fed back, the feeding shall be controlled to ensure an uniform percentage of fine materials within the limits given by the Specifications and at least 60% of the material passing the 75 micron sieve shall be filler. Overheating of aggregates and binder shall be avoided. 3.6.2.10 Transporting, Laying and Compacting

32

Wearing course material shall be transported, laid and compacted in accordance with Section 3.1 and with the following requirements. (a) At least two self propelled smooth steel wheeled rollers following closely one behind the other shall be used in conjunction with each spreader and each roller shall weigh not less than 8 metric tons nor more than 12 metric tons. At least one of these rollers shall be three-wheeled with a weight per metre width of rear wheel between 350 kilograms and 700 kilograms. This roller shall be used immediately behind the spreader with its driving wheels adjacent to the spreader, unless otherwise directed. The second roller may be either tandem or three-wheeled with a weight per meter width of roll between 300 kilograms and 700 kilograms. A self-propelled pneumatic tired smooth tread roller with tire pressures of 6.2 N/mm2 shall be used between the two steel wheeled rollers. A tack coat, complying with Section 4.4.1 of this Specifications, shall be applied to the surface of the underlying course if deemed necessary. Breakdown Temperature : Between 115C and 135C Pneumatic Rolling Temperatures : As necessary to achieve the field density specified but not less than 95C.

(b)

(c)

(d)

(e)

(f) (g) 3.6.2.11

Surface Texture The surface finish of the pavement shall be as rough as possible, free from dragging, cracks or other surface blemishes. Back casting shall not be permitted but where dragging occurs under the screed of the spreader, fine bituminous material may be cast over the surface to fill the dragging cracks, providing that this is done before the initial rolling and provided that rolling is carried out at the specified temperature. Should dragging occur frequently the cause shall be investigated without delay and rectified.

3.6.3

ASPHALTIC CONCRETE BASECOURSE Asphaltic Concrete Basecourse shall be made and constructed in accordance with the following requirements and Schedule 3.6.2.

3.6.3.1

Materials Materials shall be in accordance with Sub Section 3.1.2.1.

33

3.6.3.2

Laboratory Design of Mixture The Laboratory Design Mixture shall be in accordance with Sub Section 3.6.2.2 with the following provisions. Where reference is made to Schedule 4.6-1 refer to Schedule 3.6-2. The number of specimens required for determination for the optimum binder content shall be four consistent specimens at each binder content within the range 4.0% to 7.0% at increments of 0.5%. The mean optimum binder content shall be determined form the test curves as follows : (a) (b) (c) (d) Stability - Peak of the Stability Curve Density - Peak of the Density Curve Voids in the total Mixture - 6.0% Voids filled with binder - 70%

3.6.3.3

Trial Areas Trial Areas shall be in accordance with Sub Section 3.6.2.3.

3.6.3.4

Job Standard Mixture The Job Standard Mixture shall be in accordance with Sub Section 3.6.2.4. Where reference is made to Schedule 3.6-1 read 3.6-2.

3.6.3.5

Sampling and Testing Sampling and testing shall be undertaken in accordance with Sub Section 3.6.2.5.

3.6.3.6

Job Standard Mixture Density The density of the compacted basecourse shall be related to the absolute density. The theoretical specific gravity of the Job Standard Mixture calculated in accordance with B.S. 598, 1958 converted to kilograms per cubic metre shall be the absolute density.

3.6.3.7

Trial Areas to Establish Rolling Method After the approval of the Job Standard Mixture a further trial area shall be laid using this mixture to establish the rolling method required to produce the specified field density. Three pairs of samples shall be taken from the compacted trial area and the mean density of each pair shall be not less than 93 percent of the absolute density. If the required field trial

34

density is not obtained the rolling procedure shall be adjusted and further areas shall be laid and tested until satisfactory results are obtained. These, and the rolling method shall be submitted to the Employer before mixing or laying is continued. 3.6.3.8 Field Density Control Twin samples shall be taken from every 1,000 square metres of basecourse or every two hours whichever is the more frequent and their densities determined by the Contractor. The samples shall be 100 mm diameter cores cut by the Contractor using a suitable coring machine. The mean value obtained from the twin samples from the same area shall be taken as the field density of the compacted course. The field density is to be such that of twenty consecutive mean values, not more than three results are to be below 92% of the absolute density. Material which does not meet this requirement shall be cut out and replaced. The samples may also be used to determine the course thickness. 3.6.3.9 Heating and Mixing Heating and mixing shall be in accordance with Sub Section 3.6.2.9 3.6.3.10 Transporting, Laying and Compacting Transporting, laying and compacting shall be in accordance with Sub Section 3.6.2.10. 3.6.3.11 Surface Texture The surface finish of the basecourse shall be as close as possible, free from dragging cracks or other surface blemished. Back casting shall not be permitted but when dragging occurs under the screed of the spreader fine bituminous material may be cast over the surface to fill the dragging cracks, providing that this is done before the initial rolling and providing that rolling is carried out at the specified temperature. Should dragging occur frequently the cause shall be investigated without delay and rectified. SCHEDULE 3.6-1 Asphaltic Concrete Wearing Course Materials Aggregate : In accordance with Sub Section 3.6.2.1 (a) and (b).

Polished Stone Value of the coarse aggregate shall be not less than 49 where tested in accordance with B.S. 812

35

Filler Combined Dry Aggregate

: In accordance with Sub Section 3.6.2.1 (c). : The particle size distribution of the combined coarse and fine aggregate and added filler is to be in accordance with the following : : Percentage passing by weight 100 80 - 100 54 - 72 42 - 58 34 - 48 26 - 38 18 - 28 12 - 20 6 - 12 : In accordance with Sub Section 3.6.2.1 (a).

U.S. Sieve Size 19.00 mm. 12.50 mm. 4.75 mm. 2.36 mm. 1.18 mm. 600 Micron 300 Micron 150 Micron 75 Micron Binder Laboratory Design Mixture Combined Dry Aggregate

: The aggregate shall be in accordance with the above. The particle size distribution when plotted shall give a smooth curve throughout the entire range of sizes.

Optimum Binder Content

: Between 4% and 7%, the exact percentage shall be determined in accordance with Sub section 3.6.2.2. : Not less than 1,100 kg. : 6 - 14 : Between 3% and 5% : Between 76% and 82% : Not less than 15% : Not less than 60%

Marshall Stability Marshall Flow (0.25 mm.) Voids in the Total Mixture Voids Filled with Binder Voids in Mineral Aggregate R value

When calculating the air voids allowance shall be made for the portion of asphalt which is absorbed into the aggregate particles. R = Marshall Stability (kg) Marshall Flow (0.25 mm.)

Job Standard Mixture

36

Combined Dry Aggregate

: As used for the Laboratory Design Mixture, modified if necessary in accordance with Sub Section 3.6.2.2. : As used for the Laboratory Design Mixtures, modified if necessary in accordance with Sub Section 3.6.2.2 : Not less than 1,100 kg. : 6 - 14 : The value determined by test on specimens of the modified mixture (to be between 76% and 82%). : The value determined by test on specimens of the modified mixture (to be not less than 15).

Binder

Marshall Stability Marshall Flow (0.25 mm.) Voids in the Total Mixture

Voids in Mineral Aggregate

Plant Mixtures All values shall be as approved for the Job Standard Mixture, except that the following variations from the specified percentage shall be permitted. Combined Dry Aggregate - Aggregate retained on 2.36 mm or larger sieves - Aggregate passing on 2.36 mm, 1.18 mm, 600 micron, 300 micron or 150 micron sieves - Aggregate passing 75 micron sieve Binder Content Voids in the Total Mixture Voids Filled with Binder Marshall Stability Marshall Flow (0.25 mm.) Temperatures : = 4.0 = 3.0

= 1.5

: : : : : :

0.3 1.0 5.0 Not less than 1,100 kg. 6 - 14 Binder and aggregate are to be between 135C and 177C and are to be within 14C of each other at the time of mixing.

SCHEDULE 3.6-2 3.6.3 Materials Aggregate : In accordance with Sub Section 3.6.3.1. Asphaltic Concrete Basecourse

37

The aggregate crushing value of the coarse aggregate shall not be more than 30%. Filler Combined Dry Aggregate : In accordance with Sub Section 3.6.3.1. : The particle size distribution of the combined coarse and fine aggregate and added filler is to be in accordance with the following : : Percentage passing by weight 100 78 - 100 56 - 80 40 - 64 30 - 52 18 - 38 11 - 25 5 - 15 3-7 : In accordance with Sub Section 3.6.2.1 (d).

U.S. Sieve Size 37.50 mm. 25.00 mm. 12.50 mm. 6.30 mm. 2.36 mm. 1.18 mm. 425 Micron 150 Micron 75 Micron Binder

Laboratory Design Mixture Combined Dry Aggregate : The aggregate shall be of the nominal size appropriate to the thickness of the compacted course and in accordance with the above table. The particle size distribution when plotted shall give a smooth curve throughout the entire range of sizes. : Between 4% and 8%, the exact percentage shall be determined in accordance with Sub section 3.6.3.2. : Not less than 680 kg. : 8 - 16 : Between 5% and 7% : Between 65% and 75%

Optimum Binder Content

Marshall Stability Marshall Flow (0.25 mm.) Voids in the Total Mixture Voids Filled with Binder

Voids in Mineral Aggregate R value

: Not less than 14% : Not less than 60%

38

When calculating the air voids allowance shall be made for the portion of asphalt which is absorbed into the aggregate particles. R = Marshall Stability (kg) Marshall Flow (0.25 mm.)

Job Standard Mixture Combined Dry Aggregate : As used for the Laboratory Design Mixture, modified if necessary in accordance with Sub Section 3.6.3.4. : As used for the Laboratory Design Mixtures, modified if necessary in accordance with Sub Section 3.6.3.4 : Not less than 680 kg. : 8 - 16 : The value determined by test on specimens of the modified mixture (to be between 5% and 7%). : The value determined by test on specimens of the modified mixture (to be between 65% and 75%). : The value determined by test on specimens of the modified mixture (to be not less than 14).

Binder Content

Marshall Stability Marshall Flow (0.25 mm.) Voids in the Total Mixture

Voids Filled with Binder

Voids in Mineral Aggregate Plant Mixtures

All values shall be as approved for the Job Standard Mixture, except that the following variations from the specified percentage shall be permitted. Combined Dry Aggregate - Aggregate retained on 2.36 mm or larger sieves - Aggregate passing on 2.36 mm, 1.18 mm, 600 micron, 425 micron or 150 micron sieves - Aggregate passing 75 micron sieve Binder Content Voids in the Total Mixture Voids Filled with Binder Marshall Stability Marshall Flow (0.25 mm.) Temperatures : = 5.0 = 4.0 = 1.5

: 0.3 : 1.0 : 5.0 : Not less than 680 kg : 8 - 16 : Binder and aggregate are to be between 135C and 177C and are to be within 14C of each other at the time of mixing.

39

SECTION 3.7 : PORTLAND CEMENT CONCRETE PAVEMENT

3.7.1 3.7.1.1

DESCRIPTION General This work shall consist of constructing a portland cement concrete pavement with reinforcement, on a prepared and accepted subgrade or subbase in accordance with these Specifications and in conformity with the line, levels, grades, dimensions and cross sections shown on the drawings. Portland cement concrete shall consist of a mixture of portland cement, fine aggregate, coarse aggregate, and water, with or without admixture.

3.7.1.2

Compressive Strength of Concrete At times during the progress of concreting, test cylinders shall be made. Cylinders tested in accordance with AASHTO Test Method T 22 shall show a strength of not less than 24 Newtons per square millimetre at 28 days. Sampling and testing of concrete cylinder shall be carried out as specified in Section 4.1. If a minimum crushing strength of 24 Newtons per square millimetre is not so attained the Contractor may at his own expense, drill cores from locations selected. Where this is done the strength of cores when tested in accordance with AASHTO Test Method T 24-90 shall be accepted as taking precedence over the test cylinder strengths in determining the strength of the concrete and a core strength of not less than 24 Newtons per square millimetre at 28 days shall be accepted for a core of minimum diameter not less than 4 inches having a height/diameter ratio of 2 : 1.

3.7.1.3

Grading of Aggregates The grading of the aggregates shall be within the limits as specified in Section 3.7.2 Materials. Once the appropriate grading, including the grading zone of the fine aggregate, has been determined, it shall not be varied.

3.7.1.4

Constituents of the Mix All material in the mix shall be proportioned wholly by weight. The cement and the coarse and fine aggregates shall be as specified in Section 3.7.2 Materials.

3.7.1.5

Water Cement Ratio The ratio of free water to cement for saturated surface - dry aggregate shall not exceed 0.50 by weight for all concrete in carriageways.

40

3.7.1.6

Limit of Workability The concrete shall be of suitable workability for full compaction to be obtained with the equipment used and without undue flow. The slump as measured by AASHTO Test Method T 119 shall be not less than 20 mm and not greater than 60 mm.

3.7.1.7

Trial Mixes Trial mixes to the requirements of Sub Section 4.1.1.3 shall be arranged.

3.7.2 3.7.2.1

MATERIALS Concrete The concrete shall conform to the requirements of Section 4.1.

3.7.2.2

Reinforcement Steel Pavements shall contain steel reinforcement as shown on the drawings. Steel reinforcement shall conform to Section 4.2. Bar-mat reinforcement shall extend to within 50 mm of each side of the slab. The sheets shall be furnished in such lengths that, with at least the minimum lap between sheets, the reinforcement extends to within 50 mm of transverse expansion or construction joints. All dowel bars and tie bars shall be cut by sawing machine. They shall free from burring and other deformations. Dowel bar shall be painted by asphalt MC-250, graphite lubricant or equivalent. (a) Steel reinforcement shall conform to the requirements of TIS Standard 20-1977, Grade SR-24 and TIS Standard 24-1973, Grade SD-30 or AASHTO Standard Specification M 31 and M 42. Bar-mat reinforcement - Bar-mat reinforcement shall conform to the requirements of AASHTO Standard Specification M 54. The bars used shall conform to the requirements of AASHTO Standard Specification M 31 or M 42/Members shall be of size and spacing to meet the requirements shown on the drawings. Dowel and tie bars - Dowel and tie bars shall conform to the requirements of TIS Standard 20-1977, Grade SR-24 and TIS 241973, Grade SD-40 or AASHTO Standard Specification M 31 and M 42. All reinforcement steel shall be on site adjacent to the concreting site before any pouring of the concrete is allowed. All laps shall be 40 times diameter.

(b)

(c)

41

Dowels bars shall be plain round bars. They shall be free from burring or other deformation restricting slippage in the concrete. Before delivery to the site of construction, one-half of the length of each dowel bar shall be painted with one coat of asphaltic material. Tie bars shall be deformed bars. Rail steel shall not be used for the bars which are to be bent and restraightened during construction. 3.7.2.3 Sleeves The sleeves for dowel bars shall be of metal or approved synthetic material. This shall be designed to cover not less than 50 mm nor more than 75 mm of the dowel, with a closed end, and with a suitable stop to hold the end of the sleeve a distance equal to the thickness of joint filler or at least 25 mm from the end of the dowel bar. Sleeves shall be of such design that they do not deflect or collapse during construction, and the arrangement of sleeves shall be in accordance with Sub Section 3.7.4.9. 3.7.2.4 Sub-base Materials Granular material conforming to Section 2.1 shall be used immediately beneath all concrete pavements. 3.7.2.5 Sub-grade Paper The subgrade paper shall be polyethylene film of not less than 0.15 millimeter thick and shall conform to the requirements of ACI 316 or equivalent. Longitudinal and transverse overlap shall be as indicated on the drawings. 3.7.2.6 Joint Materials (a) Joint Filler - The expansion joint fillers shall conform to the requirements of AASHTO Standard Specification M 213-81. They shall be punched to admit the dowels where called for on the drawings. The filler for each joint shall be furnished in a single piece for the full depth and width required for the joint unless otherwise authorized for a joint, the abutting ends shall be fastened closely together securely and accurately. Performed strips joint filler made from cane will not be accepted. Joint Primer - Joint priming compound shall be Expandite No. 3 or other suitable compound. Joint Sealing Compound - The joint sealing material shall conform to AASHTO Designation M-282.

(b) (c)

42

3.7.3 3.7.3.1

EQUIPMENT AND TOOLS General Equipment and tools necessary for handling materials and performing the work shall be at the site of the Work before work is started. If any equipment is not maintained in full working order or if the equipment as used by the Contractor proves inadequate to obtain the results prescribed, such equipment shall be improved or other satisfactory equipment substituted or added.

3.7.3.2

Batching Plant and Equipment Batching plant and equipment shall be such as to comply with the requirements of Sub Section 4.1.3.2.

3.7.3.3

Mixes Mixes shall be such as to comply with the requirements of Sub Section 4.1.3.2.

3.7.3.4

Finishing Equipment (a) Finishing Machine - The finishing machine shall be of the screeding and trowelling type equipped with two independently operated screeds, designed and operated to strike off the concrete. It shall be fully and accurately adjustable for loss of crown or other disarrangement due to wear. Vibrators - Vibrators for full width vibration of concrete paving slabs, may be either the surface pan type or the internal type. They may be attached to the spreader finisher. They shall not come in contact with the joint, load transfer devices, subgrade or side forms. The frequency of the surface vibrators shall not be less than 3,500 impulses per minute and for the internal type not less 5,000 impulses per minute. At least two spare vibrators and one generating unit shall be on hand in case of any breakdown of vibrating plant in use.

(b)

3.7.3.5

Joint Cutting Saw The mechanical saw for cutting joints shall be adequately powered to cut rapidly with a water cooled diamond edge saw blade or an abrasive wheel to the depth required. The Contractor shall keep a standby power saw on the project at all times.

43

3.7.3.6

Forms Straight side forms shall be metal forms having a thickness of at least 5 millimeters and have a depth equal to the prescribed edge thickness of the pavement slab. Curved forms shall be of the radius called for on the drawings and acceptable flexible forms shall be installed with the radius. Build-up forms with horizontal joints shall not be used. Forms shall be free from kinks, bends or wraps. Forms shall not deflect more than 6 millimetres when tested as a simple girder with a span of three meters under a load equal to that which the finisher or other construction equipment shall exert on them. The base width of forms shall at least equal the effective height. The top of the form shall not vary from a three metre straight edge by more than 3 millimetres at any point and the side by more than 6 millimetres at any point. The forms shall contain provision for locking together tightly the ends of abutting form sections and for secure setting.

3.7.3.7 (a)

Cutting Materials Burlap - The burlap used for curing shall be made from jute or hemp and at the time of using shall be in good condition, free from dirt, clay or any other substances which interfere with its absorptive quality. It shall not contain any substance which would have a deleterious effect on the concrete. Burlap shall be of such quality that it shall absorb water readily when dipped or sprayed and shall weight not less than 240 grams per square metre when completely dry. Sand - Sand shall be clean, sharp and free from any clay or any other deleterious matter. Liquid Membrane Forming Compounds - Liquid membrane forming compounds shall conform with the requirements of AASHTO Standard Specification M 148, Type 2. Sheet Material - Cover material in sheet form used for covering the surface of hydraulic cement concrete to inhibit moisture loss during the curing period shall conform to the requirements of AASHTO M 171.

(b) (c)

(d)

44

BANGKOK TRANSIT SYSTEM

MATERIALS AND WORKMANSHIP SPECIFICATION FOR CIVIL WORKS (SECTION 6 TO 13)

Printed
BTS-M&W 006-13/95 Rev. (a) 7/08/95

45

46