Standard Specification For Road Works

FOR INTERNAL USE ONLY

SECTION 5
PORTLAND CEMENT
CONCRETE PAVEMENT

Cawangan Jalan, Ibu Pejabat JKR, K.L

Page 122

FOR INTERNAL USE ONLY

Standard Specification For Road Works

SECTION 5 - PORTLAND CEMENT CONCRETE PAVEMENT

Page
5.1

DESCRIPTION

S5-125

5.2

MATERIALS

S5-125

5.2.1

Cement

S5-125

5.2 2

Aggregate

S5-125

5.2.3

Joint Filler

S5-125

5.2.4

Joint Sealants and Seals

S5-125

5.2.5

Waterproof Membrane

S5-126

5.2.6

Curing Materials

S5-126

5.3

PRODUCTION OF CONCRETE

S5-128

5.3.1

Concrete

S5-128

5.3.2

Equipment

S5-128

5.4

CONSTRUCTION

5.4.1

Preparation of Subgrade or Subbase

S5-128
S5-128

5.4.2
Construction by Machine
5.4.2.1 Fixed Forms, Rails and Guide Wires For Machine Construction
5.4.2.2 Construction by Fixed Form Paving Machine
5.4.2.3 Construction by Slip Form Paving Machine
5.4.3
Construction by Hand-Guided Method

S5-128
S5-128
S5-129
S5-131
S5-132

5.4.4
Manual Construction
5.4.4.1 Side Forms for Manual Construction

S5-132
S5-133

Cawangan Jalan, Ibu Pejabat JKR, K.L

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FOR INTERNAL USE ONLY

Standard Specification For Road Works

Page

5.5

JOINTS

5.5.1

Transverse Expansion Joints

S5-133
S5-133

5.5.2
Transverse Contraction Joints
5.5.2.1 Planes of Weakness
5.5.2.2 Load Transfer Assemblies

S5-134
S5-134
S5-135

5.5.3

Longitudinal Joints

S5-135

5.5.4

Transverse Construction Joints

S5-135

5.5.5

Sealing Joints

S5-135

5.5.6

Concrete Saw

S5-136

5.6

SURFACE TEXTURE

5.6.1

Texture of Running Surfaces

5.6.2
Measurement of Texture Depth : Sand Patch Method
5.6.2.1 Apparatus
5.6.2.2 Method

S5-136
S5-136
S5-137
S5-137
S5-137

5.7

ROUNDING OF EDGES

S5-137

5.8

CURING

S5-137

5.9

REMOVING FORMS

S5-138

5.10 OPENING TO TRAFFIC

S5-139

5.11 TREATMENT OF MANHOLES AND GULLIES

S5-139

5.12 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND

SURFACE REGULARITY

S5-139

Cawangan Jalan, Ibu Pejabat JKR, K.L

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FOR INTERNAL USE ONLY

SECTION 5 - PORTLAND CEMENT

CONCRETE PAVEMENT
5.1

DESCRIPTION
This work shall consist of constructing a
Portland cement concrete pavement with
or without reinforcement in accordance
with this Specification, including all
relevant requirements of Section 9,
and in conformity with the lines,
levels, grades, dimensions and
crosssections 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.

5.2

MATERIALS
All materials shall conform to the
relevant requirements in Section 9 of
this Specification. In addition the
following requirements shall also be
complied with.

5.2.1

Cement
Cement shall be ordinary Portland
cement unless otherwise shown on
the Drawings or directed by the S.O.

5.2 2

Aggregate
Coarse aggregate to be used for at
least the top 50 mm of the slab shall
have a polished stone value of not
less than 40.

5.2.3

Joint Filler

Standard Specification For Road Works

5.2.4

Joint Sealants and Seals

Joint sealants shall consist of hot or
cold-poured compounds or pre
formed seals as indicated on the
Drawings and shall comply with the
following requirements :(a) Hot-Poured Sealants
Hot-poured sealants shall comply
with the requirements of B.S. 2499
for Type A2 sealants.

(b) Cold-Poured Sealants

Cold-poured sealants shall comply
with the performance requirements
for the Normal type of sealant given
in B.S. 5212.
The sealant shall be composed of a
curing agent and a base resin, which
shall be in such proportions as
recommended by the manufacturer
to provide a fast cure if the material
is mixed and applied by special
machines, or a retarded cure if mixed
by hand. It shall cure within 1 hour
and remain active for not less than 4
hours. The sealant shall be applied
after the curing period of the primer
and within the period that the primer
remains active.
Materials to be mixed and applied by
hand shall be supplied in separate
containers and shall be mixed in the
correct proportions using a powered
stirrer or mixer or any other method
approved by the S.O.

The expansion joint filler shall

conform to the requirements of
AASHTO M153 or M213.

Cawangan Jalan, Ibu Pejabat JKR, K.L

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FOR INTERNAL USE ONLY

(c) Gunning Grade Sealants

Gunning grade sealants consisting of
two-part poly-sulphide-based sealing
compounds shall comply with B.S.
4254. Alternatively, poly-urethanebased sealing compounds may be
used provided their performance is
not inferior to B.S. 4254 material.
(d) Preformed Compression Seals
Preformed compression seals shall
be made from natural rubber and
shall conform to the requirements
contained in Table 5.1.
5.2.5

Standard Specification For Road Works

It shall have test certificates from an
approved testing laboratory to show
that the compound has a curing
efficiency of 90%.
The curing compound shall contain
sufficient flaked aluminium in finely
divided dispersion to produce
complete coverage of the sprayed
surface with a metallic finish. The
curing compound shall not react
chemically with the concrete to be
cured and shall not crack, peel or
disintegrate within 2 weeks after
application.

Waterproof Membrane
Plastic sheeting shall have a
minimum thickness of 125 um and
shall be of a quality as approved by
the S.O.

5.2.6

Curing Materials
The exposed surface of concrete
pavements shall be cured
immediately after the surface
treatment by the application of one
of the following curing materials :(a) White Pigmented Liquid
Membrane-Forming Compound
White pigmented liquid membraneforming compound shall conform to
the requirements of AASHTO
M148, Type 2.
(b) Aluminised Curing Compound
Aluminised curing compound
shall be stable and impervious to
evaporation of water from the
concrete surface within 60
minutes after application.

Cawangan Jalan, Ibu Pejabat JKR, K.L

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FOR INTERNAL USE ONLY

Standard Specification For Road Works

TABLE 5.1 - SPECIFICATION FOR PREFORMED NATURAL RUBBER COMPRESSION

SEALS

Property.

Units

Requirement

Hardness.

IRHD

55 + 5

Tensile Strength, minimum.

MPa

15

Elongation at break, minimum.

400

Compression Set, 24 hours at

100 oC, maximum.

40

Ageing Resistance, maximum

change from unaged values after
72 hrs + 0 hrs at 100 oC :- 2 hrs
- hardness
- tensile strength
- elongation at break.

Ozone Resistance, 20%

elongation, 96 hours at
140 oC, 50 pphm.

Change in Volume after

immersion in water for 7 days at
laboratory temperature,
maximum.

Recovery of Finished Seals,

under 50% deflection, after
72 hrs + 0 hrs at 100 oC.
- 2 hrs

IRHD
%
%

0 to + 10
- 20
- 25

No cracking

0 to + 5

85

Note : All tests are in accordance with ISO Standards.

Cawangan Jalan, Ibu Pejabat JKR, K.L

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5.3

PRODUCTION OF CONCRETE

5.3.1

Concrete
Concrete shall be of the grade shown
on the Drawings and shall comply
with the relevant requirements of
Section 9 of this Specification.

5.3.2

CONSTRUCTION

5.4.1

Preparation of Subgrade or Subbase

Prior to placing concrete pavement,
the underlying subgrade or subbase
shall have been shaped and
compacted in accordance with the
provisions of Sub-Sections 2.2.7 or
4.1.2 as appropriate and the
waterproof membrane laid as
required in the Drawings.
Notwithstanding any earlier approval
of finished subgrade or subbase, any
damage to or deterioration of the
subgrade or subbase shall be made
good to the satisfaction of the S.O.
before the waterproof membrane is
laid and the concrete pavement
constructed.

5.4.2

Prior to the placing of concrete, all

of the required joint assemblies such
as dowel bars, tie bars, etc., shall be
installed in accordance with the
requirements of Sub-Section 5.5. In
one-layer construction, the slab
reinforcement shall also be installed
and fixed in accordance with the
relevant requirements of Section 9.

Equipment
All equipment used such as batching
plant and mixers shall comply with
the relevant requirements of Section
9 of this Specification.

5.4

Standard Specification For Road Works

Construction by Machine
The concrete slab shall be
constructed either by fixed form or
by slip form paving plant in a
continuous process in either one or
two layers, as approved by the S.O.

Cawangan Jalan, Ibu Pejabat JKR, K.L

In two-layer construction, the

thickness of the top layer shall be not
less than 50 mm or twice the
maximum size of the coarse
aggregate, whichever is the greater,
and shall be at least 15 mm thicker
than the depth of the groove former,
if used. Placement of reinforcement
and concreting of the top layer shall
be done immediately, and in any
case not more than 30 minutes, after
the completion of the bottom layer.
5.4.2.1 Fixed Forms, Rails and Guide
Wires For Machine Construction
(a) Fixed Forms and Rails
All forms and rails shall be made
of steel and be sufficiently robust
and rigid to support the weight
and pressure caused by the
paving equipment. Side forms
for use with wheeled paving
machines shall incorporate metal
rails firmly fixed at a constant
height below the top of the forms.
The forms shall be secured by
using not less than three pins for
each 3 m length, having one pin
fixed at each side of every joint.
Forms shall be tightly joined
together by a locked joint, free
from play or movement in any
direction.

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FOR INTERNAL USE ONLY

Forms shall be cleaned and oiled

immediately before each use.
The rails or running surfaces shall
be kept clean in front of the
wheels of any paving machines.
The forms shall be straight within
a tolerance of 3 mm in 3 m.
The forms shall be bedded on
low moisture content cement
mortar and set to the pavement
surface level as described in the
Contract within a tolerance of 3
mm. The bedding shall not
extend under the slab. There
shall be no vertical step between
the ends of adjacent forms greater
than 3 mm. The horizontal
alignment for forms shall be to
the required alignment of the
pavement edge as described in
the Contract within a tolerance of
10 mm. The mortar or
concrete bedding shall be broken
out after use.
Prior to concreting, the forms
shall be approved by the S.O.
Forms shall not be removed
earlier than 6 hours after the
completion of the construction of
the slab. Care shall be taken to
prevent damage to the concrete
and any projecting tie bars during
the removal of the forms. If the
removal of forms results in any
damage to the concrete the period
of 6 hours shall be increased to
that which is necessary to avoid
further damage and the
Contractor shall make good the
damaged areas.
b) Guide Wires
Unless otherwise agreed by the
S.O., a guide wire shall be
provided along each side of the
slab to be constructed by slip
Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

form paving plant. (Each guide
wire shall be at a constant height
above and parallel to the required
edges of the slab within a vertical
tolerance of 3 mm. In addition,
one of the wires shall be at a con
stant horizontal distance from the
required edge of the pavement
within a lateral tolerance of 10
mm.
The guide wires shall be
supported from stakes not more
than 8 m apart by connectors
capable of fine horizontal and
vertical adjustment. The guide
wire shall be tensioned on the
stakes so that a 500 gramme
weight shall produce a deflection
of not more than 20 mm when
suspended at the mid-point
between any pair of stakes. The
ends of the guide wires shall be
anchored to fixing points which
shall be not closer to the edge of
the slab than the row of stakes
and in no circumstances shall a
guide wire be anchored to a
stake.
The stakes and guide wires shall
be checked and approved by the
S.O. prior to concreting.
5.4.2.2 Construction by Fixed Form
Paving Machine
A fixed form paving train shall
consist of separate powered
machines which spread, compact
and finish the concrete in a
continuous operation.
Concrete shall be discharged
without segregation into a hopper
spreader which is equipped with
the means to control its rate of
deposition on to the subbase or
on to the lower layer. . The con
crete shall be spread in each layer
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FOR INTERNAL USE ONLY

without segregation and to a

uniform uncompacted density
over the whole area of the slab.
The deposited concrete shall be
struck off to the necessary level
by the underside of the hopper as
it is traversed across the
spreading machine. The machine
shall be capable of being rapidly
adjusted for changes in average
and differential surcharge
necessitated by changes in slab
thickness or crossfall.
Prior to being compacted, the
surface level of each loose spread
layer shall be adjusted to the
correct surcharge by means of
rotating strike off blades or a
screw device.
The concrete shall be compacted
by vibration or by a combination
of vibration and mechanical
tamping so as to comply with
Sub-Section 5.3.1 throughout the
full depth of the slab. Poker
vibrators shall be used adjacent to
the side forms and the edge of
previously constructed slabs.
The initial regulation and finish
to the surface of the slab shall be
effected by means of a beam
oscillating transversely or
obliquely to the longitudinal axis
of the pavement. This beam shall
be readily adjustable for both
height and tilt.
Joint grooves shall be constructed
in compliance with Sub-Section
5.5. The concrete shall be
recompacted around the former
by a hand held vibrating plate
compactor drawn along or on
each side of the joint, prior to
regulation of the surface by the
diagonal finishing beam.

Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

The regulation and finishing of
the surface of the slab shall be
carried out by a machine which
incorporates twin oblique
oscillating finishing beams which
shall be readily adjustable for
both height and tilt. The beams
shall weigh not less than 170 kg
per linear metre, be of rectangular
section and span the full width of
the slab. The leading beam shall
be vibrated. The beams shall be
supported on a carriage, the level
of which shall be controlled by
the average level of not less than
four points evenly spaced over at
least 3.5 m of the supporting rail,
beam, or slab, on each side of the
slab that is being constructed.
The final regulation and surface
finishing of the slab shall be
carried out after any wet forming
of joint grooves. After the final
regulation and before texture is
applied, any excess concrete on
top of the groove former shall be
removed.
When a concrete slab is
constructed in more than one
width, flanged wheels on the
paving machines shall not be run
directly on the surface of any
completed part of the slab. The
second or subsequent slabs shall
be constructed either by
supporting machines with flanged
wheels on flat- bottom section
rails weighing not less than 15
kg/m laid on the surface of the
completed slab, or by replacing
the flanged wheels on that side of
the machine by smooth flangeless
wheels. Before flangeless wheels
or rails are used, the surface
regularity of the slab over which
they are to pass shall comply
with Sub-Section 5.4.1 and its
surface shall be thoroughly
cleaned and brushed to remove
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FOR INTERNAL USE ONLY

all extraneous matter. Flangeless

wheels or rails shall be positioned
sufficiently far from the edge of
the slab to avoid damage to that
edge.
5.4.2.3 Construction by Slip Form
Paving Machine
A slip form paving train shall
consist of powered machines
which spread, compact and finish
the concrete in a continuous
operation.
A slip form paving machine shall
compact the concrete by internal
vibration and shape it between
sliding side forms or over fixed
side forms by means of either a
conforming plate or by vibrating
and oscillating finishing beams.
The concrete shall be deposited
without segregation in front of
the slip form paver across its
whole width and to a height
which at all times is in excess of
the required surcharge. The
deposited concrete shall be struck
off to the necessary average and
differential surcharge by means
of a strike-off plate or a screw
auger device extending across
the whole width of the slab. The
equipment for striking off the
concrete shall be capable of being
rapidly adjusted for changes in
the average and differential sur
charge necessitated by changes in
slab thickness or crossfall.
The level of the conforming plate
and finishing beams shall be
controlled automatically from the
guide wires by sensors attached
at the four corners of the slip
form paving machine. The
alignment of the paver shall be
controlled automatically from the
Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

guide wires by at least one sensor
attached to the paver. The
alignment and level of ancillary
machines for finishing, texturing
and curing of the concrete shall
be automatically controlled
relative to the guide wires or to
the surface and edge of the slab.
Slip form paving machines shall
have vibration of variable output,
with a maximum energy output
of not less than 2.5 kW per metre
of slab per 300 mm depth of slab
for a laying speed of up to 1.5 m
per minute or pro rata for higher
speeds. The machines shall be of
sufficient mass to provide
adequate reaction on the traction
units to maintain forward
movements during the placing of
concrete in all situations.
Joint grooves shall be constructed
in compliance with Sub-Section
5.5. The concrete shall be
compacted around the former by
a separate vibrating plate
compactor with twin plates. The
groove former shall be
compacted to the correct level by
another vibrating float which may
be included with the transverse
joint finishing beam. In addition
a hand held vibrating float, at
least 1 m wide, shall be drawn
over the surface along the joint.
Any excess concrete on top of the
groove former shall be removed
before the surface is textured.
Where a concrete surface slab is
constructed in more than one
width or where the edge needs to
be matched for level to another
section of surface slab, and the
surface levels at the edges are not
achieved, paving shall be carried
out over separate fixed side forms
supporting the edge to the
required levels.
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FOR INTERNAL USE ONLY

5.4.3

Standard Specification For Road Works

Construction by Hand-Guided
Method

Details of joints shall be as shown on

the Drawings. Joint grooves shall be
constructed in compliance with SubSection 5.5. Any irregularities at wet
formed joint grooves shall be
rectified by means of a vibrating
float at least 1.0 m wide drawn
along the line of the joint. The
whole area of the slab shall be
regulated by two passes of a
scraping straight edge not less than
1.8 m wide or by a further
application of a twin vibrating
finishing beam. Any excess concrete
on top of the groove former shall be
removed before the surface is
textured.

Areas to be constructed by handguided method shall be agreed with

the S.O. The slabs shall be
constructed in one layer. Dowel
bars, tie bars and reinforcement, if
specified, shall be fitted in position
as shown on the Drawings.
The concrete shall be spread
uniformly without segregation or
varying degrees of precompaction,
by conveyor, chute or by other
means approved by the S.O. The
concrete shall be struck off by a
screed so that the average and
differential surcharge is sufficient to
ensure that after compaction the
surface is to the required level.
The concrete shall be compacted by
vibrating finishing beams. In
addition, internal poker vibration
shall be used for slabs thicker than
200 mm and may be used for lesser
thicknesses. When used, the pokers
shall be at points not more than 500
mm apart over the whole area of the
slab, and adjacent to the side forms
or the edge of a previously
constructed slab.
The surface shall be regulated and
finished to the level of the top of the
forms or adjacent slab or pavement
layer by using twin vibrating
finishing beams. The beams shall be
metal with a contact face at least 50
mm wide and a vibrating unit having
a minimum centrifugal force of 4 kN
with a frequency recommended by
the manufacturer or an equivalent
compactive effort. The vibrating
beams shall be moved forward at a
steady speed of 0.5 m to 1 m per
minute whilst vibrating over the
compacted surface to produce a
smooth finish.
Cawangan Jalan, Ibu Pejabat JKR, K.L

The surface shall be brush-textured

as described in Sub-Section 5.6.
The concrete shall be cured in
compliance with Sub-Section 5.8.
5.4.4

Manual Construction
Areas to be constructed by manual
method shall be agreed with the S.O.
The slabs shall be constructed in one
layer. Dowel bars, tie bars and
reinforcement, if specified, shall be
fixed in position as shown on the
Drawings.
The concrete shall be spread
uniformly without segregation or
varying degrees of pre-compaction,
by conveyor, chute or by other
means approved by the S.O. The
concrete shall be struck off by a
screed so that the average and
differential surcharge is sufficient to
ensure that after compaction the
surface is to the required level.
The concrete shall be compacted by
internal poker vibrator or other
means approved by the S.O. The
vibrations shall be at points not more
than 500 mm apart over the whole
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FOR INTERNAL USE ONLY

Standard Specification For Road Works

area of the slab, and adjacent to the

side forms or the edge of a
previously constructed slab.

As soon as surplus water has risen to

the surface, the pavement shall be
given a broomed finish.

The surface shall be regulated and

finished to the level of the top of the
forms or adjacent slab or pavement
layer by using an approved portable
hand screed. The screed shall be at
least 600 mm longer than the width
of the slab to be struck off and
compacted. It shall be of approved
shape, sufficiently rigid to retain its
shape and constructed either of metal
or of other material shod with metal.
Compaction shall be attained by
raising and dropping the screed in
successive positions until the
required compaction and reduction
of surface voids is secured.
The screed shall then be placed on
the forms and slid along them, with
out lifting, in a combined
longitudinal and transverse shearing
motion moving always in the
direction in which the work is
progressing. If necessary, this shall
be repeated until the surface is of
uniform texture, true to grade and
contour, and free from porous areas.
After the concrete has been struck
off and compacted, it shall be further
smoothed, screeded and compacted
by means of a longitudinal hand float
or other equipment as approved by
the S.O.
Details of joints shall be as shown on
the Drawings. Joint grooves shall be
constructed in compliance with SubSection 5.5. Any irregularities at wet
formed joint grooves shall be
rectified by suitable means approved
by the S.O.
The concrete shall be cured in
compliance with Sub-Section 5.8.
Cawangan Jalan, Ibu Pejabat JKR, K.L

5.4.4.1 Side Forms for Manual

Construction
All side forms shall be made of
steel and be sufficiently robust
and rigid to withstand
construction forces. Timber
forms shall only be used for work
which is less than 200 m in
length.
The forms shall comply with
other requirements of SubSection 5.4.2.1 as appropriate.
5.5

JOINTS
Joints shall be constructed as specified
herein and/or as directed or approved by
the S.O. Before any joint materials are
set in place, the underlying pavement
course at those locations shall have been
approved by the S.O.
Preformed expansion joint filler shall be
placed around each structure which
extends into or through the pavement
over the full interface with the concrete
pavement slab before concrete is placed.

5.5.1

Transverse Expansion Joints

The components for each transverse
expansion joint shall be assembled in
advance and placed in position as a
unit.
Each assembly shall consist of an
installing template, preformed joint
filler of the required dimensions in a
single piece, dowel bars and sleeves
of the required sizes and lengths at
the required locations, and spacing
and supporting elements for the
dowel bars, as shown on the
Drawings.
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FOR INTERNAL USE ONLY

The installing template shall be

metal plate of adequate rigidity
approved by the S.O., cut to the
required depth and crown of the slab
and having a length 10 mm less than
the required length of the joint. It
shall be slotted from the bottom as
necessary to permit removal.
Suitable means shall be provided on
the template for facilitating its
removal.
One half length of each dowel bar
shall be thoroughly coated with a
200 pen bitumen blended with
creosote oil or other material as
approved by the S.O. A dowel
sleeve shall be fitted on to the coated
end of each dowel.
The dowel supports shall be
constructed so as to hold dowels in
correct alignment, both vertically and
horizontally, subject to a tolerance of
not more than 1 in 100.
When assembled, the top of the
installing template shall be about 5
mm above the top of the preformed
filler. The filler shall be vertical and
shall be in a plane at right angles to
the centre line of the road, subject to
a tolerance of not more than 1 in
500.
The joint assembly shall be placed so
that the installing template is on the
side of the filler remote from pouring
operations. The top of the filler shall
be 10 mm below the required con
crete surface, and the bottom shall
rest on or extend slightly into the
underlying pavement course. The
assembly and its installation shall
have been approved by the S.O.
before any concrete is placed against
it.

Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

Stakes for supporting the installing
template shall be of a cross-section
and length satisfactory to the S.O.
5.5.2

Transverse Contraction Joints

Transverse contraction joints shall
consist of planes of weakness created
by forming or cutting grooves in the
surface of the pavement and, when
shown on the Drawings, shall
include load transfer dowel bar
assemblies.

5.5.2.1 Planes of Weakness

(a) Sawn Grooves
When sawn grooves are specified
they shall be sawn in the con
crete after its initial set.
Grooves shall be at right angles
to the centre line of the
pavement, shall be true to line
and shall have the width and
depth shown on the Drawings.
All joints shall be sawn before
uncontrolled shrinkage cracking
takes place but not until the
concrete has hardened to the
extent that tearing and ravelling is
not excessive, usually 4 to 24
hours after placing. If extreme
conditions exist which make it
impracticable to prevent erratic
cracking by early sawing, formed
grooves shall be used.
Any procedure for sawing joints
that results in premature and
uncontrolled cracking shall be
revised immediately by adjusting
the sequence of cutting the joints
or the time interval involved
between the placing of the con
crete or the removal of the curing
medium and cutting of the joints.

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FOR INTERNAL USE ONLY

(b) Formed Grooves

When formed grooves are
specified, they shall be made
by depressing an approved
tool or device into the soft,
freshly laid concrete. The
tool or device shall remain in
place until the concrete has
attained its initial set and then
be removed without
disturbing the adjacent
concrete. The line, width and
depth shall be as shown on
the Drawings.
5.5.2.2

Load Transfer Assemblies

Load transfer assemblies for
transverse contraction joints
shall be as shown on the
Drawings. They shall be of
similar construction to the
assemblies for transverse
expansion joints except that
no joint filler shall be
required and, consequently, no
installing template shall be
used.

5.5.3 Longitudinal Joints

Longitudinal joints shall be
constructed as shown on the
Drawings.
Planes of weakness shall be created
by forming or cutting grooves as
previously specified.
Tie bars across a longitudinal joint
shall be placed perpendicular to the
joint and shall be rigidly supported
as shown on the Drawings. The bars
shall not be painted or coated with
bitumen or other material.

Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

When adjacent lanes of pavement
are constructed separately, steel side
forms shall be used which will form
a key along the longitudinal joint as
shown on the Drawings.
5.5.4 Transverse Construction Joints
Concreting operations shall be
planned such that transverse
construction joints shall be
constructed at designed transverse
expansion or contraction joints.
Transverse construction joints shall
be keyed or butt joints formed by
placing suitable bulkheads approved
by the S.O.
When there is an interruption of
more than 30 minutes in the
concreting operations, a transverse
construction joint shall be
constructed. As far as is practicable,
this construction joint shall be
formed at a designed transverse
expansion or contraction joint.
When this is not possible, transverse
construction joints shall be
constructed at least 3 metres from all
transverse expansion or contraction
joints. In such cases, tie bars 12 mm
in diameter and 1 metre long at 600
mm centres shall be placed at the
transverse construction joints. Wire
fabric or bar mat reinforcement shall
extend across all such transverse
construction joints.
5.5.5 Sealing Joints
Joints shall be sealed as soon after
completion of the curing period as
feasible and before the pavement is
opened to traffic, including
construction traffic. Immediately
prior to sealing, each joint shall be
thoroughly cleaned of all foreign
material, including membrane curing
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Standard Specification For Road Works

compound, and the joint faces shall

be clean and surface dry when the
seal is applied.

units and power to complete the

sawing with a water-cooled diamond
edge saw blade, or an abrasive
wheel, to the required dimensions
and at the required rate. The
Contractor shall provide at least one
stand-by saw in good working order.
An ample supply of saw blades shall
be maintained at the site of the work
at all times during sawing operations.
The Contractor shall provide
adequate artificial lighting facilities
for night sawing. All of this
equipment shall be on the job before
and continuously during concrete
placement.

The sealing material shall be applied

in accordance with the dimensions
shown on the Drawings or as
directed by the S.O.
Sealing material to be applied hot
shall be stirred during heating so that
localized overheating does not occur.
The pouring shall be done in such a
manner that the material will not be
spilled on to the exposed surfaces of
the concrete. Any excess material on
the surface of the concrete pavement
shall be removed immediately and
the pavement surface cleaned. The
use of sand or similar material as a
cover for the seal will not be
permitted.
Preformed compression seals for
sealing joints shall be of the crosssectional dimensions shown on the
Drawings. Seals shall be installed
using suitable tools, without
elongation, and secured in place with
an approved adhesive which shall
cover both sides of the concrete
joints. The seals shall be installed in
a compressed condition and shall at
time of placement be below the level
of the pavement surface by
approximately 5 mm. The seals
shall be in one piece for the full
width of each transverse joint.
Notwithstanding the above, all
sealants shall be applied or installed
in accordance with the
manufacturer's instructions or
recommendations.
5.5.6

Concrete Saw

5.6

SURFACE TEXTURE
5.6.1 Texture of Running Surfaces
After the final regulation and before
the application of the curing
membrane, the surfaces of concrete
slabs to be used as running surfaces
shall be brush-textured in a direction
at right angles to the centre line of
the carriageway.
The type of brush and method of
application for surface texturing shall
be approved by the S.O. based on
trial brushing to be conducted by the
Contractor.
The texture depth shall be
determined by the sand patch test as
described herein.
The average texture depth for each
set of 10 tests shall not be less than
0.75 mm and not more than one test
of each set shall show a texture depth
of less than 0.65 mm. In no case
shall the maximum texture depth
exceed 2 mm.

When sawing of joints is specified,

the Contractor shall provide sawing
equipment adequate in number of
Cawangan Jalan, Ibu Pejabat JKR, K.L

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Standard Specification For Road Works

5.6.2 Measurement of Texture Depth :

Sand Patch Method

31000 where D is the diameter of the of the

D x D patch in mm.

5.6.2.1 Apparatus

5.7

i) A cylindrical container - 25
ml capacity.

Where shown on the Drawings or

directed by the S.O., edges of concrete
slabs shall be rounded as follows.

ii) A flat wooden disc 64 mm in

diameter with a hard rubber
disc, 1.5 mm thick, stuck to
one face, the reverse face
being provided with a handle.

After brush texturing but before the

concrete has attained its initial set, top
edges of concrete slabs shall be worked
with an approved tool and rounded to
a radius of 5 mm. A well defined and
continuous rounded edge shall be
produced and a smooth, dense mortar
finish obtained.

iii) Dry natural sand passing a

300 um B.S. sieve and
retained on a 150 um B.S.
sieve.

At all transverse joints, any tool marks a

ppearing on the slab adjacent to the
joints shall be eliminated by brooming
the surface. In doing this, the rounding
of the edge of the slab shall not be
disturbed. All concrete on top of joints
shall be removed completely.

5.6.2.2 Method
The surface to be measured shall
be dried, any extraneous mortar
and/or loose material removed,
and the surface swept clean using
a wire brush both at right angles
and parallel to the centre line of
the carriageway. The cylinder
shall be filled with the sand,
tapping the base three times on a
hard surface to ensure
compaction, and striking off the
sand, level with the top of the
cylinder. The sand shall be
poured into a heap on the surface
to be tested. The sand shall be
spread over the surface, working
the disc with its face kept flat, in
a circular motion so that the sand
is spread into a circular patch
with the surface depressions
filled with sand to the level of the
peaks.
The diameter of the patch shall
be measured to the nearest 5 mm.
The texture depth in mm of
concrete surfaces shall be
calculated as:-

Cawangan Jalan, Ibu Pejabat JKR, K.L

ROUNDING OF EDGES

5.8

CURING
The exposed surfaces of concrete
pavement shall be cured immediately
after surface texturing and rounding of
edges by treating with a curing
compound fulfilling the requirements of
Sub-Section 5.2.6. It shall be
mechanically sprayed on to the surface
at a rate of 0.22 to 0.27 litre per square
metre using a fine spray. The
mechanical sprayer shall incorporate an
efficient mechanical device for
continuous agitation and mixing of the
compound in its container during
spraying. For the sides of slip formed
slabs or when the side forms are
removed within the curing period, and
for small areas where a mechanical
distributor cannot be used, the
compound shall be sprayed by hand
lance at a rate of 0.27 to 0.36 litre per
square metre.

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Standard Specification For Road Works

The compound shall form a uniform,

continuous, coherent film that shall not
crack or peel and shall be free from pin
holes or other imperfections. If
discontinuities, pin holes or abrasions
exist, an additional coat shall be applied
within 30 minutes to the affected areas.
Necessary precautions shall be taken to
ensure proper curing at the joints and
that none of the curing compound enters
joints which are to be sealed with joint
sealing compounds. Rope of moistened
paper, fibre or other suitable material
shall be used to seal the top of the joint
opening, and the concrete in the region
of the joint shall be sprayed with curing
compound immediately after the rope
seal has been installed.
Approved stand-by facilities or
approved alternative methods for curing
concrete pavement shall be provided at a
readily accessible location at the site of
the work for use in the event of
mechanical failure of the spraying
equipment or any other conditions
which may prevent correct application
of the membrane curing compound at
the proper time. In the event of a failure
of the regular spraying equipment, the
paving operation shall be stopped, and
the stand-by or alternative curing
method shall be used on the remaining
portion of the paving already placed.
Concrete surfaces to which membrane
curing compounds have been applied
shall be adequately protected for the
duration of the entire curing period from
pedestrian and vehicular traffic, except
as required for joint sawing operations
and surface tests, and from any other
cause which will disrupt the continuity
of the membrane. The curing
membrane so formed shall be
maintained intact for a period of not
less than fourteen (14) days.

Cawangan Jalan, Ibu Pejabat JKR, K.L

In addition, the entire surface shall be

protected from the effects of solar
radiation by the use of frames
covered with material with heat and
rain deflecting properties for not less
than 4 hours after application of the
curing compound.
Notwithstanding the foregoing, concrete
surfaces which are subjected to heavy
rainfall within 3 hours after the curing
compound has been applied shall be
resprayed, all as specified above at no
additional cost.
Concrete liable to be affected by running
water shall be adequately protected from
damage during the setting period.

5.9

REMOVING FORMS
Forms shall not be removed until the
freshly placed concrete has set for at
least 6 hours. The forms shall be
removed carefully so as to avoid
damage to the pavement.
As soon as forms are removed, the ends
of all expansion joints shall be cleaned
of concrete and the full width of the
filler exposed for the full depth of the
slab. Any areas showing a minor degree
of honeycombing shall be repaired with
1:3 cement mortar. Where the S.O.
considers that a major degree of
honeycombing is present, the work shall
be considered defective and shall be
removed and replaced at the expense of
the Contractor. In such cases, the
section of concrete removed shall be to
the full width and depth of the slab and
at least 3 metres long.

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5.10 OPENING TO TRAFFIC

No pavement shall be opened to any
traffic earlier than twenty-eight (28)
days from the completion of concreting.
The Contractor shall erect and maintain
suitable barricades and shall employ
watchmen to exclude public traffic and
that of his employees and agents from
the newly constructed pavement.
These barriers shall be arranged so as
not to interfere with public traffic on any
lane intended to be kept open and
necessary signs and lights shall be
maintained by the Contractor clearly
indicating any lanes open to traffic.
Where, as shown on the Drawings, it is
necessary to provide for traffic across
the pavement, the Contractor shall, at his
own expense, construct suitable and
substantial crossings to bridge the newly
constructed concrete pavement for as
long as the S.O. shall direct.

Standard Specification For Road Works

fixed to the slab edges so exposed. This
shall be to the full depth of the slab
allowing for the depth of the groove
required for sealing. Alternatively, the
recesses may be sawn out after the con
crete has hardened.
Reinforcement shall be placed as shown
on the Drawings and concrete placed by
hand in the space between the main slab
and the manhole or gully frame. This
concrete shall be of the same grade as
that of the main slab, and the mix shall
be modified as necessary to permit full
compaction by the methods adopted.
5.12 HORIZONTAL ALIGNMENTS,
SURFACE LEVELS AND
SURFACE REGULARITY
The alignment, levels and regularity of
the finished surface shall be in
compliance with Sub-Section 4.4 of this
Specification.

Any part of the pavement damaged by

traffic or other cause prior to its final
acceptance shall be repaired or replaced
all at the expense of the Contractor in a
manner suitably satisfactory to the S.O.
5.11 TREATMENT OF MANHOLES
AND GULLIES
Manhole covers, gullies and their frames
shall be isolated from the main
pavement slab as shown on the
Drawings and their surrounds cast in
separate operations.
Manholes and gully recesses shall be
formed by casting the main slab against
formwork boxes with vertical sides,
placed and fixed accurately. The
formwork boxes shall be removed
before the concrete around the manhole
or gully cover is to be placed and
preformed joint filler, 20 mm thick,
Cawangan Jalan, Ibu Pejabat JKR, K.L

Page 139