Roads & Highways PDF

GENERAL SPECIFICATIONS OF URBAN ROADS
CONSTRUCTION
Table of Contents
Note:
The following provisions are applicable to Divisions 1, 2 and 3 of the
General Specifications Document:
A: Division 1 The Definitions of Terms and Abbreviations

are applicable to technical terms only. For Definitions of
Contractual Terms the provisions of the General and Particular
Conditions of Contract are applicable
B: Division 2 NOT USED
C: Division 3 NOT USED
General Specifications
of Urban Roads Construction
(First Edition 2005 A.D.)
Kingdom of Saudi Arabia

Ministry of Municipal & Rural Affairs
Deputy Ministry for Technical Affairs
Table of Contents
Forward and Introduction
DIVISION 1
DEFININTIONS OF TERMS AND ABBREVIATIONS
DIVISION 2
BID SUBMISSION CONDITION
DIVISION 3
GENERAL RULES NOT USED
19
DIVISION 4
URBAN ROADS CHARACTERISTIC
45
DIVISION 5
EARTH WORKS
61
DIVISION 6
SUBBASE AND AGGREGATE BASES
181
DIVISION 7
MATERIALS OF ASPHALTIC MIXES
225
DIVISION 8
ASHPHALTIC CONCRETE WORKS
247
DIVISION 9
RECYCLING
273
DIVISION 10
SURFACE TREATMENTS
289
DIVISION 11
SPECIAL ASPHALTIC WORKS
DIVISION 12
SUPERIOR PERFORMANCE ASPHALT PAVEMENT
DIVISION 13
REMOTE AREAS PAVEMENT WORKS
DIVISION 14
CEMENT PAVEMENT LAYERS
DIVISION 15
SIDEWALKS, CURBS AND MEDIAN ISLANDS
DIVISION 16
TRAFFIC SIGNALS, TRAFFIC SIGNS,

ROAD MARKING, FENCES, GUARDRAILS
AND CONCRETE BARRIERS WORKS
NOT USED
3
13
313
325
345
DIVISION 17
WORK ACCEPTANCE
Appendix 1
Standard Testing Guide
Appendix 2
Superpave Volumetric Mix Design Example
Appendix 3
Random Sampling Method
Appendix 4
Work Evaluation Using The Statistical Method
Appendix 5
Traffic Calming Bumps
357
405
419
463
481 491
515
521
References List
Unit Conversion Table
527
F orw ard:
Urban roads represent a large part of projects carried out by MOMRA and are
considered as one of the most important aspects of national investment because they
represent services which have strong relationship with people's daily needs and that they are
the foremost pillar for construction development with all its aspects and activities.
Through its branches throughout the kingdom, the ministry has provided infrastructure
services such as all types of road systems according priorities determined by the critical
needs of the citizens. Recent years have seen an increase in the size of demand for such
services in light of the continuous increase in the size of population followed by
constructional expansion of the cities and villages in the kingdom.
In light of the new changes in modern scientific technologies, particularly those
related to construction of road elements and asphalt mixes, and in compliance with the
ministry's efforts towards controlling construction development and ensuring quality of
executed projects, the need arose for developing and updating the technical specifications
practiced in the field of road construction works so that they may match the new
developments in this technology. Some technical controls were considered in accordance
with modern innovations for constructing good roads according to the most advanced
technical specifications and requirements, and to ensure proper construction standards and
provision of safe/comfortable traffic conditions.
In preparation of those specifications, the ministry has depended on participation of
experts of the executive departments in municipalities and directorates by informing them
promptly with the plan of preparing those specifications and their methodology to get use
from their practical experience and avoid problems and obstructions which were
associated in the past with road construction. This was done through holding a number of
meetings, workshops, field visits, and questionnaires. Also assistance was sought from
national, Arab, and international experts in this field. The ministry has done great efforts
in the preparation of this content, hoping that municipalities & directorates shall get some
useful aspects which may assist them in carrying out their national obligations in the best
of ways.
All contractors working in the field of road construction shall adhere to these
general specifications when carrying out the ministry's projects, so that we may
participate in serving the construction development through executing road systems
according to scientific and well studied bases.
The ministry welcomes any views or suggestions which may be applied during
updating these specifications, according to future developments in road engineering and
material manufacturing aspects.
B est Regards
Mutaib Bin Abdul Aziz
Minister of MOMRA
Introduction:
Under the economic upheaval taking place in the Kingdom Of Saudi Arabia
during recent years, a continuous increase was noticed in construction development of
the kingdom's cities and villages. As a result of this, great deals of urban roads of
different types were constructed within a relatively short period. Consequently, this led
to a considerable growth and development in the technologies of road construction and
building material manufacturing.
Codifications of the rules governing construction of urban roads is an important
concern of the ministry and a topping for the methodology of progression and
development in organizing the municipal requirements and technical standards for
services being executed by them or supervise their construction after the modern
development and great changes in all aspects in the kingdom. No doubt, the general
specifications for urban roads construction get their importance from applying the rules
and preserving public and private rights, and they are the accurate standard for judging
on cases related to urban roads construction for implementing justice and equality and to
facilitate for officials follow-up and monitoring of such works.
Since the standard specifications of roads which were issued previously are not
sufficient any more to suit these huge developments, it was paramount that the ministry
develops those instructions and unifies the technical rules and standards to comply with,
as minimum, in road construction works through the preparation of these general
specifications for urban roads construction. These specifications aim at laying out
technical conditions for the construction of urban roads on scientific basis and methods
which consider compliance with the considerable developments in the technologies of
executing urban road projects. The ministry took much care in preparing these
specifications so that that they may suit the requirements of urban areas in the kingdom
and to get use of previous specifications, research works, experience, suitable for the
conditions of constructing roads in the kingdom, and to abide with the general
international principles for the preparation of the specifications as to clarity, accuracy,
summarization and non-contradiction. Also, including in the specifications clear
standards for quality assurance.
These specifications also handle requirements for urban roads construction in

detail. Whereas they include seventeen divisions in addition to 5 appendices which
describe a number of special issues. Those specifications shall be applied on all urban
roads being executed by the municipalities. Roads Contracting companies and
establishments shall adhere to them when constructing urban roads.
By issuing these specifications, the ministry hopes that they may lead to
executing road projects in a civilized appearance that suits the development and
constructional growth through which the kingdom currently live.
We hope from God Almighty they will achieve their purpose.
Deputy of the Ministry for Technical Affairs Abdul Aziz Bin Ali
Al-Abdulkarim
I II
Supplementary References
These general specifications include materials and methods of completing earth
works, asphalt and concrete pavement layers, pavements, road signs, signals works, and
water drainage. When some details are needed reference shall be made to the
supplementary references indicated below, without contradiction with special
specifications and these general specifications. The latest or updated issue available of
those references shall be used when announcing the competition.
The supplementary references include:
123456-
Road Engineering Designing Manual- MOMRA.

Supervision Procedure for Project Construction- MOMRA.
Manual of Traffic Control Devises at work Zones- MOMRA.
Specifications of Asphalt road Pavement layers Maintenance- MOMRA.
Distress Identification Manual- MOMRA.
Technical Specifications & General Conditions for roads, streets, and parks
lighting-MOMRA.
7- General Specifications of civil works in public utility extension projects- MOMRA.
8- Manual of Supervision Procedures for civil works in public utility extension
projects-MOMRA.
9- Technical conditions of parking areas- MOMRA.
10Standards & Rules of landscaping inside cities- MOMRA.
11Technical Conditions of Advertising & Publicity signs- MOMRA.
12Manual on Uniform Traffic Control System (MUTCD) - M. O. T.
13-Saudi Arabian Standards Organization (SASO), Standardization and Metrology
Organization for G.C.C. (GSMO).
14- American Association of State Highway and Transportation Officials (AASHTO).
15- American Society for Testing and Materials (ASTM).
DIVISION 1
1.1
Defin ition s
1.2
Abbreviations
General Specifications of Urban Roads Construction ___ Division 1- Definitions of Terms and Abbreviations
DIVISION 1
1.1
Definitions:
Whenever in these specifications the following words and terms or pronouns in place of
them are used, the intent and meaning shall be interpreted as shown in unless otherwise
clearly stated in the text.
As-built Drawings
The final drawings that showing the actual constructed works on the road including, all
changes and modifications that issued during construction period by the Ministry or the
Engineer.
Asphalt Binder
The modified or non-modified asphalt cement, liquid asphalt and emulsified asphalt
material used in producing asphalt concrete in order to obtain specific properties.
A sphalt Pavem ent Recycling
The production of asphalt mixes using aggregate composed of old disintegrated pavement
materials with or without new aggregate and asphalt materials composed of the old asphalt
binder and a new asphalt binder and with or without softening agent as specified in the
specification and ordered by the Engineer.
B ackfill
The constructed works around structures, like bridges, culverts, retaining walls and around
and above different utilities.
Bidder
The agency or firms that submits the bid; it could be a person or persons or join venture or
company.
Bid / Tender
A set of documents and application forms prepared by the contractor and submitted to the
Ministry to enter a competition for a certain work that has been circulated by the Ministry.
These documents shall show the contractor readability, qualifications to carry the works
with accordance to specifications and drawings as well as his abides with costs and time
schedule specified in that bid.
Bid / Tender Forms
These are the documents or forms approved by the Ministry, which shall be completed and
submitted by Contractors to request awarding of a certain work.
Bill of Quantities
A table included in the contract documents that describe all work items, their estimated
quantities, units, individual and total costs.
Certificate of Guarantee
A signed statement by a legally authorized agency or a person with which the
manufacturing or supplying company bind with the product specifications. Such
Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia
certificate shall mention that the material specifications and testing results conform to the
requirements specified in the specifications.
Change Order
A written order addressed to the Contractor and approved by the Ministry about important
and influence change in some items and works in the project.
Charge Order
The written instruction ordered to the Contractor issued by the Engineer and approved by
the Ministry, to require a construction of additional works according to the items of the
contract.
Consensus Properties of A ggregate
Physical properties specified for selecting aggregate used in producing high performance
and include fine aggregate angularity, coarse aggregate angularity, flat and elongated
particles and sand equivalent tests.
C ontract
A written agreement between the Ministry and Contractor that stipulates the obligations of
the two parties and explains contract documents that rule the agreement.
C ontractor
Person (s) or firms or company or join venture who has a contract with the ministry to
execute the work specified in the contract documents, and it is the second party of the
contract.
Cross Slope
A transverse gradient of the road surface (shoulders and lanes) expressed as a percentage
of the horizontal distance for that surface.
C ontract D ocum ents
A set of written documents between the Ministry and the Contractor, they include
announcement for invitation for bidders to submit offers, conditions for bidders,
Contractor's tender, explanatory questions and answers, award notification, contract text,
general and special conditions, general and complimentary specifications, special
specifications, Bill of Quantity and their inclusiveness, drawings, change orders,
appendixes required for work execution and other documents listed in the contract text.
C ontract Period
The number of working days or calendar days specified for the completion of contract
works, including official holidays in the Kingdom of Saudi Arabia and it start from the
date of handing the site to the Contractor in a written minutes.
C ross-S ection
A plan or figure formed by the perpendicular intersection of heights and road profile that
showing vertical and horizontal dimensions, elevations and slopes, embankment layer
thickness or cutting, and pavement layer thickness.
Em bankm ent
The fill material to be constructed on the natural ground surface or on the existing surface
up to the bottom level of subgrade layer.
Engineer
The officially authorized person by the Ministry, and works directly or through officially
authorized representatives, who responsible for supervising the construction of the works
included in the contract and its supplements. The word (Engineer) means, wherever
indicated, the approved representative of the Ministry at the site.
Engineer's Representative
The person or persons authorized by the Engineer to monitor the detail of work.
Equipm ent
All machines and tools required for their operation and maintenance, devices and systems
required for the construction of contract works in a technically acceptable method and to
perform them properly within contract period.
Equivalent Standard Axle loads
The equivalent standard load in terms of 8.2 KN dual tandem standard rare load.
Final Handing over
A final approval of the work issued by a technical committee assigned by the Ministry
after expiry of the guarantee period and according to approved minutes by the ministry as
indicated in the contract documents.
A group of technical requirements and conditions describing the works required to be
constructed, construction methods, equipments, materials, analysis methods, quality
control procedure, quality assurance procedure and acceptance methods.
Guarantee Period/ Maintenance Period
The period that stated in the contract during which the contractor carries out maintenance
works and observe the constructed works and it started from date of completion as decided
by the preliminary handing over committee.
H olidays
Means all official holidays recognized in Saudi Arabia.
Item of Work
A specific work unit for which a price has been defined in the contract.
Job Mix Formula
A report that shows the proportional percents of the mix components, mix proportions
regarding some work construction, mix methods and the properties obtained based on
laboratory test results as specified in the specifications.
Letter of Acceptance
The official acceptance letter issued by the Ministry to one of the bidders by which the
works execution is awarded to that bidder.
Ministry
The Ministry of Municipal and Rural Affairs in Kingdom of Saudi Arabia, or its
representative (municipalities, directorates and rural councils). And it represents the first
party in the contract.
Municipality (Amanah)
A service system of a legal entity has financial and administrative independence headed by
an official called secretary who carries out its delegated duties specified by assignment
resolutions.
M unicipality of province (B aladiah)
A legal entity of financial and administrative independence has its own separate budget
and serves the city and related villages established by a Ministerial resolution issued by the
Minister of Municipal and Rural Affairs.
Overburden Materials
The soil materials that covering rock or gravel or other materials at source, which shall be
removed before, transporting those materials to avoid their contamination.
Pavem ent Layers
The layers that compose Asphalt or cement concrete pavements and it consists of asphalt
or cement surface layers, asphalt base layers, treated or untreated aggregate base layers and
Subbase layer.
Performance Bond
The approved form of guarantee submitted by the contractor or his Surety(s) to guarantee
the proper execution by the contractor and all relevant obligations according to the
contract, and for deducting delay penalties and all other compensations for default and
damage inflicted on the Ministry due to Contractor's breach of his obligations.
Pre-construction meeting
A meeting between the Engineer and the Contractor and his representatives, to discuss
work plan, progress and contract requirements prior starting of the work.
Prelim inary handing over
The partial or complete approval of the work by a technical comity assigned by the
Ministry based on a request from the Contractor according to approved minutes by the two
contract parties and the Ministry as stated in the contract documents.
Price B reakdown
The Contractor's proposal that submitted to the Ministry which shows the costs of all items
indicated in the Bill of Quantity and describes the details contents of cost for each work
item.
Profile Grade
The trace of a vertical plane intersecting the upper surface of the proposed surface layer,
along the road centerline, or a line parallel to it.
Program and Time schedule of work

A time table prepared by the Contractor and submitted to the Engineer for approval prior
starting of the work, which indicates the construction periods, equipments, labor, work
sequence and methods applied by the Contractor for works construction.
Quality Control
A set of specific procedures for measurements, samplings, testing, and evaluation of tests
and measurements results carried to determine the degree of compliance with quality
requirements and standards indicated in the specifications and implemented by the
Contractor.
Quality A ssurance
A group of planned regulatory procedures for taken measurements and samples, testing
and evaluation for tests and measurements results, in order to provide satisfactory
confidence to assure that the constructed works conforming to the specified requirements
in the specifications, these regulations shall be applied by the Ministry or specialized firms
assigned by the ministry.
Random sam ple
A sample selected in such a way that for each statistical event has the same chance to be
within that sample.
Road
Whenever it appears the road phrase in these specifications shall mean road and street that
is accessible to vehicle movements.
Roadbed
The soil on which the treated or untreated subgrade layer is to be constructed and it consist
from all or part of the following according to its location and design levels: - The natural
ground.
- Bottom of the excavation.
- The existing road surface.
- The upper part of road embankment.
The road bed shall be considered as the upper most 30 cm of the embankment for the local
roads and 60 cm for arterials, collectors, industrial area roads and heavy trucks parking
areas, below the bottom level of the subgrade layer.
Rural council
A legal entity of financial and administrative independence and has its own budget formed
to serve a group of villages and its head office shall be located in one of those villages.
Site
Lands and places handed on which the works shall be executed either above or below or in
it, or any lands offered by the Ministry as areas for project construction specified in the
contract.
Site Engineer
The Engineer who represents the Contractor at the site according to his specialization and he
is officially authorized to execute all instructions of the Engineer or Engineer's
representatives and to manage and monitor all construction works carried out by the
Contractor during all work phases.
Source Properties
Physical properties specified for selecting aggregate used in producing high performance
asphalt, concrete and include toughness, soundness and deleterious materials.
Special Specifications
Additional requirements, modifications and amendments made in the general and
complimentary specifications to interpret and cover works required to be constructed for a
particular project according to the requirements location and prevailing conditions.
Specification Limits
Lower and upper limits which should be achieved on the constructed works using the best
available materials and construction methods.
Statistical Evaluation
An analytical method for measurements or tests results for the purpose of determining the
degree of compliance of the constructed works with contract documents using statistical
methods.
Subcontractor
Person or firms or company or join venture to whom the Contractor assigned for them
execution of some part of the work according to approval of the Ministry.
Subgrade
The part that located below Subbase or Aggregate Base or asphalt layers.
Superior Performance A sphalt Concrete (Superpave)
The concrete produced using asphalt binder that classified according to Performance
Grade and selected according to the last version of AASHTO Specification MP-1, and the
used aggregates were selected on the basis of the results of source and consensus
properties tests and the asphalt mix shall be designed in accordance of volumetric mix
design method or superpave mix design level one.
Supplem ental A greem ent
A written agreement signed by the Ministry and Contractor including works not indicated
in the original contract or their value exceeds the allowable extra percent of cost in the
contract. Agreement shall be made between the Ministry and Contractor on the prices of
those works and on the extension of contract period.
Supplem entary Specifications
Additional instructions or amendments, which might be made on the general specifications
to explain and cover special type of work required to be constructed at specified project
according to the prevailing conditions.
Temperature Reliability
The percent of probability in which the actual temperatures do not exceeds the selected
temperature for of superpave asphalt concrete design.
Work Drawings
A set of drawings and figures for work construction that includes plans of temporary and
permanent structures , profiles, cross sections, typical models, detailed sections together
with supplementary and any additional plans showing work site, type, dimensions and
details, submitted by the Ministry or prepared by to the Contractor and approved by the
ministry.
1.2
Abbreviations:
Whenever the following abbreviations were used in the specifications or on the plans, they
shall represent the same meaning indicated below.
Abbreviation
AASHTO
ACI
ACPA
ASTM
BS
CBR
ESALs
JMF
QL
QU
Lat
MS
PCA
PG
PI
PVC
RAP
IRI
IFI
SASO
SI
Meaning
American Association Of State Highway And Transportation Officials
American Concrete Institute
American Concrete Pavement Association
American Society for Testing and Materials
British Standards
California Bearing Ratio
Equivalent Standard Axle Load
Job Mix Formula
Lower quality index
Upper quality index
Latitude of Project Location in Degree
Series of the American Asphalt Institute references according to the
number attached to letters.
Portland concrete Association of America
Performance Grade
Plasticity Index
Polyvinyl Chloride Pipes
Recycled Asphalt Pavement
International Roughness Index
International Friction Index
Saudi Arabian Standards Organization
International system for units
DIVISION 2
13
2.1
2.2
In trod u ction
Language of Bid
13
13
2 .3
Competition D ocuments
13
2 .4
C ontract Rates
14
2 .5
P relimin ary G u aran tee
14
2 .6
2 .7
Final Guarantee
Bid Submission Manner
14
15
General Specifications of Urban Roads Construction ____________ Division 2- Bid submission conditions
DIVISION 2
2.1
Introduction:
Invitation for tenders and submission of proposals shall be conducted in
compliance with regulations and laws implemented in KSA, specifically the latest issue of
the form of the general works contract, & regulations for provision of government
purchases and execution of its projects and works.
Whatever is not stipulated in this division or contradicts with what is indicated in
the general works contract form and regulations for the provision of government
purchases and execution of its works and projects, is subject to the general works
contracts regulations and regulations for the provision of government purchases and
execution of its projects and works.
2.2
Language of bid:
Arabic Language is the approved language for the interpretation of the bid and all
correspondence between the ministry and contractors, and all documents proposals shall
be submitted in Arabic language.
2.3
Competition documents:
Before he submits his proposal, contractor shall review drawings and documents
which are the subject of the bid he intends to submit. He shall examine and audit these and
enquire about all the details. Also, he shall provide his comments and opposition against
them within the period specified in the invitation.
Contractor is considered, immediately at submitting his proposals, that he has
studied, understood, conceived, and accepted all the articles of the tender.
He has no right to oppose or claim any additional costs arising from undue
assumption of non-clarity or misunderstanding or not reviewing competition documents or
contract or work drawings, specifications, details, and sites. All participants in the
competition shall enclose all the documents indicated in the announcement with their
proposals. And the ministry has the right of rejecting any bid that has not completed those
documents.
Competition docum ents inclu de:
1- An introduction letter showing that contractor has studied competition documents,
terms and conditions and his commitment to all the instructions and conditions
indicated in them. The letter shall be signed and stamped from the contractor.
2- A copy of the invitation announcement.
3- A copy of a valid Commercial Registration certificate.
4- A copy of a valid Chamber of Commerce membership certificate.
5- A valid Zakat & Income tax certificate.
6- A copy of valid Classification certificate.
7- A description of contractor's previous works.
8- Any other documents indicated in the announcement.
9- A valid bank guarantee for 1% of the tender value for a period not less than 3
months.
13
2.4
Contract rates:
Contractor shall submit his rates in Saudi Riyals and no other currency is
acceptable. Prices shall be written by ink can not be canceled in words and figures
showing unit prices for each work item according to the measuring units indicated in the
BOQ. Total amounts shall be shown for each work item after multiplying the unit price by
the estimated quantity, also total proposal price resulting from all total prices of all work
items.
When there is a difference in the bid between unit price and total price, the unit
price is the one to be applied, but if there is a difference between figures and wordings, the
latter is applied.
It is not permissible to cancel or amend on the BOQ, and when it is necessary
contractor may (cancel) then write the correct rate in red color providing that he signs and
stamps besides cancellation.
Prices shall be based on a study made by the contractor for work items, his review
for contract documents and work site, materials sources and prices for all the works. The
information indicated in the invitation or special specifications, general specifications,
drawings, materials availability, soil and site condition are considered as inferential and
shall not be taken as a basis for price estimations. Contractor shall base his prices on his
own studies, and no objection concerning this will be accepted after proposal submission.
Contractor shall submit together with BOQ another table showing constituents of
each price for each work item.
Prices specified in the tender are considered as a basis for contract prices in case
tender has been awarded according to them. They shall include submission of labor,
materials, mixes, machines, equipments, conducting measurements and testing, report
submissions, all third party charges, expenses, and payments, and all other requirements
for the completion of the works in accordance with contract, drawings, special and general
specifications.
2.5
Prelim inary guarantee:

Contractor, together with his proposal, shall submit an unconditional preliminary
letter of guarantee issued from one of the banks approved by SAMA (Saudi Arabian
Monitory Agency) valid for the period indicated in the invitation announcement,
providing that it is not less than 3 months, with the value of 1% of the contract total value
or for the value indicated in the announcement. The Ministry shall not consider any
proposal that does not include the L/G (Letters of Guarantee).
2.6
Final Guarantee:
Contractor who has been awarded the contract, on the basis of the award letter, and
within 10 days from receiving award letter, shall submit to the ministry an irrevocable bank
guarantee issued in its benefit from an approved bank at SAMA for this purpose, it shall be
in the value of 5% of the contract total value, or the value specified in the contract.
14
2.7
Bid subm ission manner:

Contractor shall submit his bids according to the form which is specified for that,
to the ministry enclosing all the documents and information indicated in the
announcement. All the required documents shall be original or an approved and
authenticated copy.
Bid submission shall in accordance with the announcement in two separate
envelopes placed inside a third wax sealed one. On the envelope contractor shall write
contractor's name, competition name, competition subject, invitation number and date,
and envelopes opening date.
The two envelopes include the following:
1- Th e first one includes the financial proposal according to the approved tender form,
which include total price of contract, unit prices of work items according to the BOQ
attached with the invitation, and a table that includes analysis of price details.
2- Th e sec o n d envelope is submitted when the invitation stipulates that, and it includes
a technical report from the contractor in which he describes his plan for completion of
the works, a list of the engineers, technicians, equipments and machines as required in
the invitation announcement.
Contractor shall meet all the conditions indicated in the announcement and other
documents approved in the kingdom, & the Ministry of Municipal & Rural affairs, which
are indicated in the invitation.
Contractor shall be committed to his proposal for a period not less than 3 months or
the period indicated in the announcement, whichever is longer. Also, he shall be
committed to that tender after opening envelops, contract award, and before contract
signing, till the end of the period stipulated in the conditions, specifications or
announcement, or public works for and government purchases regulations, and manuals
& instructions applied in the kingdom and by MOMRA (Ministry of Municipal & Rural
affairs).
All documents and sheets submitted in the tender shall be signed and approved by
the contractor, and it is not permissible to incorporate any amendments in these.
15
Kingdom Of Saudi Arabia

M inistry Of M unicipal & Rural A ffairs
Secretariat/M unicipality/ A ssem bly
Ten d er S ubm ission F orm
H. E . .. God Blesses Him
Reference to competition No. . Dated . Announced by Concerning the
works of ... ,
We are pleased to submit our bid for executing the required works in accordance
with the approved conditions & specifications, within the contract period stipulated in the
competition documents, for an amount of (SR ...), only .... SR. We
hereby enclose work items unit and total price table, and another table for the details of
prices of each work item.
We, acknowledge that we have reviewed the competition documents, drawings,
and the approved specifications for the works, the project site, and materials type and
source. We accept awarding the contract to us according to the prices and period
indicated in our proposal and the competition conditions, without any objection or claim
or price increase, and that we shall commence work immediately after being handed
over the site.
Official A ddress:
Mail Address:
Telephone No.:
FAX No:
Email:
Best Regards:
Bidder:
Name : .... Title : Signature: ... Stamp ...
16
DIVISION 3
GENERAL RULES
3.1
Introduction
3.2 Work Scope and Documents 3.2.1
Contract Purpose 3.2.2 Contract
Documents 3.2.3 Contract
Language 3.2.4 Additional
Drawings 3.2.5 Special Work
3.2.6 Non-Estimated Items
3.2.7 Addition, Omission, and Modification In Work Items
3.2.8 Introduction of New Items to the Project
3.2.9 Modification Claims And Disputes
3.2.10 Removal And Disposal Of Structures And Obstructions
3.2.11 Power & Water Supply 3.2.12
Coordination Between Works
3.2.13 Site Evacuation And Cleaning After Work Completion
3.2.14 Construction & Execution Record Books
3.2.15 Workshop Drawings
3.3 Legal Relations And Responsibility Towards The Public
3.3.1 Law Abidance
3.3.2 Authorizations, Licenses, And Charges
3.3.3 Patent Right And Ownership
3.3.4 Royalties
3.3.5 Relations Between Contractor And His Employees And
Employees Of His Subcontractor 3.3.6 Insurance
3.3.7 Monuments And Fossils Etc
3.3.8 Alcoholic Drinks, Drugs, Weapons, Ammunition, and Keeping
Order
3.3.9 Property Preservation
3.3.10 Contractor's Responsibility For Work
3.3.11 Personal Responsibility Of Government Officials
3.3.12 Preservation Of Environment
3.3.13 Dangerous Wastes
3.3.14 Using Explosives
3.3.15 Losses On Persons and Properties
3.3.16 Traffic Control At Work Site 3.3.17
Safety Precautions At Project Site 3.3.18
Guiding And Lighting
3.4 Supervision On The Works
3.4.1
3.4.2
3.4.3
3-4.4
3.4.5
Supervision Staff
Supervision Staff Duties
Supervision Staff Authorities
Supervision Staff Facilities
Laboratory, Measuring And Testing Systems And Equi
3.4.5.1 Measuring Equipments
3.4.5.2 Sampling, And Samples Storing And Testing Systems
and Equipments
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3.4.6 Client Commitments

Execution Conditions And Work Progress
3.5.1 Work Site Inspection 3.5.2
Work Site Handing In 3.5.3
Contractor Commitments 3.5.4
Work Site Planning
3.5.5 Compliance With Drawings And Specifications
3.5.6 Coordination With Public Utilities & Structures Authorities
3.5.7 Signs
3.5.8 Contractor's Technical Staff
3.5.9 Penalty For Absence Of Contractor Technical Staff
3.5.10 Work Program And Time Schedule
3.5.11 Construction Equipments
3.5.12 Pre-Construction Meeting
3.5.13 Subcontracts
3.5.14 Night Work
3.5.15 Unusual Traffic
3.5.16 Temporary Work Halting
3.5.17 Defects And Failure 3.5.18
Work Withdrawal
3.5.19 Assigning Withdrawn Works To Another Contractor
3.5.20 Contract Period
3.5.2 1 Delay Penalty
3.5.22 As-Built Drawings
3.5.23 Ending Contractor's Responsibility
Control And Acceptance Of Materials And Works
3.6.1 Materials And Works Control Procedures 3.6.2
Material Sources
3.6.3 Material Transportation And Storing
3.6.4 Work Inspection Before Covering
3.7 Measuring And Payment
3.7.1 Work Measuring
3.7.2 Payment Scope
3.7.3 Compensation For Modified Quantities
3.7.4 Additional Work And Work According To Calculating
Manpower
3.7.5 Unauthorized Work 3.7.6 Lump Sum
3.7.7 Fixtures & Accessories 3.7.8 Payments
3.7.8.1 Current Payment 3.7.8.2 Final Payment
3.8 Work Handing Over
3.8.1 Preliminary Handing Over 3.8.2 Final Handing Over
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General Specifications of Urban Roads Construction ____________________ Division 3- General Rules
DIVISION 3
GENERAL RULES
3.1
Introduction:
The general rules stipulated in this division are subject to the rules of public works
form, regulations of government purchases & execution of its projects/works, and their
executive bill and amendments at contract signing. The rules indicated in the public works
form, regulations of government purchases provision and execution of its projects and
works take priority in case there is contradiction between these and what is indicated in
these general rules. Any matter, for which no stipulation has been indicated, is subject, in
these general rules, to public works form, regulations of provision of government
purchases and execution of its projects and works implemented at the time of contract
signing.
This division includes the general rules concerning the execution of roadway
works, and includes the following sections:
1- Work scope and documents.
2- Legal relationships and responsibility towards the public.
3- Supervision on the works.
4- Execution conditions & work progress.
5- Materials & works control.
6- Measurement & payment/.
7- Handing over of the works.
3.2
Work scope and documents:
3.2.1 Contract purpose:

The purpose of the contract is completion of the works listed in the BOQ (Bill of
Quantities), additional works and modifications which contractor may intend to execute
according to updated items, according to drawing specifications, general specifications
and professional standards. Contractor shall provide trained and qualified manpower,
machines, equipments, technically acceptable materials, conducting measurements and
testing, submission of technical reports and drawings, in addition to all requirements for
carrying out the works and finishing these according to drawings and approved
specifications within contract period or agreed extension period.
3.2.2 Contract documents:
Contract is composed of the following documents:
a- Main contract document.
b- Special conditions (if any).
c- General conditions.
d- Special specifications (if any).
e- Drawings & diagrams.
f- General specifications.
g- BOQ & price rates.
h- Award letter.
Contractor shall abide with contract documents with all their details and to deal with these
as an integrated package which compliment, clarify and explain each other.
19
He shall not exploit any mistake, ambiguity, or apparent shortage on the drawings or
specifications and take it as a basis for claiming additional payments or lowering the
quality of used materials or executed works. When contractor notices such mistake, or
ambiguity or shortage, he shall inform the engineer who shall explain and clarify that and
return to the agency which prepared specifications and drawings to enquire, when
necessary.
When a difference or contradiction is encountered in the contract documents or in
case of dispute, contract documents shall be handled on bases of the following:
1- When there is a contradiction or difference between rules of contract documents, the
former document prevails over the subsequent one according to the order indicated at
the beginning of this paragraph.
2- Measurements shown in figures are adopted and measurements on the basis of diagram
scale are not adopted.
3- Adopted special work drawings are those provided by the ministry or those submitted
from the contractor and approved from the ministry or its representative, if any.
Standard drawings are not adopted.
4- Project special specifications or disputed work item are adopted, but general or
complimentary specifications are not adopted
5- Special specification stipulation is adopted when there is contradiction between it and
standard drawings or special drawings.
6- In case there is a difference between dimensions shown on the drawings and those
listed in the BOQ, dimensions shown on the drawings are adopted.
7- When there are no specifications for a certain item or article, reference is made to
specifications applied for similar works and prevailing norms.
8- Contract text rules, contract general specifications, and regulations for tenders
implemented in the kingdom, at contract signing have priority on rules and conditions
indicated in these general specifications.
9- When there is a difference between the Arabic and an English version of the contract
documents, the Arabic version shall adopted for all contract documents, including
general specifications and contract conditions, and if there is difference between the
digits and the letters of the numbers the numbers with written letters is adopted.
10- Specifications issued from SASO (Saudi Arabian Standards Organization), if any,
shall be implemented for all materials and works, and shall take priority over other
standard specifications, except otherwise special specifications stipulate for a more
recent standard specification that achieves technical requirements even better.
3.2.3 Contract language:
Arabic is the approved language for interpreting and executing the contract. Both
parties may write the contract or part of it by one of the foreign languages besides Arabic.
In case, there is contradiction between the Arabic and foreign text, the Arabic version will
be adopted. Arabic is adopted in general specifications, and it is possible that the two
parties may use an English copy, however, the Arabic version is the one which is
considered when there is contradiction between the two versions.
Correspondence between the two parties shall be in Arabic, and contractor may use a
foreign language, providing that he submits with it an approved translated copy in Arabic
(which will be considered as the basis in case of contradiction).
20
3.2.4 Additional drawings:

When additional drawings are prepared and submitted, those additional drawings
aim at showing contract work details and not changing it. Those drawings shall have the
same rating as to contract control and execution requirements. 3.2.5 Special work:
Special works are those parts of work included in the contract but not sufficiently
described in the general specifications or complimentary specifications, and for which
special specifications were prepared. Those works shall be considered as part of the
contract, all contract requirements are applicable to them and their special specifications
are considered as part of the contract documents.
3.2.6 Non-estimated items:
The ministry (when necessary and without violating the law) in case it expects
appearance of some work items which should be executed to complete the project
properly, while it is not possible to estimate their quantities; has the right to prepare prices
for those works on the basis of prevalent prices at the time of announcement. Those prices
become the contractual rate for such works, and the quantities of those works are
estimated during execution.
3.2.7 Addition, omission, and modification in work items:
The Ministry has the right, at any time during contract period, to make any
changes in the quantities of work items whether through adding or reducing. Any
omission or addition or modification in contract work items, shall be made on the basis of
the legal documents approved in the contract, particularly Article 43 of public works form
and/or government purchases regulations and its executive bill or legal documents of
contract. At all times, it is not allowable for the contractor to take any measures or actions
arising from the addition or omission or modification without obtaining an approved
written acceptance from the ministry or its representative within the authorization
delegated to him.
Changes in the quantities of work items shall not lead to a change in contract
works or sites or an increase in contract quantities of more than the rates specified in the
public works form, plus 10% or minus 20% of contract total value. Contract value shall be
amended with the addition or omission accordingly.
3.2.8 Introduction of new items to the project:
When it is necessary to introduce works not clearly or inclusively included in the
contract, that shall be done on the basis of the public works form, government purchases
and its contracts regulations, and approved legal principles. Those works shall be so
necessary that their non-execution shall prevent completion of other items and works in
the project, or prevent or reduce getting use from the project or limit its technical quality.
Introduction of any new items shall be made according to article 43 & 44 of the
public works form and other legal documents approved in the contract. Also, introduction
of new item shall be made on the basis of a technical report prepared by the specialized
technical agency including the technical justifications for the introduction, specifications
and quantities of the works for which new items are proposed. Also, it shall include a
confidential report for the costs of carrying out introduced items; then contractor is asked
to submit his prices for carrying out those items and discuss those
21
prices with him. These prices shall be in compliance with prevalent prices for such works
at the time of their introduction.
It is allowable to commence execution of any introduced works before completion
of regulatory procedures and the introduction approval. The introduction shall not result in
an increase in contract value by more than the maximum allowable increase rates.
3.2.9 Modification claims and disputes:
When contractor considers that he has a right to claim additional costs against
work or item that has not been included in the contract clearly, or has not been assigned as
an additional work by the ministry, he shall inform the engineer in writing about his
intention to submit a claim before submitting any claim for additional compensation.
Engineer shall review the request, calculate the quantities, evaluate the cost, and prepare
his report on this. These procedures from the engineer shall not be considered as an
acceptance for the right of contractor on compensation.
Decision on the contractor's right shall be decided by a committee formed from the
ministry to study the request, engineer's report, and review contract documents; then
submit a report to the authorized agency in the ministry. The ministry takes its decision on
the basis of the submitted reports and legal documents.
When disputes or conflicts appear during contract execution, they shall be handled
by a committee formed from representatives of the ministry, the engineer, and the
contractor. Its task is to try to reach a mutual rapprochement. When this committee fails in
achieving understanding within 28 days, the dispute is forwarded to the grievances board
in KSA, which study the dispute and take decision. The decision from the grievances
board is obligatory to all parties.
3.2.10 Removal and disposal of structures and obstructions:
Contractor shall remove structures, obstructions and materials which interrupt
project works or its permanent or temporary structures, transporting removed products to
approved sites. Removal and disposal works shall be on the contractor's account and
considered incurred by other work items under construction; except otherwise mentioned
in a separate item of BOQ.
3.2.11 Power & water supply:
Contractor, on his own account, shall make the required arrangements to provide
power and water supply required for executing the project works. It is strictly prohibited
to supply power and water from public networks without prior coordination with the
concerned authorities.
3.2.12 Coordination between works:
On the basis of Article 24 of the public works form, contractor shall provide the
opportunity to other contractors and he shall inspect site, verify information on projects
being executed by other contractors which may contradict with works of his contract.
Also, he shall coordinate with those contractors and project owners, and prepare his rates
and work plan accordingly. That shall not taken as pretext for amending prices or
modifying completion period after assignment.
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3.2.13 Site evacuation and cleaning after work completion:

Contractor shall, in lieu of article 25 of public works contract form & other legal
documents approved in the original contract, and immediately after completion of the
project works and before submission of work handing over request, evacuate all the
project sites from all works and temporary structures, machines, equipments, and wastes;
and he shall clear those sites. Also, he shall evacuate, arrange, and clean all extraction
sites and stockpiling yards of materials used for the project.
Contractor shall obtain the engineer's acceptance for evacuation and cleaning
operations before handing over the project works, and contractor shall not be paid any
additional costs against that but shall be considered as charged on all contract items.
3.2.14 Construction & execution record books:
Contractor, on his own account, shall open a record for work phases in the project
in which he records daily work sites and phases, layers and/or works under progress, list
of equipments and machines operating in the project, attendance of contractor's technical
teams, proposed materials and summary of testing and measuring results, while keeping a
copy of this with the supervising engineer. This record shall be approved and signed from
the engineer. When the engineer requires, contractor should take photos structures and
distinct works.
Contractor shall submit periodical reports on work progress in completing the
project together with a summary of the results obtained and the work plan for the next
phases of the project; including difficulties and problems he is encountering during
execution.
3.2.15 Workshop drawings:
Contractor shall submit workshop drawings required by the engineer. Those
drawings show all the details related to various work items which are not shown on the
standard drawings provided from the ministry. Also, he shall make the modifications and
changes required by the engineer on the standard drawings delivered to him with contract
documents, before he commences execution of those items by a period not less than 15
days. Those drawings shall include all the details required for the execution of work items
and traffic control plans at work site and temporary detours if any. Contractor has no right
to commence relevant works before he obtains the engineer's acceptance for the workshop
drawings, modifications and additions.
3.3
Legal relations and responsibility towards the public:
3.3.1 Law abidance:

Contractor shall abide completely with the existing laws and regulations in the
KSA and shall be aware of those regulations and laws; since his ignorance of those
regulations and laws does not release him from any responsibility arising from his
violation, or the violation of any one of his employees or his subcontractors, to existing
regulations and laws.
3.3.2 Authorizations, licenses, and charges:
Before starting work, contractor shall obtain all authorizations and acceptances
required for work completion from all the concerned governmental and private authorities
and he shall pay all charges and expenses arising from this. He has no right to claim any
additional payments for that.
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3.3.3 Patent right and ownership:

Contractor shall adhere to patent rights and ownership directives. He shall protect
and compensate the ministry for any claims and actions arising or caused by violation of
any right or privilege or design or commercial brand or name or other registered rights
concerning any equipments, or machines, or materials used in carrying out the works or
temporary works or any of those, in compliance with Article 21 of the public works
contract form. Contractor remains responsible throughout work period and after it for any
violation related to patent right and ownership.
3.3.4 Royalties:
Contractor shall obtain the special acceptances for material extraction, and he
bears all royalties arising from that or any other royalties he incur, and no amounts shall
be paid for him against that but shall be considered as charged on work items.
3.3.5 Relations between contractor and his employees and employees of his
subcontractor:
Contractor shall implement all the laws and regulations existing in KSA regarding
his relations with his employees and employees of his subcontractor. He shall incur all
expenses and charges arising from that. He is responsible alone for all compensations and
expenses resulting from harm to any one of his employees or his subcontractor
employees, and the ministry is not responsible for any consequences arising from that.
3.3.6 Insurance:
Contractor shall adhere to all stipulated insurance procedures against any losses or
damages for which contractor are considered as responsible according to contract and
approved legal documents. Insurance shall be made in accordance with Article (12/5) of
public works contract form and other legal documents approved in the original contract.
Contractor, before he starts work, shall submit a copy from the insurance
policy/policies approved from the insurance company. Also, all insurance contracts shall
be valid throughout execution periods and those policies shall stipulate that the insurance
company undertakes to inform the ministry about its intentions for nullifying the
insurance before taking such action by sufficient period not less than 15 days.
3.3.7 Monuments and fossils etc:
Contractor shall adhere to all laws, regulations and instructions related to dealing
with archeological buildings and sites and with all materials, pieces, fossils, and precious
materials he may encounter during work execution. Those materials should be treated
according to Article (20) of public works contract form.
Contractor shall report such materials immediately after discovering them and
within a period not more than 24 hours. He shall maintain those items and protect them
from damage or any harm. He shall prevent their transfer by his employees or any other
person, and he shall stop work at those areas until he receives written instructions from
the engineer and concerned authorities.
3.3.8 Alcoholic drinks, drugs, weapons, ammunition, and keeping order: Contractor
shall adhere to regulations and laws concerning prevention of importing, producing,
selling or using or transporting alcoholic and drug materials by
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him or by his employees, and he shall abide with regulations and laws concerning
weapons, ammunition and all law/order regulations.
3.3.9 Property preservation:
Contractor shall prepare work plan and work execution in such a way which does
not lead to any damage on adjacent property and structures. Before he commences
execution, contractor shall identify all the structures, public utilities and any other
elements which lie within work boundaries or which may be affected by those works, then
he shall prepare a technical report in coordination with all the concerned parties, and
obtain approval for the solutions for each of them.
Contractor shall abide with all approved solutions and shall not inflict any
damages on structures, public utilities and identified elements. When he encounters during
work any of those undiscovered elements during preparation of the report, he shall stop
work and inform the engineer and coordinate with the concerned authorities to approve
the suitable solution. Contractor bears the whole responsibility for damages that may be
inflicted on structures, public utilities and elements arising from movement of his
equipments or any of his activities. He shall repair those damages according to the
requirements of the concerned authorities, and he has no right to claim for any additional
cost against such repairs.
3.3.10 Contractor's responsibility for work:
Contractor remains responsible for all project works up to the end of the guarantee
period stipulated in the contract and preparation of final handing over minutes.
Throughout this period, contractor shall carryout all maintenance and repair works which
the works may need. He shall carryout all repair works required by the preliminary &
final handing over committee, and he has no right to claim any additional costs for that.
Exceptions are made for damages arising from special risks, overcoming force or
third party which are reasons outside the scope of contractor's control and are not
expected. These are not arising from a mistake or shortage or negligence from the
contractor's side, and contractor in this case does not incur repair costs and compensation.
He shall inform the ministry about any damages arising from such conditions within a
period not more than 10 days from the date of damage. In such case Article (55, 56) of
public works contract form is implemented.
3.3.11 Personal responsibility of governm ent officials:
The engineer or any of his authorized assistants do not bear any responsibility for
practicing the powers and authorizations granted to them according to contract for
executing its items; whether individually or in his capacity as an employee of the ministry,
since he is carrying out this work as a representative and an agent of the ministry.
3.3.12 Preservation of environment:
Contractor shall adhere to all the environmental and health standards approved
from the concerned authorities during all phases of work. Before commencing production
and execution works, he shall obtain the approved environmental standards, and shall
study, understand them, and apply them.
25
Contractor shall take all the measures and arrangements required for reducing
contamination arising from any of his activities during executing contract works including
reduction of noise levels and dust propagation and control of vibration rates. He shall
calibrate all his machines, equipments, asphalt or concrete mixes production plants,
production and storage centers of different materials and to make arrangements of
contamination level control to remain within approved allowable levels from the
authorities concerned with the environment.
3.3.13 Dangerous wastes:
Contractor shall adhere to all environmental and health standards approved by the
concerned authorities when encountering or using materials or wastes considered as
dangerous to public health and environment. Immediately after discovering any materials
or wastes or spilling of any hazardous materials, which he needs for work, contractor shall
coordinate with health and environment authorities to approve the procedures he shall
apply. Also, he shall review all publications regarding handling of dangerous materials
used in his work and he undertakes to deal with such materials according to the
instructions of health authorities and manufacturer's recommendations.
When it is necessary, contractor shall provide all protection requirements and
apply all its arrangements. He shall train his employees who deal with such materials on
methods of their usage and handling, and training them on safety procedures, first aid and
to require from them to use all required safety devices. Contractor bears alone all the
results arising from his failure in this regard.
3.3.14 Using explosives:
Explosive shall be used in carrying out the works only in very critical situations
and when there is no other way for executing the work, after the ministry acceptance.
Explosives shall be used according to Article 49 of public works contract form.
Contractor shall obtain all the required licenses and approvals from the concerned
authorities regarding the use of explosive materials in executing the project works.
Contractor shall obtain, transport, store, and use explosives according to the
instructions and written acceptances from the concerned authorities, and he shall keep the
records of quantities of materials supplied to the project and the used quantities.
In all cases, contractor shall prove to the ministry his previous experience in
blasting works or sign a contract with a qualified agency to carryout these works. He shall
obtain the acceptance of the ministry and concerned authorities for that contract.
Contractor bears alone any consequences or damages that arise from his failure in
obtaining the acceptances or licenses or for not abiding with the regulations and laws
related to using explosives or using these improperly. Also, he shall be responsible for any
harm on life and property including project structures arising from use of explosives.
3.3.15 Losses on persons and properties:
Contractor shall preserve all public and private properties and he bears losses and
damages on persons and properties arising from any action or failure or negligence or
misbehavior during construction and maintenance of project works. Also, when that is due
to a defect in the materials and used construction methods. Damages shall be
26
estimated on the basis of Article (18) of public works contract form, legal documents and
other contract documents.
3.3.16 Traffic control at work site:
All traffic control works shall be made at work sites according to traffic control at
work site manual issued from the ministry of municipal and rural affairs, under the
supervision of the central committee for projects coordination, special specifications these
general specifications and traffic regulations. Costs of all traffic control works are
considered as charged on contract items, except otherwise stipulate special specifications
and BOQ for separate items for those works.
Contractor, before he starts construction works, shall prepare the traffic control
plan during execution and shall obtain the acceptance of the engineer and concerned
authorities for it. In all cases, the traffic control plan shall provide continuity of public and
pedestrian traffic and access to all buildings and adjacent structures. Also, the plan shall
result in the least possible interruption for traffic movement. Contractor shall carry out all
the necessary works on the basis of that plan including placing signals, signs, direction
signs, barriers, construction of temporary detours and walkways and their maintenance. In
addition, he shall remove all the temporary elements and equipments and return their sites
to their original state after completion of the project works.
Contractor has no right to commence construction works before he performs
traffic control procedures and works according to the approved plan and handing over
those works to the engineer. Also, contractor bears all the financial and legal
consequences which may arise from his failure in traffic control procedures.
3.3.17 Safety precautions at project site:
Contractor shall make all arrangements and execute all the works necessary for the
safety of employees, pedestrians, neighbors, buildings, and adjacent structures from any
damage due to contractor works and he shall support excavation sides fence excavation
and trenches when required.
In addition, he shall provide protection means such as safety barriers, protective
hats hoods and gloves and he shall instruct his employees to use them and provide them
with the first aid supplies together with firefighting systems which should be placed in a
clear location. Contractor shall bare full responsibility for any damages arising from his
failure in providing safety arrangements and applying them.
3.3.18 Guiding and lighting:
According to Article (17) of the public works contract form, contractor shall
execute lighting, fencing, and guiding works for all work sites including warning lighting
at excavation and trenches sites. Also, he shall provide guiding at all the sites of his
machines, equipments and material stores.
3.4
Supervision on the works:

Supervision works shall be performed according to the latest edition of Projects
Execution Supervision Procedures Manual issued by the Ministry of Municipal & Rural Affairs
in KSA, and the ministry appoints, the supervision staff, their duties and authorizations.
27
3.4.1 Supervision staff:

The produced and used materials and executed works shall be inspected, tested
and accepted from the approved authority assigned from by the ministry to supervise the
project. Contractor shall facilitate access to the ministry representative to all work and
production sites, material stores, sampling and measuring areas.
3.4.2 Supervision staff duties:
The task of the supervision staff is concerned with monitoring, inspecting, testing,
and measuring project materials and works Also, inspection of contractor's equipments
and machines and to verify that contractor has carried out the work by using the materials,
work methods, dimensions, and levels shown on the drawings, special and complimentary
specifications, general specifications, and other contract documents.
Supervision staff performs the following:
1. Audit all reports, work plan, time schedules, and design job mixes submitted by
the contractor and to provide the necessary comments, if any, or approve them.
2. Assist contractor to understand and conceive drawings and specifications for
executing project works with the required technical standard.
3. Review results of measurements, material and work testing, and verify contractor's
implementation of approved drawings and specifications.
4. Audit project daily record books and audit all shop drawings and as-built drawings
prepared by the contractor and approve these.
5. Audit executed work quantities and approves current payments and final payment.
6. Keep copies all of specifications, drawings, contract documents, project records
and reports.
3.4.3 Supervision staff authorities:
The authorities of the supervision staff are determined on the basis of the latest
edition of the projects execution supervision manual issued from the ministry of
municipal and rural affairs and similar manuals approved from the ministry. The engineer
is empowered to:
1- Stop work completely or partially when he notices contractor's failure in abiding with
approved drawings, work mixes and methods; and he may require removal of
materials or works or machines or equipments which he considers as unacceptable and
replace them with others technically accepted on the contractor's account.
2- Instruct for necessary modifications in applied work methods for the purpose of
obtaining work compliant with specifications and drawings within allowable
tolerances shown on the approved drawings specifications.
3- Stop work due to climatic conditions or other important reasons decided by the
ministry.
4- Monitor work attendance and efficiency of the contractor's technical teams, his
machines, and equipments and to require replacement of those who lack the efficiency
required for executing project works.
3-4.4 Supervision staff facilities:
Contractor shall, when contract documents require that, provide and prepare
supervision staff facilities such as offices and their accessories; transportation means to
enable the supervision staff to carry out his duties, according to contract. Supervision staff
facilities shall be composed of engineer offices which are provided with computer, printer,
and telephone/fax line, computer systems, all according to contract documents.
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The facilities shall be compliant in all aspects with government and municipal regulations
and instructions concerning abidance with medical principals and separation between
facilities and other details indicated in contract documents.
3.4.5 Laboratory, measuring and testing systems and equipments:
Contractor shall provide at site, and on his own account without the ministry being
incurred additional costs, all the systems and equipments required for conducting work
measuring, sampling and sample storing/testing which include at least the following
systems and equipments:
3.4.5.1 Measuring equipments:
It must include surveying equipment that measure the distances and angels and
elevations with the required accuracy for the works, with all its accessories, these
equipment should be in good technical case and they have to be calibrated from
specialized team, the contractor shall provide leveling steal rod with dimensions as shown
in the specifications.
3.4.5.2 Sampling, and samples storing and testing systems and equipments:
Contractor shall provide at site all the systems and equipments required for
materials and works sampling and testing. Also, the required molds for blending mix
samples and equipments of storing them according to approved standard specifications for
the purpose of taking and blending samples and testing them. Contractor can, with the
acceptance of the ministry, contract an independent laboratory approved from the
ministry, to carry out the sampling, preparing, and testing processes, and in such case the
laboratory technicians shall be available at all times of sampling.
3.4.6 Client commitments:
Client shall provide all the facilities required from him for executing project works
in compliance with approved drawings and specifications. Some of those facilities are
addressing letters to all other authorities for facilitating contractor's task and assistance in
coordination concerning public utility works, providing necessary services for carrying
out project works, speed up approval of sudden modifications on drawings and/or
specifications, and quantities. Also, speed up replying all the enquiries and paying all
contractor and supervision staff dues.
3.5
Execution conditions and work progress:
3.5.1 Work site inspection:
Before submission of his bid, contractor shall inspect the work site and study all
details, obstructions, structures and any obstacles which may encounter during execution.
He shall include in his proposal all his comments, suggestions, and reservations and any
comments, submitted by the contractor after submission of his bid, on amendment of work
item prices or increasing contract period or reducing work quality, are not considered. All
the information indicated in the drawings and special specifications are considered as
inferential primary information and contractor shall prepare his prices and work plan
according to the information gathered ___________________________ by him on work
site and availability of construction materials and supplies.
3.5.2 Work site handing in:
The engineer shall hand in work site to contractor, which mean all lands and locations to
be used for executing contract works, according to minutes signed by
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contractor or his authorized representative and the engineer. Work site handing in can be
made in the form of sections which provide the possibility of project work completion
according to the contractual period and construction time schedule. The site shall be free
from all work obstructions of which removal or transfer are not part of work scope.
Work site handing in procedures shall be conducted after contract signing by
following the steps indicated in the latest edition available at the time of contract signing
of Road Project Supervision Procedures Manual issued from the Ministry of Municipal
and Rural affairs. The separating period between contract signing date and date of work
site handing in shall not exceed 30 days, except otherwise the delay was due to
substantive reasons decided by the ministry or otherwise stipulate contract.
In case there are obstructions which prevent site handing in, the procedures stipulated in
the Projects Execution Supervision Procedures Manual shall be completed.
3.5.3 Contractor commitments:
Contractor shall provide qualified engineers, technicians, skilled/unskilled labor
force, for carrying out contract works. Also, he shall provide all materials which are
compatible with approved specifications, machines and equipments which are capable of
executing the works according to the drawings and approved specification within the
specified periods and approved time schedules.
The engineer, when he notices delay from the contractor's side in work execution,
has the right to instruct him to work additional hours without having the right to claim any
additional costs arising from that.
3.5.4 Work site planning:
Immediately after work site handing over and pilot survey points, contractor shall
carry out the necessary survey works for determining road centerline, and all elements and
structures attached to it. And he shall determine work boundaries by the method accepted
from the engineer, and establish survey link points & protecting them from removal or
damage for any reason. Contractor has no right to commence work before auditing survey
works and approve them from the engineer.
3.5.5 Compliance with drawings and specifications:
Contractor shall provide all materials and execute all works according to the lines,
levels, cross sections, dimensions, and material requirements shown on the drawings or
mentioned in the approved specifications within allowable tolerance limits. Contractor
shall remove all works and materials which are not in compliance with the drawings and
approved specifications, shall replace them with other acceptable materials/works on his
own account; and he has no right to claim any additional costs for that.
3.5.6 Coordination with public utilities & structures authorities:
Contractor shall, with the help of the ministry and before commencing work
execution, coordinate with public utilities or structures owners. This shall be done to
determine utilities and structures lying within project boundaries or those which may be
affected by the project works during construction or operation. Coordination with those
authorities to approve the solutions related to those facilities and/or structures whether
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through reconstruction, or modification or transference or removal; and to approve the

work plan and work phases.
Organization and recording of coordination works shall be done according to
official minutes approved from all parties (the ministry, structure and public utilities
owners, contractor); and these minutes, solutions and plans are added to the contract
documents.
3.5.7 Signs:
Contractor shall, within 60 days from contract signing or 2 weeks from date of site
handing over whichever is closer, place two signs at two prominent locations at the
beginning and end of the project on which is written project name, project owner,
contractor name, project period, expected date of completion, both in Arabic and English.
Dimensions and sites of the two signs shall be determined through agreement with
the engineer and he shall maintain the signs and clean them throughout project period.
Contractor shall not be paid any amounts for that.
3.5.8 Contractor's technical staff:
Contractor shall provide sufficient number of engineers, inspectors, surveyors, and
technicians according to project execution requirements. Contractor's technical staff shall
be suitable for project works as to qualification and experience. Contractor, before
commencement of the works, shall submit to the engineer a list containing names,
qualifications and experience of his proposed technical staff for approval, and he has no
right to change any of the technical staff after being approved before obtaining a written
acceptance from the engineer.
The engineer has the right to reject or require change any one of the technical staff
when he notices his lack of efficiency and abidance with work conditions or due to his
bad conduct. Contractor shall replace him with another more qualified and capable of
carrying out the work according to drawings and approved specifications. Also, contractor
shall name the project manager and his assistants and obtain engineer's acceptance for
this.
3.5.9 Penalty for absence of contractor technical staff:
The engineer has the right to impose absence penalties on one or some of the
members of contractor technical team according to the contract signed with the contractor,
requirements of the nature of the work and assignments of the absent staff. Deduction for
each absence day is made according to contract stipulations. The engineer has the right stop
contractor from work temporarily if he noticed that existing contractor's staff is not
capable of executing the work in compliance with approved specifications, and contractor
has no right to claim any compensation or additional periods due to that.
3.5.10 Work program and time schedule:
Before he starts construction works, contractor shall submit to the engineer the
work plan and time schedule for completion of all items and phases of work. The
proposed completion period shall be compliant with contract period. The time schedule
shall be submitted in the form of a graphic chart based on critical rout that show work
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dates and phases and work sites. Also, it shall consider overlapping between various item
works, also, it shall show machines, equipments, labor and materials required at each
phase.
Contractor shall consider the necessity for coordination with other contractors who
are, during project works, carrying out works at his work sites, also coordination shall be
made between works such that obstructions arising from work overlapping for any of the
contractors shall be as few as possible.
3.5.11 Construction equipments:
Before starting construction works, contractor shall submit to the engineer a list of
all machines and equipments he proposes for use to carry out project works. These
equipments shall be technically capable of carrying out works in accordance with
specifications and drawings within the contract period.
Contractor is not allowed to transfer any of the equipments and machines for work
in other projects or sites or replace any equipments or machines before obtaining the
engineer's acceptance. Also, contractor shall keep equipments and machines in an
operational condition and shall carry out the necessary maintenance and repair works.
The engineer has the right to reject or require replacement any of the equipments
and machines when he notices its repeated failures or incapability to execute the works
according to approved specifications.
3.5.12 Pre-construction meeting:
Immediately after contract awarding, work site handing over, submission of work
plan and time schedule, and list of machines and equipments, the engineer may call for a
meeting attended by the engineer and contractor or their representatives. In this meeting
all details concerning the project and the contractor's proposed work plan shall be
discussed.
Meetings shall be held before executing some work items for which a separate
detail plan shall be prepared, such as blasting works. Also, mutual meetings shall be held
with the owners of structures and public utilities lying within or adjacent to work site
which may be affected by the project works for the purpose of discussing and approving
solutions related to those utilities and structures.
3.5.13 Subcontracts:
Contractor can subcontract for executing some contract work items and that shall
be done according to Article 4 of public works contract form and other legal documents
approved in the original contract. In all cases, contractor shall submit to the engineer a full
report on the subcontractor with whom he intends to make the agreement, that includes
name of company or contractor, his qualifications and previous experience, and the works
he is intended to carry out. The sub-contractor is not allowed to commence work before
obtaining the engineer's acceptance.
The engineer's acceptance does not release contractor from his full responsibility for
executing the contract according to approved drawings and specifications. Contractor
alone bears the responsibility for any failure or violation that occur from the subcontractor
or his employees on contract execution or site.
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3.5.14 Night work:

The Ministry may allow contractor to carry out some works at night when the need
calls for executing works within a short period or when work execution requires relatively
moderate temperatures or for reasons decided by the ministry. In all cases the contractor
shall, when the ministry allows him to work at night, prepare a detailed plan together with
specific time schedule four night working hours, coordination with concerned authorities,
and provision of the supervision staff during night work.
Contractor shall place warning signs and provide sufficient lighting to ensure
safety conditions for public traffic movement and neighborhood. Lighting shall be
sufficient enough for executing the works accurately and according to approved
specifications. Also, contractor shall take all the required measures to lessen noise level to
the neighborhood due to his works.
3.5.15 Unusual traffic:
Contractor shall adhere to allowable vehicle dimensions and loads when driving
on public roads and their elements such as bridges and tunnels. He shall apply all the
required efforts to ensure that cars and machines he uses do not exceed those limits. He
bears the full responsibility for not adhering to those allowed limits.
When contractor needs to transfer some machines and equipments which do not
comply with dimensions and loads allowed in the kingdom, he shall prepare a technical
report including dimensions, values, and axial/total loads transferred on the road. Also,
dimensions of the transportation means he intends to use and selection of a certain rout.
In addition, he shall submit a technical report prepared by a specialized agency
showing that the load passing according to the proposed rout shall not result in any
damage on the road and structures according to the proposed rout and indicates the
required works for temporary supports for bridges, culverts and other structures and
construction of temporary detours when needed.
Contractor has no right to transport before obtaining the ministry's acceptance of
the report, study and completion of all the works related to load passing.
3.5.16 Temporary work halting:
When the ministry decides the necessity for halting work in executing the works or
part of them temporarily, in accordance with Article 32 of the public works contract form
or other contract legal approved documents; that shall be done according to the procedures
and conditions specified in Projects Execution Supervision Procedures Manual issued by
the Ministry Of Municipal & Rural Affairs and contract approved legal stipulations.
3.5.17 Defects and failure:
Consultant has the right, at any time during work execution, to require from the
contractor to remove works, transport technically unacceptable materials and replace these
with other technically acceptable and compliant with specifications, drawings and contract
documents. Contractor shall carry out the engineer's instructions immediately
onhisownacountandhehasnoigrhtoclaimanyadditonalcostforthat.
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Contractor shall preserve the executed works throughout construction period and
guarantee period. Also, he shall carry out all the required repairs for any defect that may
appear on his own account without having the right to claim any additional costs for that.
The Ministry has the right, when it notices that the contractor is delaying or failing
in carrying out protection and maintenance works required from him, to assign a third
party for carrying out those works and deduct costs resulting form this from contractor's
dues with the ministry or from his insurance or may be collected from him legally when
his dues are not sufficient for covering those costs.
3.5.18 Work withdrawal:
When the Ministry decides to withdraw contract works, for one of the reasons
stipulated in Article 53 of public works contract form or other legal documents approved
in the contract, procedures of work withdrawal shall be done according to public works
contract form or those legal documents. Also, when resorting to work withdrawal, the
engineer shall, in the presence of contractor or his representative, carry out the following:
1- Prepare a full report on the project including quantities of completed and handed over
works, inspection of incomplete works and handing them over, measuring their
quantities if acceptable and adding them to the completed works. Also, an inventory
shall be made for the remaining works which should be completed to accomplish the
project and their locations.
2- Inventory, inspection, and testing of quantities actually supplied for use in the project.
The ministry has the right to accept these as raw materials in case they comply with
specifications required for uncompleted works within the required quantities for
completing the works.
3- To prevent contractor from withdrawing any of the contractor's or subcontractors
technically accepted materials, equipments, and machines to be held for the benefit of
the project.
No dues will be paid to the contractor before completing the works by another
contractor, handover the works, expiry of the contract guarantee period, and verification
of that no financial obligations or any other obligations are due to the ministry on
contractor which may prevent that.
3.5.19 Assigning withdrawn works to another contractor:
Assignment of withdrawn works according to the previous paragraph shall be
made according to Article 54 of public works contract form and other legal documents
approved in the contract. And the ministry has the right to hold machines, equipments,
and materials. Also, can hold contractor's financial dues with the ministry, until
withdrawn works are completed, financial accounts finished, and required actions for
covering execution costs are taken according to stipulations and legal standards.
3.5.20 Contract period:
Contract period is the period specified in the contract. Contractor shall prepare his
work plan and work time schedule, provision of sufficient number of equipments and
machines, and labor so that he may be able to complete the project within the specified
period.
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The date of site handing over is considered as the actual date for starting works
and work site shall be handed in according to an official minutes signed from the
contractor and supervising engineer from the ministry. The contract period is considered
the complete period including official holidays.
Contractor is allowed to carry out work only in official working days, and when
the need calls for work in holidays he shall obtain the ministry's acceptance, providing
that arrangements shall be made for supervision on work execution.
The ministry can extend the contract period according to Article (9-b) of the government
purchases and execution of its projects/works regulations and the regulations and legal
stipulations approved in the contract, in case the required conditions for that prevail, such
as assigning the contractor execution of additional works which can not be completed
within contract period.
Also, the ministry may grant the contractor an additional period if he has been
delayed for reasons outside his power or when he has been stopped from work
temporarily by the ministry for a certain period, providing that he submits a request to the
ministry, before contract end, including a justification for the delay in which he indicates
delay reasons and dates in which he was compelled to stop work for insurmountable
reasons attached with reports and official correspondence which confirm this. Decision on
the request is taken by a special committee formed for this purpose at the ministry.
3.5.21 Delay penalty:
In case contractor delayed in completing the contract works and handing over at
the specified date without justifying the delay period, or the ministry has not decided that
there is a reason for withdrawing the work, contractor shall undertake to complete
execution. In such case the delay penalties are calculated according to Article 39 and
supervision costs during delay period according to Article 40 of the public works contract
form and contract approved legal documents.
The delay penalty is calculated according to the following:
a- A penalty for the first part of the delay period in the rate of 1/4 the daily cost average
for each delay day until the greatest of the two periods amounts to 15 days or 5% of the
contract period.
b- A penalty on the second part of the delay period in the rate of 1/2 the average daily cost
for each delay day until the two parts amount to more than 30 days or 10% of the
contract period, whichever is greater.
c- A penalty on the third part of the delay period in the rate of the average daily cost for
each next delay day for the greatest of the two periods indicated in paragraph (b).
It is not allowed for the penalties imposed to exceed 10% of the contract value.
But if the ministry surmised that the delayed part does not hinder getting use from the
work at the time specified for its completion, or does not cause confusion in using any
other facility, and does not adversely affect what has been completed of the work itself,
total penalty shall not exceed 10% of the delayed works value.
Contractor, in addition to the stipulated delay penalty, incurs the charges of the
project supervising penalty during the period in which the contractor is subjected to the
penalty, and those charges are calculated on the basis of the supervisor's contract whether
it is a periodical amount or a percentage from contract value.
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But if supervision was against lump sum amount or if it was performed from a
governmental authority, supervising penalty is equal to the delay period percentage from
contract period multiplied by the contract value, and calculated as follows:
Supervisor Penalty = (Delay period/contract period) x (1/100) x contract value
3.5.22 As-built drawings:
Contractor shall prepare as-built drawings in such a way that reflects actually
completed works. They shall show lines and sites of all public utilities and structures lying
within work boundaries. They shall be prepared with the suitable scale accepted and
approved by the engineer. Contractor shall submit three copies of as-built drawings
approved from the engineer to the ministry at completion of the project works and before
the preliminary handing over.
3.5.23 Ending contractor's responsibility:
Contractor remains responsible for all executed works and he shall carry out all
protection and maintenance works throughout work guarantee period stipulated in the
contract. Contractor is not released from the responsibility until the final handing over
minutes are prepared, approved and delivered to the contractor.
3.6
Control and acceptance of materials and works:
3.6.1 Materials and works control procedures:

Materials & works shall be controlled through quality control and assurance
procedures shown on the drawings, special specifications, general specifications,
complimentary specifications, and other approved contract documents.
Quality control procedures shall be performed by the contractor through sampling,
measurements, testing, and result analysis for all the properties which are required to be
achieved and in the rates shown on the drawings and special specifications or in the
divisions/sections dealing with quality evaluation of the works, of these general
specifications.
In addition, contractor shall draw quality maps of critical properties by using
statistical technical methods. Those maps shall be conducted in the form of graphic charts
showing the properties they represent and numbers of tests and measurements, while
showing and highlighting target value line and allowable tolerance limits. Contractor shall
provide the engineer immediately with results of all the tests, measurements, and quality
control charts.
Quality assurance procedures are conducted by the ministry by verifying that
contractor has executed quality control procedures by the proper method. The ministry
carries out this either through direct supervision on application of quality control
procedures or by performing quality assurance procedures in an independent neutral way
on representative samples in adequate number, to judge the execution standard and decide
about accepting or rejecting executed work. This is done according to the principles
detailed in special specifications, other contract documents, and division 17 of these
general specifications, except otherwise specify special specification or other contract
documents.
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The ministry has the right to review contractor's quality control records and
comparing them statistically with the results it obtains through the method it specifies for
quality assurance. Also, it has the right to inspect contractor's laboratory, equipments,
technical staff, investigation, testing, and execution methods he applies, to ensure
efficiency of his technical staff and suitability of the equipments for the work being
executed. Also, compatibility of investigation, testing and execution methods with approved
methods.
Sampling shall be done according to the random method and those samples shall
be representative to the material or work to be verified for compliance with requirements.
Sampling and samples storing, preparation, and testing shall be according to the methods
indicated in the standard specifications issued by SASO, if any, or by other international
agencies such as ASTM or AASHTO, all according to contract approved specifications.
3.6.2 Material sources:
Before commencing supplying materials, contractor shall submit to the engineer a
report including material sources, source guarantee certificate, results of tests on
representative samples of materials which show their compliance with the approved
specifications, and he has no right, by any means, to commence material supply before
obtaining the engineer's acceptance of the sources and materials.
Engineer's acceptance for materials and source does not release contractor from his
responsibility for achieving the requirements stipulated in the specifications and shown on
approved drawings during the whole construction period. He shall, on his own account,
transport all materials the sources of which has already been accepted and shall remove all
the materials found to be, through testing results, not compatible with approved
specifications. These shall be replaced with other materials and works technically
acceptable, and he has no right to claim any additional costs arising from that.
3.6.3 Material transportation and storing:
Contractor shall store materials at the sites approved from the engineer by using
the methods and equipments/machines which do not lead to change in the properties of
stored materials. It is not allowed to use public squares inside urban areas for storing
materials before obtaining written acceptance from the owners and the engineer. He shall
take all the required measures for protecting neighboring property from damage or noise
or pollution as a result of this and he shall apply all applied standard particularly those
dealing with lessening dust propagation.
Contractor shall transport earth materials, aggregate materials, asphalt and
concrete materials and mixes, with covered transport means which prevent material
scattering and consequently cause contamination to the environment and the streets they
pass through. These means of transportation shall be organized and their routes chosen in
such a way that cause minimum possible interruption to the traffic movement.
Contractor shall transport and store explosive materials according to the
instructions and rules implemented by the specialized authorities outside residential areas
and populated areas away from populated buildings. The distance between those stores,
structures and mentioned areas shall not be less than 300 m.
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Contractor shall provide strict guarding for those stores and shall keep records
which show quantities of explosives received, explosives and exploding systems
consumption rates, and how much have been used according to dates, types, and locations.
If there were surplus of these materials after completion of relevant works, these extra
quantities and blasting systems shall be returned to the authorities from whom they were
received, and prepare an official minutes approved from the concerned authorities
showing this, and delivering a copy to the engineer.
3.6.4 Work inspection before covering:
According to Article 30 of public works contract form, contractor should not cover
any work or start any subsequent works before inspection, testing, measuring, acceptance
and handing over by the engineer.
Contractor shall notify the engineer in writing with completion of the works he
intends to cover and their readiness for inspection and handing over. Within 24 hours
from receiving the notice by the approved and agreed method, the engineer shall inspect
those works, conduct the required measurements and takes the written decision on the
possibility of covering the works or require from the contractor to carry out the necessary
repairs.
The ministry has the right, when it deems necessary and when the engineer could
not investigate, inspect, and test the works during the period stipulated above and
contractor covers them, to instruct contractor to uncover the unexposed works for
inspection and testing. In case it was found that the works were technically unacceptable,
contractor shall incur all the costs arising from that, but if the works were found to be
acceptable, the ministry shall justify the time period required for inspection, re-covering,
and compensate contractor by the agreed method on the basis of the practiced methods in
such cases.
3.7 Measuring and payment
3.7.1 Work measuring:
According to Article 46 of the public works contract form, the quantities indicated
in the BOQ are estimated quantities and actually executed quantities shall be measured for
all items. Measuring shall include, for the purpose of payment the works which were
executed, technically accepted, and handed over to the engineer within the work limits
shown on the drawings, specifications and/or specified only by the engineer. No
measurements shall be conducted for works outside the mentioned limits for the purpose
of payment.
Executed and technically acceptable works, shall be measured by using
engineering practiced measuring methods and devices. Quantities are calculated according
to the measuring units shown on the BOQ for each work item. All the measurements shall
be conducted by the contractor with the attendance of the engineer promptly with work
progress. Quantities are calculated by the contractor and submitted to the engineer for
auditing together with the original copy of measuring results and cross sections, or
dimensions of the elements according to which quantity calculations were made. All this
shall be done before periodical payment date by a period sufficient enough for auditing
and approval; providing that it shall not, by any means, be less than 5 days.
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The engineer shall keep a copy of all measurements and quantity calculations of
executed works to be submitted to the ministry at work end.
3.7.2 Payment scope:
Prices indicated in the contract are considered full compensation to the contractor
for all labor, and extraction, or production or supply of materials and mixes,
transportation, work execution and finishing according to approved specifications and
drawings. Also, submission of reports, mix design, work testing and measuring, protection
and maintenance works, provision of required machines and equipments and all
requirements for executing work items and servicing them during the guarantee period in
accordance with approved drawings and specifications. Also, costs of work organization,
general expenses, benefits, fees, and third party payments for any reason related to project
works, in addition to costs of all works indicated in the contract documents,
specifications, and drawings for which payment is not made separately but considered as
included in some or all contract items.
3.7.3 Compensation for modified quantities:
Modified quantities which are different from the estimated quantities indicated in
the BOQ are paid according to the original rates stipulated in the contract for each work
item. No objection is accepted from the contractor concerning benefit or loss in any work
item. The modified quantity rates shall be within the modification rates, plus or minus,
allowable in the contract.
3.7.4 Additional work and work according to calculating manpower:
Additional works, which the ministry assigns contractor to carry out according to a
variation order, are paid according to unit price or lump sum as the variation order may
stipulate.
When payment is for all or some of the contract items and additional works is
made based on calculating manpower (i.e. man/month), contractor shall daily submit a list
of the names of all employees working in the project, their professions and the duties
assigned to them. The engineer shall verify employees attendance through out the period
for which he pays the contractor. In this case payment shall be according to the rates table
which includes monthly payment for each of them. Deduction shall be made from the
wages of the absentees according to contract documents, providing that absence does not
lead to any defect in the quality standard of the executed works.
Payment for machines and equipments work, when agreed in the contract to pay
for their work on the basis of time period, shall be made according to actual work lists
which show numbers and types of actually working machines in the project and time
period of work for each one of them. Deduction shall be applied for absence from work or
failure of each machine in the project, and for machines related to the work of those
machines according to contract documents.
3.7.5 Unauthorized work:
Payment is made only for works executed in accordance with the dimensions,
thickness, and at the sites shown on the drawings, and special specification or determined
in writing by the engineer. Contractor has no right to claim any costs for works which
were executed outside the mentioned boundaries, except otherwise that
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occurred according to a written assignation approved from the ministry before execution.
3.7.6 Lump sum:
When lump sum payment is specified in the contract, the indicated amount is
considered as full compensation against work completion according to approved drawings
and specifications.
3.7.7 Fixtures & Accessories:
All fixtures and accessories are considered as charged to the prices of the work
item in which they shall be used.
3.7.8 Payments:
Payment for executed and technically accepted works from the engineer, is made
according to periodic payment certificates as specified in the contract, and a final payment
arranged at completion of the works and after handing over.
3.7.8.1 Current payment:
Contractor shall prepare the current payment according to the approved form and
the payment certificate shall include only works which were executed during the payment
period and inspected, tested, accepted, and handed over by the engineer. He submits it to
the engineer for auditing and the latter compares the quantities indicated in the payment
certificate with the quantities he accepted. If it was found that the payment certificate is
compatible with the executed work, the engineer then forwards it to higher authorities
after approved by him, or he may return it to the contractor to correct mistakes and
shortages. Contractor shall enclose with the payment certificate all the enclosures which
the ministry may require.
3.7.8.2 Final payment:
When contract works are completed and preliminary handing over minutes are
prepared, the engineer and contractor's representative shall calculate and count all
executed and technically accepted quantities subject for payment. Contractor shall submit
as-built drawings when contract indicate that, and provide adequate number of employees,
systems and equipments required for measuring works and calculate quantities and due
amounts after deducting all penalties and deductions incurred by the contractor.
The payment is signed and approved by the engineer and contractor and quantities
indicated in the final payment are considered final. In case contractor does not accept the
quantities indicated in this payment, he shall submit a written objection together. The
engineer studies contractor's objections and verifies calculated quantities then with
enclosing all proofs and documents which justify his objection within 10 days, give his
view on contractor's objection.
If contractor made no objection during 10 days, the payment is considered as final
and contractor's objection shall not be accepted after that. Payment then is forwarded to
the concerned authorities together with all the required documents stipulated in the
contract and in the projects execution supervision procedures manual issued by the
ministry of municipal and rural affairs; to complete auditing and payment procedures.
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3.8
Work handing over:
Handing over of the works shall be according to contract documents in two stages:
preliminary handing over and final handing over.
3.8.1 Preliminary handing over:
Immediately after completion of works, contractor shall notify the ministry on
work completion according to a letter approved from the engineer. The ministry shall
form a handing in committee and the engineer shall be one of its members. The committee
studies all contract documents, periodic reports, results of tests and measurements, and
shall review contractor performed quality control records. Also, results of quality
assurance results by the ministry and informs the contractor on the date of attending
inspection of executed works on the field and carries this inspection with the attendance
of contractor. The committee has the right, when it deems necessary, to require carrying
out some measuring and testing of some or all work items at its own discretion, or may
become satisfied by visual inspection, quality control and quality assurance results.
The committee edits the preliminary handing over minutes according to one of the
following cases:
1- Acceptance without any deductions when it surmises that works have been completed
according to drawings and special specifications.
2- Preliminary handing over with some reservations which do not prevent getting use
from the project and do not lead to technical fault. In such case it has the right to apply
deduction in the rate it considers as suitable for commented items; or existence of
some shortages which were not executed, do not prevent use from the project, do not
affect the project safety, it is possible to dispense with, and their value does not exceed
20% of contract total value. In such case the committee recommends handing in the
project preliminarily providing that deduction against comments and shortages shall
be made from the final payment.
3- Existence of some comments which, if contractor does not repair, no use can be
obtained from the project. In such case the committee require contractor to carry out
the required repairs within a certain period and comes to verify that contractor has
conducted the required repairs.
Ministry may, when it considers there is a need for opening a part of the project to
get use decide, according to notice from the contractor, that part is ready for preliminary
handing over. And it receives this part preliminarily and preliminary handing over
procedures for this part are conducted according to the above mentioned. The guarantee
period for that part starts from the date of its preliminary handing over.
Contractor remains responsible for protecting and maintaining project works during the
guarantee period stipulated in the contract, and he shall carry out all the required
maintenance works without having the right to claim any additional compensation for
that.
3.8.2 Final handing over:
When the guarantee period, specified in the contract, which starts from the date of
preliminary handing over for project works or part of them expires, contractor shall
submit a request to the ministry to carry out final handing over.
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The ministry forms a final handing over committee with the engineer as member.
The committee studies contract documents, testing and measuring results, quality control
and quality assurance results, minutes and comments of preliminary handing over and
specifies a date for attending work inspection physically carries out the inspection and
prepares a minute, according to the following cases:
1- Receiving the works without comments when it is convinced that the works have been
executed according to the drawings and specifications; and that no defects appeared on
them arising from contractor's failure during the guarantee period.
2- Existence of some comments and in such case requires from the contractor to carry out
the required repairs within a certain period after which it returns back to complete
handing over procedures.
The committee prepares the final handing over minutes and signs them from all
parties (the committee, engineer, contractor or representative) and submits the minutes to
the higher authorities to complete the required action.
Contractor remains responsible for all the defects, arising from improper execution
or materials, which may appear during the period specified in the contract after final
handing over is completed.
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DIVISION 4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12

Introduction
Urban Roads Classification
4.2.1 Local Roads
4.2.2 Collector Roads
4.2.3 Arterial Roads
4.2.4 Highways (Freeways)
4.2.5 Industrial Roads
Pavement Thickness
4.3.1 General
4.3.2 Pavement Thickness According To Urban Roads Classification
Correlation of Pavement Layers With Non-Pavement Road
Structures
Environmental Principles For Urban Roads Construction
4.5.1 Noise
4.5.2 Vibration
4.5.3 Air Pollution
4.5.4 Material Extraction and Disposal Sites
4.5.5 Hazardous and Dangerous Materials
Traffic Control During Construction
4.6.1 General
4.6.2 Traffic Control Procedures
Work Site Protection
Maintaining Or Transferring Utility Lines
Common Transport Stops
4.9.1 General
4.9.2 Construction Requirements
Protection of Adjacent Streets From Wastes And Contamination
Drainage Works For Urban Roads
4.11.1 Surface Drainage
4.11.2 Underground Water Drainage
4.11.3 Drainage Requirements For Trees And Plants Irrigation Water
4.11.4 Sewage Water Drainage
4.11.5 Water Draining During Construction
Traffic Safety Requirements On Urban Roads
4.12.1 Sidewalks
4.12.2 Pedestrian Crosswalks
4.12.3 Safety Barriers
4.12.4 Informatory Signboards And Panels For Pedestrians And Cars
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General Specifications of Urban Roads Construction__________ Division 4- Urban Roads Characteristics
DIVISION 4
4.1
Introduction:
Road network is a major factor, which reflects the economic development of
countries. They provide the capability to move and travel from one place to another and
the roads development is reflected on different aspects of economical and social life.
Urban roads are different from rural highways by a group of characteristics, which affect
their design and construction conditions. These characteristics are:
- Considerable volume for passenger cars of low axial loads (ESALs).
- More number of road intersections.
- Small areas designated for construction.
- Passing of those roads through residential areas, which impose a group of executive and
environmental conditions.
This division contains the most important factor that characterizes urban roads and
which may be reflected in the specifications of urban roads construction, and includes:
- Urban roads classification.
- Pavement layer thickness.
- Correlation (Relationship) between pavement layers with non-paving elements.
- Environmental principles for constructing urban roads.
- Traffic control during construction.
- Work site protection.
- Maintaining or transferring public utilities.
- Common Transport Stops.
- Protection of adjacent roads from wastes and pollution.
- Drainage works on urban roads.
- Pedestrian and vehicles safety requirements.
4.2
Urban Roads Classification:

The classification of roads in these general specifications is aimed at describing
the specific characteristics of each category and to facilitate the link between the specific
requirements of materials and works, which shall be indicated later in different divisions
of these specifications for each category.
Urban Roads classification in these specifications is based on the classification
included in the Geometric Design Manual for Roads issued by the Ministry of Municipal
and Rural Affairs which complies with the S.A Ministry of Transport and international
organizations Methodology such as AASHTO which classify roads according to their
function in the network.
Roads shall be classified into the following classes:
4.2.1 Local roads:
Thefunctionoflocalroadsitoprovideapproachtohousingentrances, buildings and adjacent property and they are mostly used for traffic
generated from or ends at the same area from which traffic moves directly to adjacent roads.
45
These roads may service residential or residential commercial areas and in the
latter case the volume of traffic is higher. However these roads can be multi lanes but
rarely contain medians.
Traffic volume in these roads does not exceed 3000 cars per day and it composed
mainly of passenger cars, waste collection trucks and construction equipments, and
generally not utilized by buses.
In industrial areas it is possible that percent of heavy vehicles is predominately
more and the axial loads at these areas are higher despite of their low traffic volume.
Local roads are connected with other local roads and collectors and may directly
connect with arterials in some industrial and commercial areas.
Traffic access on these roads is unrestricted and traffic control means are simple,
composed of stop signs or Traffic signals.
4.2.2 Collector Roads:
The function of collectors is to provide connection between local and arterial roads
and normally direct access to adjacent areas is allowed. Traffic volume in collectors varies
from 1000-12000 vehicles per day and it might have more than two lanes and divided by
medians.
Traffic flow in commercial and industrial areas is mixed and include passenger
cars and trucks moving from or to arterial roads, however, in residential areas passenger
cars are the predominate and heavy vehicles are only the service vehicles.
The movement on collectors in commercial centers and adjacent areas is
interrupted due to traffic signals but at residential areas the traffic control means are
simpler.
There are some restrictions for parking at peak hours and there are no restrictions
for pedestrian crossing but it is preferable to designate specific places for crosswalks in
the parts having high traffic volume.
Sometimes it is preferred to construct special bays and turning lanes for buses.
4.2.3 Arterial Roads:
The function of arterials is to provide connection between collectors and major
highways.
Traffic volumes on arterials are high with medium to high speeds, and composed of
passenger cars and heavy vehicles. The arterial roads serve the traffic between the traffic
generation areas and main attractive centers; also it links with rural, collective and local
roads, and in areas where no highways, the arterial roads provide the best traffic services.
Traffic volume on arterials varies from 5000 to 30000 vehicles per day and the
direction of traffic is divided by medians.
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Traffic flow in these roads is continuous except at traffic signals and pedestrian
crosswalks, traffic signals might be used to minimize interface to through traffic. Parking
in areas where stopping lead to serious interruption to traffic is prohibited particularly at
peak hours and it is preferable to allow pedestrian crosswalks only at intersections or at
special crosswalks.
Traffic flow is mixed and composed of passenger and heavy vehicles, the percent
of heavy vehicles may reach up to 20%, Arterials roads can be used with express and local
buses.
Arterial roads shall be connected with highways and other Arterial and it is not
preferable to connect local residential roads directly with arterial roads, and it is possible
to connect directly arterials roads with the industrial and commercial local roads
according to the site or traffic volume.
4.2.4 Highways (Freeways):
The function of freeways is to provide conditions for continuous movement
without interruptions or crossings for heavy traffic volumes between the main traffic
generation areas.
They represent an extension of the main rural highways and they link residential
and large commercial and industrial areas with the commercial center of the city. Parking
and surface pedestrian crosswalks are prohibited on freeway and it should be separated
from the adjacent areas.
Traffic volume on freeways may exceeds 20000 vehicles per day and composed of
all types of vehicles, percent of heavy vehicles may exceed 20%. The movement of
express buses is allowed but bus stops are allowed only at interchanges.
These roads are connected with rural expressways and arterial roads, direct
connection to local roads is allowed only at the city center. And all crossings should be
grade separated intersections (interchanges).
4.2.5 Industrial roads:
The function of these roads is to provide traffic movements within industrial areas
and to connect these areas with roads of other types. This includes roads in industrial
areas and roads of bus stations, railway stations, airports and ports.
Traffic volumes may not be high, but the percent of heavy vehicles is high,
therefore when designing pavement layers they are treated as arterial or freeways. The
pavement layers in some parts may require special design and treatment for resisting
heavy loads such as good's container at storage areas in airports, ports and railway
stations. Also, they require special treatments for resisting oils and spilled materials.
4.3
Pavement thickness:
4.3.1 General:
The structural design process for road includes selection of pavement materials
and determining pavement layer thickness required to sustain axial loads of vehicles.
Pavements are divided into two main types:
47
The first type is the cement concrete pavements which is composed of cement cast
insitu or precast concrete layers or precast concrete elements placed on aggregate subbase
or base course Division 14 from these specifications includes the construction
specifications for cement concrete pavements.
The second type, which is more widespread, is the flexible pavement, which is
composed of several asphalt concrete layers, aggregate base, and subbase and subgrade
layers. Divisions 5, 6, 8, 9, 12 and 13 of these specifications include the construction
specifications of asphalt pavement layers.
4.3.2 Pavement Thickness According to Urban Roads Classification:
Pavement layer's thickness is calculated and determined using several methods and
AASHTO method is considered the most widespread ones in the world. It requires certain
inputs that include design period, equivalent single axial loads (ESALs) in the design
period, environmental elements and soil bearing value like California bearing ratio (CBR)
or modulus of resilience (Mr) and other.
Whenever all design or part of the design data are not available the pavement
thickness indicated in Table 4.3.1 shall be used, these table shows the layer thickness for
flexible pavement in urban areas with low traffic loads only when the equivalent standard
axles loads in the design period (20 years) is less than one million axles, While for roads
with high traffic loading the design of pavement layers shall be carried according to
AASHTO design method or any other approved method. The pavement layers shall be
constructed according to the specifications indicated in the following Divisions in these
general specifications.
4.4
Correlation of Pavement layers With Non-Pavement Road Structures:

Urban Roads pavements are correlated with some non-pavement structures such as
internal and external pedestrian walkways, medians, trees, lighting posts, traffic signals
and sign and publicity boards etc.
These structures require identifying some requirements, which include but not
limited to:
1. Sidewalk construction shall be in accordance with specifications stated in division 15
of these general specifications to.
2. Special areas with specific slopes shall be constructed on sidewalks near the traffic
signals and crosswalks, so they may be used by the handicapped with wheel chairs and
children carts. Division 15 shall be referred to for more details.
3. Informatory signs, traffic and publicity boards shall be placed on sidewalks and
medians in such a way that does not obstruct pedestrian movement and reduce sight
distance for the drivers and it shall be installed according to technical conditions stated
for publicity boards issued by ministry of municipality and rural affairs, while traffic
signs shall be constructed according to unified traffic manual issued by ministry of
transport.
4. The planting works on sidewalks and medians shall be constructed according to
construction manual for planting and conditions and related technical specifications
issued by ministry of municipality and rural affairs.
5. Extra water from trees and plants irrigation process shall be drained by using required
arrangements when executing the planted islands and provision of water proofing and
to prevent its leakage and collection on the road surface.
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6. Road lighting works shall be constructed according to technical specifications and

general conditions for roads and streets lighting issued by ministry of municipality
and rural affairs.
7. Non-pavement structures shall be constructed in a reasonable sequence such that the
under construction works will not cause any damage to previous works.
Table 4.3.1: Guide of minimum thicknesses for urban road layers
Urban
Road Class
Local
residential
roads
Collectors
and
arterials
Traffic volume level

(ESALs) in 20 years
design period
Level 1
(less than 10,000)
Level 2
(10,000-50,000)
Level 3
(50,000-100,000)
Level 4
100,000-250,000)
Level 5
(250,000-500,000)
Level 6
(500,000-1000,000)
Average
daily
number
of
trucks
Asphalt layer thicknesses (surface and base)

/ aggregate base/subbase layer, (cm).
According to bearing capacity of the
roadbed.
poor
fair
Good
3 <CBR ~ 5
5 <CBR ~ 10
CBR >10
5/10/13
5/10/0
2-7
5/10/15
5/10/13
5/10/10
7-14
10/10/12
10/10/0
10/10/0
14-35
15/10/10
35-70
15/10/18
15/10/0
13/10/0
15/10/30
15/10/0
15/10/0
70-140
12/10/10
5/10/0
12/10/0
Notes:
1.
2.
3.
4.
5.
The pavement layers indicated in the table above shall be constructed over subgrade layer that
conform to the requirements indicated in section 5.5 from these specifications.
The road bed is the soil that on which the subgrade layer shall be constructed as specified in
paragraph number 5.4.3 "preparation of road bed" from these specifications.
When constructing in high or variable water level areas, sabkha soils and volumetric changed soils
areas, the required solutions for these problem and pavement layers thickness and type shall be
studied and specified before starting road construction.
The asphalt layers shall be constructed in layers its thickness shall be conform to minimum and
maximum requirements and limits for nominal maximum aggregate sizes used in mixes as indicated in
Table 8.5.5 of this specifications.
Numbers from left to right show the asphalt layers thickness (wearing and base), aggregate base and
subbase course thickness, for example 15/10/18 means:
15 cm asphalt layers (it can be 5 cm wearing course and 10 cm asphalt base layer).
10 cm aggregate base
18 cm subbase layer
4.5
Environmental Principles for Urban Roads Construction:

This section indicates conditions to be applied for environment preservation when
constructing and operating urban roads and includes description of Contractor's
duties in various project stages.
Contractor shall recognize and abide with all environmental ordinances and regulations
related to all types of contamination, issued from the concerned authorities
and he alone shall incur the legal, financial and social responsibility for any breach to
them.
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4.5.1 Noise:
Contractor, throughout execution phases, shall refrain from using any machines or
equipments which transmit a noise of more than 70 decibels according to scale (A) at a
distance of (16) meters during the period between 6 AM and 7 PM.
When the Contractor is allowed to work at night the noise level shall not exceed
65 decibel.
Rock blasting shall not produce noise exceeds 128 decibel at any day time
Local limits shall be applied if they are stricter.
4.5.2 Vibration:
Contractor shall use machines and equipments when used or operated which
produce vibrations that do not lead to any damage on buildings, structures and public
utilities.
Contractor shall apply all possible methods and arrangements to limit harmful
effects on his employees resulting of using some vibration equipments and abide with the
specified working hours for those equipments.
When executing blasting rock excavation he shall set out the suitable plan for
controlling and monitoring vibrations. Resulting vibrations shall not exceed the limits
stated in the special specifications or section 5-3 excavation works of these general
specifications.
4.5.3 Air pollution:
Contractor shall calibrate all his machines, equipments and material and mixes
production centers so that their operation does not lead to the propagation of air polluting
gasses in rates exceeding those allowed in environmental standards approved by the
concerned authorities in the Kingdom of Saudi Arabia.
Contractor shall prepare a plan for controlling dust during materials producing,
mixing, transporting, spreading and compacting and during excavation and extraction
works. This plan shall include water wetting or using dust reducing materials at work sites
and covering materials during their transportation. Also, it shall include control on dust in
aggregate and other materials stockpiles and stores, control on dust and other emanating
materials in various production centers such as asphalt and concrete plants and providing
them with the required filters, periodic monitoring and calibrating procedures.
Any plants or aggregate crushers or quarries or and other materials stores, which
leads to environment pollution shall not be constructed within urban areas. Permission of
such centers shall be subjected to the required acceptances from the Ministry, the
authorities concerned with environment and public health, and they shall be subjected to
monitoring and inspection periodically.
4.5.4 Material extraction and disposal sites:
Contractor shall extract the materials required for work execution from the sites
shown on the drawings and special specifications or those proposed by him and accepted
by the Engineer and he shall get the required written permission for using these sites from
the concerned parties and property owner. It is not allowed to extract
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materials within urban areas, or where extraction leads to changes in natural landscape
and valley flow lines. Contractor shall level and process these sites and make them in
harmony with the surrounding natural environment at the end of using.
Contractor shall dispose surplus and unsuitable materials at sites shown on the
drawings and special specifications or those proposed by him and he shall get the required
written permission for using these sites from the concerned parties and property owner
and written approval from the Engineer. In all cases, the selection of sites and method of
disposal shall not lead to environmental contamination.
Disposal sites shall not lie within urban areas, water flow lines, and agricultural
lands or near water sources and reservoirs.
Disposal sites shall be leveled and processed in a way that makes them in harmony
with the surrounding natural environment.
4.5.5 Hazardous and dangerous materials:
Contractor shall take all required precautionary measures to prevent any
environmental contamination as a result of using some materials considered as harmful to
environment such as oils and chemical materials, carry out all works and procedures
required when those materials spill for any reason outside areas in which they are allowed
to be used.
Generally, it is prohibited to use any materials considered to be harmful to public
health or environment before obtaining the acceptance, instructions related to the methods
and conditions and safety procedures when working with such materials.
Contractor shall, when he encounters during work execution any materials, which
may be considered harmful to public health or the environment, immediately report about
that to the engineer and dispose those materials at sites specified and approved by
concerned health and environment authorities using approved methods and arrangements.
It is absolutely not permissible to dispose these materials randomly and at the
public dumping sites that are not designated for such materials.
4.6
Traffic Control during Construction:
4.6.1 General:
Urban roads construction processes such as transportation, spreading and
compaction are characterized by their interlocking with each other and with other living
activities of the population such as moving, crossing, walking.. etc. Therefore, it is
paramount that pedestrians and vehicles traffic movement should be regulated at the area
of executing construction or reconstruction or maintenance works to ensure traffic safety
for road and street users and to ensure rapid execution with the required quality.
4.6.2 Traffic control procedures:
All traffic control works shall be done according to the traffic control devices
manual at work zones issued by the central commission for project coordination under the
supervision of the Ministry of Municipal and Rural Affairs on 1421H or any amendments
incorporated in it.
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At least the following procedures shall be applied for the purpose of traffic control
during construction:
1. Setting out a clear and comprehensive traffic plan, to eliminate traffic contradictions
with the execution activities.
2. Identifying alternative roads and the approximate time period for publicizing and
generalizing it through mass media, not less than two weeks before starting execution,
to ensure the safety of the roads network users and construction employees.
3. Construction of all required items for carrying out execution works such as
temporary detours and routes, warning and alarm signals, flashlights and concrete
and metal barriers. Contractor remains responsible for the operation and
maintenance of those items.
4. Provision of the information campaign at the locations specified for traffic
direction in addition to special boards written in Arabic and English showing the
start and end of construction.
5. Construction of temporary routes separate from alternative roads and detours for
transporting the vehicles and equipments required for construction.
4.7
Work site protection:
Contractor shall make all the necessary arrangements and procedures required for work
sites protection of such as barriers placing and warning lights, fencing of work zones and
guarding when required and he shall construct stores for materials, equipment and
machines at the specified sites accepted by the Engineer and ensure their protection,
fencing and guarding. In addition, he shall install warning boards that identify the project.
4.8
Maintaining or transferring utility lines:

Contractor shall, before he commences work, inspect site and coordinate with
various authorities to recognize various public utility elements, structures and lines
existing within work limits or those, which may be affected by them.
Contractor shall execute all works related to maintaining or transferring those
utilities according to the solutions and specifications approved by the client. Contractor
shall take all necessary requirements to maintain the utility works during construction and
prevent them from any damages that may affect them and he only bare any result of any
damage caused to those utilities, because of his failure in coordination or in providing the
required arrangement. The construction shall be done according to installation manual
issued by ministry of municipality and rural affairs in relation to coordination, releases
and arrangements.
Transferring works shall be executed so as to construct the transfer lines and
correlation structures and elements between the main lines and the lines transferred before
cutting services of the transferred utilities then transference is done for the purpose of
reducing the service cutting time to the least possible period.
Contractor shall Coordinate with, and approve detailed time schedule for these
works by the public utility owners. The beneficiaries of public utilities shall be informed
by dates and periods of service cutting before the specified time by not less than two
weeks through the information methods approved by the concerned authorities.
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Contractor shall make all required arrangements for maintaining protecting public
utilities during execution from any damages, which may occur to them. He shall choose
suitable execution methods and equipments and carry out support works when required.
Contractor is responsible for any damages may be inflicted on the public utility
lines and their elements as a result of his failure in making the required coordination,
arrangements and work execution. Contractor shall follow guide of public utility works
issued by the Ministry of Municipal and Rural Affairs.
Converting or removing works must be done that the new converting lines and
construction link elements between new and old lines must be available before cutting and
removing any structures, and converting will be done to reduce service cutting time to
lower limits. Contractor must coordinate with public structure owners for depending the
necessary solutions and detailed time schedule for such works, and inform them with
detailed dates and periods of service cutting before starting works with less than two
weeks, and that shall be done using general depending informing devices.
4.9
Common Transport Stops:
4.9.1 General:
This item includes construction of confined areas between the road pavement edge
and the right lane designated as side stops areas for buses and taxis. Those areas are
characterized by repeated stopping for relatively long periods until passengers and their
baggage are loaded and dropped. Also, these areas are characterized by slow movement
(causing creep) of buses which result in slipping and displacement for the upper pavement
layers causing asphalt corrugations in addition the possibility of the spilling of oil and fuel
from buses during their stopping. Therefore, it is vital to choose suitable pavement layers
for such conditions.
4.9.2 Construction requirements:
When the special specifications or drawings or other contract documents indicate
the construction of stop areas, Contractor shall comply with the following:
1. Use suitable Sub grade and aggregate bases according to the structural design and
according to materials and execution requirements indicated in sections (5, 6).
2. One of the two following options shall be used respectively for constructing buses
and taxis parking pavements:
- First option: Using cements concrete pavement layers to avoid surface corrugations and
according to materials and execution, requirements indicated in division 14 from these
- Second option: Using asphalt mixes containing a high percentage of coarse aggregate
according to Table 8.2.2 as a guide for selecting asphalt works according to roads and
parking areas classification, or super pave Mixes as indicated in the contract.
3. Some modifying materials shall be added to the asphalt mixes indicated above to
increase the capability of the asphalt binder for resisting distress. It is possible to use
any of the special polymer additives or a seal coat composed of rubber asphalt to seal
off leakage of oils and fuel to the asphalt pavement layers.
4. Geometric design used shall ensure easiness of entrance and exiting from the parking
and passengers. Pedestrian's sidewalks shall be constructed according to
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technical specifications for parking issued by ministry of municipality and rural

affairs.
4.10 Protection of Adjacent Streets from Wastes and Contamination:
Contractor shall take all the required arrangements and procedures required for
protecting roads and property adjacent to work areas from any contamination by materials
and wastes resulting from his works such as:
- Using covered vehicles for transporting various materials
- Keep of all his work sites clean and arranged.
- Disposal of all surplus and wastes products and materials promptly and it is not allowed,
in any way, to accumulate these materials within urban areas.
- At the end of the works contractor shall clean, arrange and evacuate all sites used by
him.
4.11 Drainage Works for Urban Roads:
Contractor shall construct all the urban roads drainage works indicated on the
drawings, special specifications and other contract documents according to special
specifications requirements or section 5.7 of these general specifications. He shall drain
and protect all executed works from the effects of water. When designing the surface
drainage facilities considerations should be given to the volume of water as the highest
volume occurred during the 25 years to confirm that no permanent or temporary
accumulations of rain fall water
4.11.1 Surface drainage:
During designing and executing roads in urban areas consideration shall be given
to water drainage by applying the following:
1- Designing and executing all items of surface drainage such as culverts, surface or
under surface side drains, execution of granular filter layers, cross drains, catch basins
in such a way that ensures storm water and surface water draining rapidly and prevent
water collection permanently or temporarily on the road surface or by its side or its
leaking to its structural layers.
2- When constructing soil, aggregate, pavement layers for streets, Contractor shall abide
with longitudinal and cross slopes shown on the drawings and contract documents for
each layer, and it is not allowed, by any means, to achieve slopes only for the surface
layer and ignore that in the bottom layers.
3- Provision of surface drainage during construction from all executed layers and
provision of required and effective tools to achieve this drainage so that no damages
result for the roads, adjacent structures and environment. These works are subject to
the conditions indicated in each paragraph of the works that include requirements
related to drainage during execution of these general specifications and special
specifications of the project.
4- Surface water collected from sidewalks, paved shoulders and pavements shall be
drained picked before reaching traffic lanes by constructing traps, side channels and
catch basins.
4.11.2 Underground water drainage:
During the designing and construction of roads consideration shall be given to
existing, future, permanent and temporary underground water and to provide required
devices of under drains and control water level by methods that limit its effect on the road
performance. Those devices include, but not limited to, the following:
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1- Using soil materials and asphalt mixes that are not highly affected by water.
2- Construction of free drainage granular layers.
3- Using under and edge drains, Drainage pipes or geotextiles, geocomposites and pumps
required for pumping collected water to the drainage systems or catch basins, or other
suitable solutions and arrangements.
4.11.3 Drainage requirements for trees and plants irrigation water:
When designing and constructing roads and pavements consideration shall be
given to the effect of planting irrigating and arranging trees and plants in the medians and
sides on the functional operational and structural performance of the road. To ensure that
Contractor shall:
1. Control water irrigation and prevent it from reaching road surface or leaking into its
structural layers and damaging them or changing their properties in such a way that
adversely affect the road and its various structures.
2. Do not plant thick rooted trees since their roots may extend to the road bottom, its
structures and different elements and subsequently damage them or lead to the
concentration of moisture and the occurrence of deformations.
3. Abidance with the conditions and special specifications for planting and irrigating
trees and plants.
4. Sequence of construction works so that no mixing occurs between the agricultural
soils with the pavement layers materials, and when such a case occurs all the required
arrangements shall be made to remove the agricultural soil from affected materials.
5. Do not plant trees that grow in such way that may affects the capacity and sight
conditions.
4.11.4 Sewage water drainage:
During the designing and executing of urban roads, consideration shall be given to
the effects of existing and future sewage water lines on execution operations, devices and
materials. When the construction coincides with the construction of sewage water lines,
the following shall be considered:
1. Setting out a plan for the sequence of the road construction and drainage works such
as pipe installation and manholes construction, in order to fulfillment the required
compaction degrees for all roads layers.
2. Provision of connection between pipes and manholes according to the drawings
specifications and conditions indicated in these general specifications plus the general
technical specifications for utility works and the special conditions of the project.
3. Execution of embankment and compaction by using methods, devices and
equipments, which do not lead to dislocation or damage of joints between pipes.
4. Fulfillment of compliance of the manhole surfaces with the road final surface slopes.
5. Not allowed to start backfilling around pipes and manholes before fixing the pipes and
hardening of their bases and joints and reaching the required strength.
6. Using the materials indicated in the special specifications and drawings for backfilling
around manholes and pipes and if no particular materials were indicated then
Contractor shall use materials of not less quality than those used and required for the
road layers. Backfilling shall be in layers with thicknesses provided required
compaction degrees.
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4.11.5 Water Draining During Construction:

When work conditions require, contractor shall provide equipments, labors and
devices required for draining and disposing drained water whatever its source, during
execution from work sites at the locations specified by the Ministry and in such a way that
does not lead to damage to the structures and properties. All environmental conditions
shall be considered and it is not permissible to dispose this water in private or public
property before obtaining the written acceptances for that. Contractor is responsible for
any damages, which may arise from this.
Contractor shall execute the required supports for excavation slopes using the
suitable methods.
Contractor shall not commence these works before he obtains the approval of
support, pumping and water disposal methods from the supervising authority.
4.12 Traffic Safety Requirements on Urban Roads:
Urban roads and city centers are characterized by the existence of conflicting
movements of pedestrian, road users and vehicle traffic movement. This conflict may lead
to traffic accidents and delay in trips and increase traffic congestion, the vehicle traffic
conflicts with pedestrian movement on both sides of roads or crosswalks and during their
movement from homes to their work, schools, entertainment and shopping places. This
requires setting out a traffic design that ensures pedestrians safety and provides smooth,
safe and comfortable traffic conditions through the suitable organization of movement and
construction of pedestrian sidewalks, footpaths, safety barriers and side.
During execution contractor shall abide with executing all of traffic control works
and provide traffic safety conditions at work sites according to requirements stipulated in
the traffic control devices manual at work sites issued by the central committee for
projects coordination under the supervision of the Ministry of municipal and rural affairs
on1421H and all its amendments.
4.12.1 Sidewalks:
Sidewalks shall be designed so that they provide safe and comfortable movement
conditions for pedestrians. When placing some obstructions on sidewalks this shall be
done such that the remaining space is sufficient for the movement of pedestrians. Also,
consideration shall be given to the conditions and requirements concerned with the
movement of the handicapped.
Contractor shall apply the requirements and execution phases indicated in division
15.
4.12.2 Pedestrian Crosswalks:
The following requirements shall be achieved:
1. Designating special crosswalks or pedestrian crossing at traffic signals for their
movement between the two sides of the road. Crosswalks shall be marked with ground
marks (paint) or raised marks (using special tiles) and the required traffic signs shall
be installed according to requirements indicated in division 16 from these
specifications and dimensions stipulated in the manual of traffic control device issued
by ministry of transport.
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2. Designating special Crosswalks for pedestrians at sites other than traffic signals and
intersections sites such as schools, mosques, entertainment areas and commercial
complexes.
4.12.3 Safety Barriers:
The following requirements shall be achieved and refer to division 16 for details:
1. Installation of a concrete barrier at medians to prevent pedestrian crossing except in
the designated places.
2. Installation of a metallic barrier between the road edge and sidewalk to ensure
directing pedestrians to the specified crossing areas near the traffic signals or areas
designated for crossing.
3. Installation of safety barriers (metal or concrete) near schools gates to insure the safety
of students when they come out of their schools and directing them to crossing areas
designated for that purpose.
4.12.4 Informatory signboards and panels for pedestrians and cars:
The following requirements shall be achieved:
1. Traffic signboards shall be installed at the suitable places so that they provide the
drivers with the required message about pedestrian crosswalks areas and show
pedestrians the areas designated for crossing.
2. Those panels and signboards shall achieve all the requirements indicated in division16
of these general specifications and the specifications issued from traffic departments
and authorities in the KSA.
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DIVISION 5
5.1
5.2
EARTH WORKS
Scope
Site Preparation
5.2.1 Description
5.2.2 Inspection And Survey Works
5.2.3 Equipments
5.2.4 Environment Protection
5.2.5 Protection Of Utilities And Properties
5.2.6 Removed Materials Ownership
5.2.7 Removal Or Transfer Of Utilities
5.2.8 Removal Of Materials, Debris, Plants And Trees
5.2.9 Removal Of Structures And Obstructions 5.2.10
Disposal Of Removed Materials
5.2.11 Works Acceptance
5.2.12 Measurement
5.2.13 Payment
5.3 Excavation Works
5.3.1 Description
5.3.2 Preliminary Works
5.3.3 Types Of Excavation
5.3.4 Equipments
5.3.5 Excavated Materials
5.3.6 Execution Of Common Excavation
5.3.7 Rock Excavations
5.3.7.1 Mechanical Ripping 5.3.7.2
Chemical
Fracturing
5.3.7.3
Blasting Rock Excavation
5.3.7.3.1 Preliminary Works
5.3.7.3.2 Work Plan
5.3.7.3.3 Execution
5.3.8 Structural Excavations 5.3.9
Finishing Requirements 5.3.10
Works Acceptance
5.3.11 Measurement
5.3.12 Payment
5.4 Fill Works
5.4.1 Description
5.4.2 Road Embankment
5.4.2.1 Surface Preparation
5.4.2.2 Materials
5.4.2.3 Borrow Pits
5.4.2.4 Water
5.4.2.5 Equipments
5.4.2.6 Construction
5.4.3 Roadbed Preparation
5.4.4 Structural Backfill
5.4.4.1 Materials
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5.4.5 Compaction Experimental Sections

5.4.6 Maintaining Of Embankment 5.4.7
Finishing Requirements
5.4.8 Works Acceptances
5.4.9 Measurement
5.4.10 Payment
5.5 Subgrade
5.5.1 Description
5.5.2 Untreated Subgrade
5.5.2.1 Description
5.5.2.2 Materials
5.5.2.3 Equipments
5.5.2.5 Maintaining Of The Constructed Layers
5.5.2.6 Finishing Requirements
5.5.2.7 Works Acceptance
5.5.2.8 Measurement
5.5.2.9 Payment
5.5.3 Lime Treated Subgrade
5.5.3.1 Description
5.5.3.2 Materials 5.5.3.3
Equipments
5.5.3.4 Job Mix Design Formula
5.5.3.5 Experimental Section
5.5.3.7 Safety Requirements
5.5.3.9 Works Acceptances
5.5.3.10 Measurement
5.5.3.11 Payment
5.5.4 Cement Treated Subgrade
5.5.4.1 Description 5.5.4.2
Materials
5.5.4.3 Job Mix Design Formula
5.5.4.4 Weather Limitations
5.5.4.5 Traffic Control
5.5.4.6 Equipments
5.5.4.10 Works Acceptances
5.5.4.11 Measurement
5.5.4.12 Payment
5.6 Civil W ork s In Utilities Projects
5.6.1 Description
5.6.2 Preliminary Works
5.6.3 Trench Excavation
5.6.4 Backfill
5.6.5 Pavement Re-Construction
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5.7
5.8
5.5.7 Measurement
5.6.8 Payment
Water Drainage
5.7.1 Description
5.7.2 Surface Drainage
5.7.2.1 Surface Slopes
5.7.2.2 Surface Side Drains
5.7.2.3 Surface Drainage Systems
5.7.2.3.1 Materials
5.7.2.3.2 Construction
5.7.3 Under Drains Works
5.7.3.1 Materials
5.7.4 Edge Drains
5.7.4.1 Materials
5.7.5 Filter Layers
5.7.5.1 Filter Layers From Untreated Aggregate
5.7.5.2 Cement Treated Filter Layers
5.7.5.3 Asphalt Treated Filter Layers
5.7.6 Culverts
5.7.6.1 Materials
5.7.8 Measurement
5.7.9 Payment
Slope Rip Rap And Protection
5.8.1 Description
5.8.2 General Requirements
5.8.3 Stone Rip Rap
5.8.3.1 Description
5.8.3.2 Materials
5.8.3.3 Execution
5.8.4 Concrete Rip Rap
5.8.4.1 Materials
5.8.4.2 Cast Insitu Concrete Rip Rap
5.8.4.3 Premix Concrete Rip Rap
5.8.4.4 Rip Rap With Concrete In Bags
5.8.5 Culvert Inlet And Outlet Lining
5.8.7 Measurement
5.8.8 Payment
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General Specifications of Urban Roads Construction _______________________ Division 5- Earth Works
DIVISION 5
EARTH WORKS
5.1
Scope:
This Division consists of site preparation, earth works and water drainage works,
and includes the following sections:
- Site preparation
- Excavation
- Embankment
- Subgrade
- Civil works for utilities
- Water drainage works
- Slope rip rap and protection
5.2
Site Preparation:
5.2.1 Description:
This section consists of site preparation and includes inspection and survey works,
protection, transfer or removal of utilities, removal of materials, debris, plants, trees,
structures and obstructions from the right of way.
Site preparation shall be carried out according to special specification, this general
specifications and specifications for utilities issued by the client. Contractor shall
undertake the works inconformity with the conditions and instructions issued by the
authorities concerned the environment preservation like the noise levels, air pollution,
vibration and dust. Contractor shall protect water resources from pollution, and take all
actions which provide safety for employees, neighborhood and highway users and to
complete temporary structures which permit the movement of vehicle and pedestrian
traffic throughout the construction period.
5.2.2 Inspection and survey works:
Immediately after contract assignment, Contractor shall inspect the site to explore
the general conditions and to set out the suitable plan for performing the works, and carry
out the necessary survey for fixing the road centerline and the related structures,
determining levels and dimensions, and link the neighboring buildings and structures with
the road alignment, and he shall determine the plans, longitudinal and lateral cross
sections and identify the project boundaries.
Contractor, in coordination with the Ministry and the clients representatives, shall
specify all utility lines existing within the boundaries of the project according to the types
and depths. Contractor shall hold a Coordination meetings with the authorities related to
these utilities to obtain the required release regarding transfer/removal of the existing
utilities and services, or to preserve and protect them according to specifications approved
by those authorities.
Contractor shall identify and estimate the quantity of waste and plants to be cleared from
the site and identify the number of trees to be removed and replanted in
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other places, or to keep them in the same location and he shall mark all trees and other
structures assigned to be kept in their places.
Contractor in coordination with the Engineer shall specify sites for storing the
removed elements and preserving them for use in the same project or other projects, new
sites for planting the removed trees and site for dumping removed materials. These sites
shall be specified in the contract documents or approved by the Ministry. Contractor shall
obtain a written agreement from the site's owners for the locations used for the disposal of
debris and wastes when these locations have not been identified previously.
The removal of waste materials and structures include hazardous materials shall be
made using proper methods. These materials shall be identified in coordination with the
Ministry and with the health and environment preservation authorities.
After completion of his investigation and survey works, Contractor shall prepare a
complete report which shall include the following:
1. Survey results and drawings including plans, longitudinal profile and
cross-sections and identify the relative distances to the near by buildings, various
utilities elements, structures, trees with a distinction between those which shall be
removed and those which shall be preserved or transferred.
2. List of structures and obstructions existing within work zones which should be
removed or preserved.
3. List for all lines and elements of various public utilities to be removed or
transferred.
4. List for materials and elements to be removed or dismantled and preserved and
delivered to the Ministry or to relevant authorities.
5. Approved minutes of coordination meetings with authorities related to structures
and public utilities. The requested approvals for the transfer or removal methods
and copies of the conditions and specifications approved by those authorities shall
be included.
6. A list for sites, material quantities and structures which may be classified as
hazardous to public health or environment and which should be removed or
disposed and related approved specifications.
7. A list of sites in which the cleaned and removed materials shall be dumped and a
copies of the written agreement from the owners of those sites.
8. Contractors detailed plan and time schedule for clearing, removal, transfer or
preserving works of utilities and structures.
Contractor is not allowed to start cleaning and removal works before receiving the
Engineers approval about the report, work plan, and time schedule. The Contractor shall
be responsible for the results of any damages arising from his failure in executing the
preliminary works or construction activities and he shall pay the cost of carrying out all
repair works.
5.2.3 Equipments:
Contractor shall, on the basis of exploration, survey works and the work plan
approved by the Engineer, provide all equipments and materials capable of carrying out
removal works of debris, materials, plants and trees, removal or transfer or preservation of
utilities and removal of structures and obstructions. These equipments, and tools
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required for the work shall be in a good technical condition and it shall include milling
scraping, loading, transporting and unloading equipments, and equipment required for the
cutting, removal and cleaning trees, roots plants and grass, equipments required for
removal of buildings, and all other equipments required for the construction.
5.2.4 Environment Protection:
Removal works shall be carried out according to the conditions and instructions
issued by authorities concerned with environment preservation as to noise level, air
pollution, vibration, dust and water sources protection from contamination. In addition
Contractor shall take all the measures, construct the temporary structures and detours
which insure vehicular traffic and pedestrian flows.
5.2.5 Protection of utilities and properties:
Contractor shall take all the required arrangements and carry out all the necessary
works to protect utilities such as of electrical lines, communication lines, water and sewer
lines which lie within the right of way and the public utilities which lie near work's zone
which may be affected by construction activities using suitable methods including manual
methods. And he shall carry out the temporary or permanent transfer works for these
utilities according to a plan set out by him and approved by concerned authority.
Contractor shall be responsible for any damages, resulting from construction
activities, affect the utilities indicated on the drawings or indicated in the coordination
meeting minutes with relevant authorities and he shall carry out all repair works on his
own account without having the right to claim any additional compensation for this item.
Contractor shall, halt construction activities in utility area when any damage was occurred
for utilities or when finding un-identified utilities, and inform the Engineer who informs
relevant authorities, and he has no right to recommence the work before receiving the
required instructions in this regard.
The contractor shall protect all the existing neighboring structures from any
damages which may results due to construction activities throughout the project period
and he shall install the temporary fences which separate work zone from neighboring
property when indicated in the special specifications, and preserve all the existing walls
and gates and not to remove or replace them with other temporary ones before agreement
of the owners or before the ends of the notification period which shall not be less than 30
days.
Contractor shall be responsibility for any damage occurred due to construction
activities on the neighboring buildings and structures or to those which were required to
be preserved within work limits and he shall carry out repair works and pay necessary
costs for this and he has no right to claim any additional costs for this.
5.2.6 Removed materials ownership:
The inspection and survey report shall include a list of all materials and elements which
shall be dismantled, maintained, and delivered to the client.
The ownership of all removed elements or materials shall be to the Ministry unless
otherwise clearly stated in the special specifications or minutes of coordination.
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Contractor shall take all required precautions and arrangements for dismantling,
cleaning and storing the materials and elements using suitable methods which do not
expose them to any damage or rendering their using.
The special specifications and contract documents shall identify the method and
amount of compensation to be incurred by the Contractor for the materials and elements
required to be dismantled or to be delivered or reinstalled, which have been damaged as a
result of the construction activities.
Contractor shall pay the required compensation for the materials or elements
which have been damaged and the ministry or the concerned authority may approve that
contractor can replace the damaged materials with other suitable materials similar or
better in quality.
5.2.7 Removal or transfer of utilities:
Contractor- in coordination with the Ministry and in attendance of the relevant
authority, shall inspect site and identify all utilities structures, elements and lines such as
telephone, electricity, water, sewage and fire hydrants and he shall use all related
information and drawings available with the relevant agencies concerned with the public
utilities at site and he shall indicate these lines on the drawings according to their
classification, materials, diameters, levels and depths as specified in the drawings and
investigation reports which shall be approved by the Contractor, Engineer and owners of
the utilities.
Also he shall identify the utilities and their elements reports approve these from all
concerned authorities. In addition Contractor shall obtain the specifications and special
conditions for utilities from the concerned authorities and prepare a work plan that
includes method, equipments, machines and materials which he shall use to carry out the
removal or transfer works and the procedures which he shall follow to protect those utility
lines which shall be preserved.
Except otherwise the special specifications indicate, relevant utilities
specifications or written instructions of the client, all utilities lying within the project
works zone, at a less than sixty (60) centimeter depth of the base layer levels shall be
removed or transferred or protected.
Removal, transferring, protection or preservation works of utility lines and their
structures shall be carried out according to the work plan prepared by the Contractor and
accepted by the authority and the Engineer. These works shall be executed under the
supervision of the authority's representative, and any fill works shall not commence
around and over the utility lines which were transferred and protected, before being
handed over to the authority's representative and verified according to the technical
specifications for such works and completion of all required tests. Fill works around pipes
and manholes shall be done according to technical specifications for installing public
utilities and specifications approved by the concerned authorities or section (5.6) of this
division.
In case special specifications or minutes of coordination meeting with the
authority, indicate dismantling of pipes, culverts, gutters, manhole covers and pumps store
them, completion of this work shall be done by using the proper means and
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equipments which do not inflict damage to these elements. These elements shall be
cleaned, transported, and stored at locations approved by the authority client or special
specifications. Delivery of these elements shall be handed to their owners according to
handing over minutes signed by the concerned parties.
Existing electricity towers and posts, telephones, transfer chambers and stations
and all ancillary structures and elements shall be removed according to the specifications,
methods and through using the equipments and machines approved by the concerned
authorities and under the supervision of representatives from these authorities. These
works shall be completed by qualified technicians. Contractor shall take all necessary
measures and precautions for the safety of employees, neighborhood and pedestrians.
The removal, protection or transfer of existing utilities shall be carried out
according to a time schedule and method approved by the concerned authorities and these
shall insure continuity or minimum interruption of their services. Users of this service
shall be informed by dates and periods of stopping service through the information media
approved by the concerned authorities, all on the Contractors own account. In addition
Contractor shall pay the responsibility for any damages which may results from his works
or his failing to fulfill the sufficient coordination.
Any structures used by pedestrians or vehicles shall not be removed before taking
the necessary arrangements to insure the continuity for traffic.
In case Contractor finds any public utilities lines or elements which have not
previously been located during the inspection or survey or coordination with the client, he
shall immediately report these to the Engineer and the concerned authority and stop work
at that area till he receives the approved decision in this regard and he shall report any
damage or fault that may occur to the existing services elements or structures during
execution of the works and carry out the required procedures, arrangements, and repair
works according to the Engineers and the concerned authority instructions.
Contractor alone incurs costs for repair or replacement of utilities, structures, and
elements, specified in the minutes and drawings, which are damaged as a result of his
works. However, those facilities which were not specified shall be repaired by him
according to the specifications and instructions of the concerned authority and he shall be
paid for this according to the agreed prices with these authorities.
Contractor shall fill all the trenches and pits resulting from removal works, wells,
absorption pits, catch basins, and building basements which lie within work boundaries or
conflict with these, by using fill materials, methods and specifications stipulated in the
special specifications or in the general specifications for layers of similar depths from the
finished highway surface.
5.2.8 Removal of materials, debris, plants and trees:
These works include removal of all debris, plants and grass; trees cutting or
Before starting work, Contractor shall take all the necessary arrangements to protect
neighboring structures and buildings from any damage results from the
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construction activities and he shall protect trees and other elements to be preserved from
any damage throughout the project period.
Contractor shall clear the highway right of way and its various structures from any
ingredients, debris of building materials, or products of any works which may be existed
within right of way and obstruct completion of work. These materials shall be collected,
loaded, transported and disposed at the approved sites.
In case any materials that may be hazardous to the health of the employees or
pedestrians are encountered, contractor shall take the necessary protection arrangements
for the employees and pedestrians and to carry out collection, loading and transporting
and disposal of hazardous materials according to the health and environmental approved
standards and at the approved sites.
Contractor shall commence removal of trees specified to be removed or grubbed in
contract documents or the instructions of the Engineer and planting in specified areas
within or outside the project. These trees shall be protected from any damage during
extraction, transportation, storage or planting and this shall be done by trained personnel
and by using equipments approved for such work. Contractor shall remove the remaining
roots of removed or extracted trees to a depth no less than one (1) meter from the lowest
level of the Subgrade layer.
Pits resulting from trees removal shall be filled with suitable material which
complies with the next layer materials at fill areas and these materials shall be compacted
to the next layers compaction degree.
Contractor shall dispose all removed and undesired materials from the boundaries
of the highway works immediately and transport these to the approved sites. It is not
permissible to collect these for long periods within urban areas.
Contractor-during all work stages-shall take the required procedure to protect
neighborhood and pedestrians and to carry out works which reduce dust by spraying water
or any other method approved by the Engineer.
Contractor shall separate and store materials indicated by contract documents in
certain areas and with a method specified in the special specifications or according to the
Engineers recommendations. Except otherwise contract documents stipulate, Contractor
has the right to act as to getting use of the cleaning and removal products such as wood
and trees.
5.2.9 Removal of structures and obstructions:
These works shall include removal of all obstructions, buildings and structures
within or conflict with the projects works or its utilization. All these works shall be
carried out according to the requirements of special specifications and these general
specifications, of these structures and obstructions.
Contract documents and inspection/survey reports will include a complete
inventory for the obstructions and structures which should be removed or dismantled and
stored, the structure and elements to be removed and copies of the minutes of
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coordination meeting with the authorities and their acceptance for the works to be
executed and specification condition related to the work.
Contractor, before starting removal works, shall submit a detailed work plan which
describes the execution method, equipments, and machines list, methods and sites for
transporting debris and waste materials, sites for transporting and storing the materials and
elements to be preserved, protection arrangements for elements and structures which shall
be preserved, public safety, environment protection procedures, plan, and methods for the
disposal of hazardous materials. The plan shall not contradict with laws, regulations and
instructions being implemented. It is not permissible to commence removal works before
obtaining all the written approvals from authorities related to the structures and
obstructions and submission of these to the Engineer and receiving his written acceptance
for the work plan.
Contractor shall remove all structures, obstructions from the areas shown on the
drawings to a depth no less than sixty (60) centimeter below natural ground at fill sections
or below the excavation level except otherwise the special specifications indicate.
Contractor shall submit a technical study from an approved authorized agency
which includes methods for removing buildings, bridges, and other similar structures, the
special specifications, required protection and support arrangements for buildings which
shall be preserved or those which might be affected by the works. Contractor is not
allowed to commence these works before receiving the written acceptance of the Engineer
and he bares full responsibility for any damage which might occur to employees or
structures and buildings as a result of his work.
Buildings, bridges, structures and fences within the projects boundaries or
ancillary works shall be removed according to the approved technical study using the
methods and equipments which do not lead to damage to neighboring buildings and
structures. Public and private agencies which own the buildings and structures shall be
notified, before a period not less than thirty (30) days from commencement of the removal
works, with the necessity to evacuate these buildings and structures, dismantle systems
and equipments and transfer existing property and objects. Contractor has no right to
commence the works before verifying the completion of this requirement.
Breaking of concrete elements of buildings and structures shall be done by using
hydraulic and air compressors or any other method accepted by the Engineer to the
required pieces with dimensions and weights which allow their transportation and disposal
to the specified locations. Metal structures shall be dismantled and their components
marked with numbers and codes in such way that it could be reused.
When removing, pavements, curbs, and middle islands, works shall be carried out
according to contract documents and approved work plan using the methods and
equipments suitable for these works.
It is preferable to remove asphalt concrete layers using milling and grinding
machines which enable fragmentation, transportation and storage of materials at the
Ministrys approved sites for reuse.
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It is not permissible to use removed materials in the works except after verifying
their compliance with the requirements related to materials of these works.
The disassembling of all traffic safety and control elements which lie within work
boundaries, or which conflict the works shall be carried out by the methods and
equipments which dont result in deformation or not prevent their reusing in the future.
This includes dismantling of panels, posts, metal/concrete protective barriers, light
signals, direction/warning signals and any other element which the special specifications
specify for disassembling and removing for the purpose reusing.
Removed materials which might be useful shall be loaded, transported, and stored
in the locations shown on the drawings or areas specified by the Ministry in compliance
with the instructions and regulations implemented by the Ministry and instructions
concerned with environment protection.
Contractor shall pay full responsibility for any damage which may occur to the
public and neighboring buildings and structures as a result of removal works.
5.2.10 Disposal of removed materials:
Contractor shall dispose all removed materials and transport them immediately to
the disposal approved locations and it is not permissible to store these materials within the
project boundaries or within the boundaries of the city, municipality or public/private
properties.
When burning of removed wastes and materials is required it shall be done in sites
specified and approved by the Engineer, according to an approved plan which fulfills
safety requirements and environmental preservation conditions. It is not permissible to
burn materials within project works boundaries or within the boundaries of the city,
municipality or near buildings and structures. Contractor shall be held fully responsible
for any damages which arise from this. The burning waste shall be disposed according to
the standard requirements in the approved sites.
Contractor must separate the materials which have special conditions to be dispose
according to environmental requirements and burying, dispose it according to related
specifications, conditions and instructions.
5.2.11 Works Acceptance:
Contractor shall apply quality control for site preparation work through carrying
out all the required procedures to insure that used materials, completion methods and
completed works fulfill quality requirements stipulated in the special specifications and
clients specifications or general specifications and other contract documents.
The Ministry shall apply quality assurance and verify the Contractor quality
control procedures either through direct supervision or by carrying out neutrally quality
assurance procedures using test on representative samples and in adequate numbers to
judge about the quality level and accept or reject the executed works according to the
principles detailed in Division (17) of these general specifications except otherwise
specified in the special specifications and other contract documents.
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1. Quality Control:
Contractor shall apply quality control on the constructed works and he shall
monitor, record, and analyze results and draw quality charts for critical properties and he
shall carry out all the tests and measurements for measurable and testable works and
investigate immeasurable and un-testable works.
Contractor shall submit to the Engineer copies for all the measurements and tests
promptly and he shall apply all the items indicated in subsection (17.1.1) of these general
specifications.
2. Quality Assurance:
Ministry, at any time, has the right to assure the quality of materials and
constructed works through carrying out or ordering others to carry out under its
supervision the tests and measurements for constructed works. The Ministry has the right
to review Contractors quality control records and compare these records with quality
assurance data to assure quality according to what is specified in Division (17) of these
general specifications. The ministry has the right to inspect Contractors laboratory
equipments, technical staff, and methods of investigations, testing to insure the efficiency
of Contractors staff, equipments and degree of conformity of investigation, testing and
construction methods with approved methods.
5.2.12 Measurement:
Measurement shall be carried out for site preparation works for actual work
specified in the special specifications and the investigation and survey report approved by
the Engineer. It is not allowed to make any measurements for the purpose of payment for
quantities and constructed works outside the specified locations in the contract documents
or those which are not approved in the investigation /survey report approved by the
Engineer except when the Contractor has been assigned in writing.
The special specifications and other contract documents shall include a table for
work items and measuring units. Except when the special specifications otherwise
indicate, measurement shall be carried out for the actually executed and technically
accepted works according to the following:
1- Removal works for existing buildings, structures, pavements and clearance
works, removal of debris, and grass, are measured in square meters. Area
of multi-story buildings is calculated by multiplying the area of one story
by the number of the floors.
2- Works of removal or transfer for utilities lines, removal of fences and gates
or removal, dismantling, cleaning, storing and preservation of various
safety barriers and protective barriers are measured in linear meters and
this includes all the elements, materials and ancillary structures except
when contract document indicate otherwise.
3- Works for removing, dismantling, cleaning and storing elements which are
required to be dismantled, stored and preserved or delivered to the concerned
authorities or the Ministry are measured by numbers.
4- Works of trimming trees or extracting and replanting them in other locations or
preserve them are measured by number and trees are considered to be all the trees
with an average diameter of more than
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15cm. Below this diameter trees are considered plants even if these were
required to be extracted and replanted or preserved.
5- Works for dismantling, cleaning or removal of electricity posts and towers,
telephones and light signals are measured by number for actually executed
works. This includes dismantling or removal, cleaning, transportation,
storage works and coordination works with the concerned authorities to
insure the continuity of service.
6- Dismantling or removal of transformer stations, power stations, panels and
reinstallation works when the special specifications stipulate for this are
measured by number if possible according to power.
5.2.13 Payment:
Payment shall be done for site preparation works according to actually constructed
works which are included in the special specifications and in the approved investigation
and survey report minutes of meeting and in accordance with contract prices. These prices
shall be considered as complete compensation for the completion of all the works
according to the special specifications or these general specifications or the special
specifications of the owners of utilities, structures and lines including preparation of
required reports and studies, provision of machines, equipments and labor , completion of
all the temporary detours and paths, safety arrangements, support works and all other
requirements for the completion of the works plus transportation and disposal of produce
or storage and/or reassembling of the elements in addition to all revenues, fees and
payments to third parties.
The following work items table shall be considered only as an example, and the
special specifications and contract documents shall include a table for work items to be
measured and paid. Payment shall be according to one or more of the f items indicated in
Table (5.2.1).
Table (5.2.1): Items for site preparation works
Work
Item No.
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
5.2.11
5.2.12
Work item
Public utilities and lines removal
Transfer of utilities lines (shall be classified
according to types)
Preservation for public utilities lines
Dismantling of electricity or telephone posts and
towers
Dismantling of traffic signals plus different
components
Removal of signals and traffic control elements
Removal of safety barriers
Removal pavements layers, foot path, etc
Removal of fences & gates
Cleaning of debris, materials, plants & grass
removal
Removal and replanting of trees
Removal of buildings & structures
Measuring Unit
Linear Meter
Linear Meter
Linear Meter
Number
Number
Number
Linear Meter
Square meters
Linear Meter
Square Meters
Number
Square Meters
70
5.3
Excavation Works:
5.3.1 Description:
This section includes removal for materials within work boundaries according to
the dimensions, levels and lateral cross sections indicated in the drawings and other
contract documents or specified by the engineer. These works include excavation works
required for the completion of the highway and all its elements, structures and water
drainage structures whatever materials and soils to be excavated. Including loading and
transporting of excavated materials to locations of their use or storage or disposal at the
approved sites.
Any information about surface or subsurface soil shown on drawings or in the
projects special specifications or the technical reports submitted during discussions with
the engineer are considered as primary information and shall not be taken as a basis for
the estimation of prices. Work plan preparation and the time schedule. Contractor shall
prepare his prices, choose equipments and execution methods and prepare his work plan
and time schedule on the basis of the information which he obtains from his own studies.
5.3.2 Preliminary works:
Contractor, starting of excavation works, shall complete site preparation works
indicated in section (5.2) of this division or according to the special specifications.
Contractor shall link excavation work boundaries with neighboring structures and
building, inspect types of soil to be excavated and submit a full report on
investigation/survey works together with drawings, cross sections, levels, boundaries for
excavation slopes.
Contractor shall, on the basis of types of soil to be excavated, excavation depths,
external limits of the final excavation slopes, topography, distance between buildings or
fences or neighboring property boundaries and excavation, choose excavation method that
do not cause any damages to existing buildings and structures or affect neighboring
property. And submit the required support studies for the protection of buildings,
structures and utilities which might be damaged as a result of executed works and the
studies/solutions required for supporting excavation sides during construction together
with all details and particular specifications for these works. It shall include methods and
equipments for the disposal of waters during excavation, methods for protection and
transferring utility and uncompleted utilities lines during the site preparation phase. No
additional payment shall be made to the Contractor for this studies except otherwise
indicated in the special specifications.
Contractor shall submit, on the basis of inspection, survey and study, the detailed
work plan, the list for the equipments and machines, traffic control plan, sites and details
of pedestrian sidewalk, barriers around excavation areas and type of warning lighting for
work areas, within a period not less than 30 days from commencement of protection and
supporting works.
It is not permissible for the contractor to commence excavation works before the approval
of the work plan by the engineer, time schedule and finishing of enforcement,
71
General Specifications of Urban Roads Construction ______________________ Division 5- Earth Works
protection, detours, and traffic control works, and before obtaining the excavation
permission from the concerned authorities.
Contractor alone indorse full responsibility for any person injury or damages,
caused by executed works, on structures, public utilities, and public/private property
which lie within or near the projects work boundaries and which are required to be
preserved.
5.3.3 Types of Excavation:
Excavations shall be divided into the following types according to excavation
methods, type of excavated soil or nature of the structure except otherwise is indicated in
the special specifications.
1.
Common excavations:
Excavations are considered as common when carried out in all non-rocky soils
such as clay, silt, sand and aggregate materials or loose and soft rocks by using common
excavation methods and equipments such as bulldozers and similar excavation
equipments without the need for ripping or blasting.
2.
Rock excavation:
This shall include excavation in hard and solid rocks such as hard lime or shale or
basalt rocks which can not be excavated through using heavy and technically efficient
excavation equipment not more than 5 years old with a horse power of 350 for open
excavations or a drilling machine of 250 HP for trench excavations or confined pits or
when the rate of distribution of seismic waves velocity in the material to be excavated
exceeds 2000 m/sec, excavation in this case, shall be done by using ripping machines
and/or blasting.
3.
Structural Excavation:
These include excavation works required for completing various structures such
as bridge foundations, retaining walls and culverts if separate pay item is included in
special specifications or project quantities and can be classified in to common or rock
excavation.
5.3.4 Equipments:
Contractor shall provide all equipments and machines required for the completion
of different excavation works, in enough numbers and types capable for carrying out the
works according to the work plan and time schedule approved by Engineer. These
equipments shall be capable of working in on site and suitable for soil types in excavation
site and available space areas for execution. And it shall not adversely affect neighboring
buildings and properties and the Contractor shall be responsible for any damages which
may caused as a result of used method of excavation.
The Contractor equipment shall not lead to extra noise, air pollution or vibration
levels higher than the tolerance limits specified in the approved manuals, specifications
and environmental instructions. The Contractor equipment shall includes drilling
machines, bulldozers and/or grinding equipments, loaders, dumping trucks, water pumps,
pipes and tankers as required for work constructions according to the approved
specification.
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5.3.5 Excavated materials:

Contractor shall be responsible to mention in the plan of works his proposal for
using excavated materials elsewhere in the project, where surplus and unsuitable
excavated materials shall be disposed on definite sites after a written agreement is
obtained from property owner.
Excavated materials suggested to be used shall comply with materials
requirements, liquid limit, plasticity index, California bearing ratio, salt content, swelling
and grain size graduation and it is not permissible to use excavated materials before
carrying out all the necessary tests on representative samples to verify their compliance
with the specifications required for the work in which proposed to be used or according to
various sections of this general specifications or special specifications or as directed by
the Engineer.
When using excavated materials it should be directly transported from excavation
site to the site of work or stored at specified sites approved by the engineer and the
Contractor shall take all the required precautions to prevent mixing of these materials with
unsuitable ones during excavation or transportation or storage.
The Engineers acceptance for using any excavation materials is considered as a
preliminary and it should be finally approved on the basis of tests carried out on samples
from the actually hauled materials to the work site. Contractor shall remove any materials
which are not in compliance with work specifications, remove any executed works in
which these materials were used and replace them with suitable materials conform to the
specifications and reconstruct the removed parts with technically acceptable materials
according to the specifications for those works without having the right to claim any
additional cost.
Contractor shall transport all unsuitable and surplus materials immediately at the
approved locations; the dispose materials shall be graded and compacted in such a way
that it becomes uniform with surrounding terrains. The hauling operation shall be done
through specified routes using covered dumping trucks. It is not allowed to dispose
excavation materials or stockpile them within urban areas boundaries or in valley. The
disposal of these materials should not lead to any damage to public or private property.
When some industrial wastes or similar materials encountered in the project it
shall be disposed according to the instructions and requirements followed by
health/environmental authorities requirements.
No additional amounts shall be paid for disposal of surplus or unsuitable materials
and their costs shall be included in excavation prices except otherwise indicated in the
special specifications.
When the special specifications or other contract documents indicate that the
disposal of unsuitable or surplus materials shall be disposed in certain sites lie within
certain distance, while during the work execution it was found that these locations are not
allowed for use, then the price amendments should be made according to the ratio and
proportion of the of hauling distances.
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5.3.6 Execution of common excavation:

Contractor shall carry out common excavation works by using suitable equipments
and machines and approved work plan according to dimensions, levels and slopes
indicated in drawings and other contract documents and he shall prepare excavation
bottom and finishing their side slopes according to the dimensions and levels as indicated
on the drawings, in the contract documents and general specifications.
Before commencement of excavation works, contractor shall obtain excavation
permission and complete all the preliminary works indicated in item (5.3.2) of this
section.
When special specifications or the Engineer require contractor shall commence
removal of vegetation top soil suitable for planting to a depth not less than fifteen (15)
centimeter, hauling and storing it in approved locations as directed by the engineer. No
additional payment shall be paid for the Contractor corresponding these items except
otherwise indicated by the special specifications.
Contractor shall take all the necessary precautions and arrangements to prevent
failure of excavation slopes and furnish suitable enforcement according to soil type, depth
and slope of excavation.
Contractor shall carry on his expense if not otherwise specified in the special
specifications and submit a study on slopes stability prepared by an approved specialized
agency when the depth of excavation exceeds three (3) meter or when the excavation edge
is near to buildings or structures which may be affected, except otherwise this study was
included in contract documents. This study is considered to be charged on excavation
work items, except otherwise indicate special specifications.
Loose aggregate, clay and silty soils are considered as susceptible to failure, so
when back slope of the excavation exceeds 1 vertical to 2 horizontal (1:2) the side slopes
should be supported in these soils.
Contractor shall prevent movement and stopping of equipments and traffic near
excavation edge and separate it with suitable barriers, with the minimum save distance
between the excavation edge and the nearest parts of chains or wheel which does not leads
to damages in excavation edges , this distance in no case should not be less than one and
half (1.5) meter.
Contractor shall not use any vibratory machines near excavation areas consist of
sand or loose gravelly-soil to prevent failure or loosening of slopes of the excavation.
Contractor shall take all the required precautionary arrangements to prevent water,
whatever its source; from reaching excavation sides or bottom and he shall dewater the
excavation bottom by pumping, or drains or any other effective method approved by
Engineer. Special precautions shall be taken for the excavation in high water level areas to
prevent water from reaching the excavation area and more consideration should be give to
the extra pressure arising from water in the design of side slopes and side supports.
74
In case the Engineer or Contractor notice that the excavation side is subjected to
slide or failure, contractor shall evacuate all employees and equipments and halt the work,
until on his expense submits a suitable solution for the problem, and he shall be
responsible for any damages which might arise due to his failure in providing a suitable
protection arrangements for employees and structures.
When contractor encounters any underground previously unknown structures or
utility he shall halt the work at that area and inform the Engineer who shall inform the
concerned authorities and approve the suitable solution in coordination with those
authorities and contractor shall complete all the required works to remove or transfer or
preserve the structure or public utility according to the approved solution agreed upon,
except otherwise indicated in the contract documents.
Whenever carrying excavation works near utilities, structures or lines contractor
shall take all required arrangements and suitable excavation method such as using of light
equipments or manual excavation to avoid any damage which may occur to the structure
or public utilities. It is absolutely prohibited to excavate near foundations of buildings,
structures and public utilities and expose their foundations before completing the
necessary supporting works according to the technical study prepared by a specialized
agency and approved by the Engineer.
Contractor shall finish excavation according to the levels, depths, dimensions and
slopes indicated in the drawings and other contract documents. Excavation sides and
bottom should be leveled and cleaned from loose and susceptible sliding materials as
specified in the specification, and he shall inspect and test the bottom of the excavation
and maintain it in clean and dry situation until construction of the subsequent layers.
Contractor test the material below bottom of the excavation to ensure its
conformity with the requirements of the following layer to be constructed, and when it is
technically accepted the contractor shall pulverize the bottom of the excavation to a depth
not less than 20 cm, wetting up to optimum moisture content and compacting it to a
degree not less than 95 % of the maximum dry density according to modified proctor test.
When materials beneath the bottom level of excavation are not suitable as a
roadbed according to item 5.4.3 requirements "road bed preparation" of this division
contractor shall excavate these materials to the lines, levels and depths instructed by the
Engineer providing that the depth of the excavation should not be less than sixty (60)
centimeter for collector, arterial and main roads, and not less than thirty (30) centimeter
for local roads below the bottom level of subgrade surface. The excavated materials shall
be removed and disposed according to Disposal of surplus and unsuitable materials item
in the general specifications, and substituted by suitable processed, compacted roadbed or
Subgrade material as required in section 5.4 "embankment" from these specifications.
However, when excavation depth exceeds the specified depth below subgrade
layer the contractor shall level the bottom of the excavation and backfill the extra
excavation in layers having thickness not more than 15 cm using material comply with
roadbed or subgrade material requirements according to layer depth, then contractor
75
shall level, wet and compact the to a full depth of the layer to not less than 95% of the
maximum dry density according to modified Proctors test for the used material , and it is
not allowed using of sandy soil for backfilling the extra excavation.
When excavation is done in loose sandy soil contractor shall carry out excavation
in such a way that its side slope shall not exceed 1 vertical to 6 horizontal. Sides and
bottom of excavation shall be protected and confined by using materials indicated on the
drawings and special specifications providing that their classification is no less than
A-1-a, or A-1-b, or A-2-4, with plasticity index not exceeding 10% according to
dimensions and thickness indicated on the drawings or as instructed by the Engineer
providing that thickness should not be less than twenty (20) centimeter. No additional
payment shall be paid for these works and their prices should be included in the
excavation price.
5.3.7 Rock excavations
This work consists of excavation works for materials classified as rocky, including
preparation of all technical studies, reports, formation of side slopes, removal of materials
susceptible to failure, traffic protection and control devices, supporting and finishing these
works according to the dimensions, levels and slopes indicated in the drawings and other
contract documents, using grinding and/or blasting, methods.
Rock excavation may be performed by one of the following methods:
Mechanical ripping
Chemical fracturing
Blasting
Contractor shall, before commencement of the rock excavation works by a period
not less than thirty (30) days, submit to Engineer his work plan, time schedule, equipment
and devices list, protection plan and arrangements proposed to be used together with a
study prepared by a specialized agency approved by the Ministry about rock layers,
proposed methods of excavation and method of protection of buildings, structures and
public utility lines (which might be afected by excavation works) and supporting
procedures. Contractor is not allowed to commence the works before the approval of the
work plan by the engineer and the concerned authorities of public utilities and structures.
5.3.7.1 Mechanical ripping:
Contractor shall perform rock excavation by ripping when the project period and
rock types allow the use of this method. Rocks are considered as susceptible to ripping
excavation if velocity of the seismic wave in the excavated rocks varies between 2000 to
3000 m/sec.
Contractor shall provide an adequate numbers of suitable rippers for the rocks
nature and with an adequate number to perform excavation works according to the
approved time schedule and within the boundaries, dimensions and levels indicated on the
drawings. The vibrations caused by ripping work shall not result in any damage to the
structures, buildings and utility, and the Contractor shall perform all the necessary
protection and supporting works on his own account and he alone incurs any damages that
might arise from his work.
76
Excavation works shall be from up to downward throughout excavation limits and

the excavation machines and stages of the work should be distributed in such a way that
prevents a failure of the rock layers. Contractor shall furnish trained labor to perform the
work, and shall provide all safety and protection requirements to instruct all employees
within the work zone.
Rock boulders shall be removed and loaded after ripping and transported by trucks
to the approved sites using suitable machines, it is not permissible to stockpile excavated
material within the projects areas or urban areas.
5.3.7.2 Chemical fracturing:
The fracturing excavation may be used when it is stated in the special
specifications or if it is proposed by the contractor in technical study shows the reason,
advantages, specifications, method of construction and the general requirements, with
dates and results of previous construction in similar sites and including the environmental
measurements such as, vibrations, gasses and their effect on the health.
The materials proposed to use should be from the type that approved in the
Kingdom of Saudi Arabia and country of production for such works.
Such works will be performed by qualified contractors who have previous
experience under the supervision of an approved technical authority.
5.3.7.3 Blasting rock excavation:
This work consists of breaking rock boulders to construct fixed and stable
excavation sides using controlled blasting to form back slopes for excavation sides
through executing cutting surfaces that match the approved slopes in the excavated rock
layers.
It is permissible to perform rock excavation using blasting in urban areas only if
necessary and in rocks which can not be excavated with any other method.
Rock excavation works shall be performed according to the vital regulations and
laws in the kingdom and should be carried out by specialized, qualified and approved
firms and on the basis of a technical study prepared by a qualified specialized agency.
5.3.7.3.1
Preliminary works:
Before commencement of blasting works, contractor shall complete the following
preliminary works:
1.
Blasting consultant:
Contractor shall seek for a consultant specialized in rock blasting or an approved
qualified technical agency to monitor records and analyze reports of seismographic
vibrations caused by the blasting works and submit his/its name and qualifications to the
Engineer for approval before commencement of work. The proposed consultant shall have
the adequate experience in blasting activities and the ability to analyze vibration records,
ground motion and energy transmission path emanating from blasting activities. The
minimum qualifying requirements for consultant shall be Bachelor of Science Degree (B
SC), with accredited courses in at least three of the following disciplines: Seismology,
Geophysics, Geophysical Eng., Vibration Eng., Soil or/and
77
Rock Mechanics, Foundations and/or Explosives Engineer. He shall perform the required
certificates to prove his previous experience in blasting works.
Consultant shall direct and instruct the contractor in its operations to control
vibrations within the approved limits and he is in charge of making the preliminary blast
survey, monitoring and recording vibrations, preparation of reports and submitting
recommendations to the contractor on daily basis, describing level of observed vibrations
attributed to project blasting activities and their subsequent effects on surrounding
structures.
2.
Survey works:
The blasting consultant shall conduct full survey for all buildings, structures,
utilities and water tanks in the area adjacent to the site within the one hundred fifty (150)
meter distance, to describe its existing condition before blasting and to record and
evaluate all cracks and other defects according to the approved method preparing a
technical condition survey report signed by the contractor and submitted to the Engineer
for review and approval.
Contractor shall issue an advertisement about the blasting in the mass media and
submits a notice to adjacent properties owners or tenants, the concerned authorities and
the engineer, identifying the project, date and time of the blasting, site location and the
blasting contractor. The announcement will be displayed in exposed areas near the site
before a period no less than7 days from the blasting date.
Contractor, after completion of rock excavation works, shall carry out post-blast
survey for the site and neighboring structures to determine their condition after blasting to
identify any damages that may occur due to blasting operation. Notice shall be given to
the concerned authorities, the Engineer and owners/tenants of the properties and buildings
near by, specifying the date for the final survey after blasting.
3.
Control and monitoring of vibrations:

Contractor undertakes to abide with the vibration limits approved in these general
specifications and the special specifications. The Contractor shall incorporate the
vibration limits and the velocity of particles in the blasting plan, and adjust the blasting
plan whenever the vibration values not comply with the approved limits. The following
items shall be considered:
a) The maximum peak particle velocity for ground vibrations, in any of the three
mutually perpendicular components for above ground residential structure, shall
not exceed the limits indicated in Table 5.3.1. The indicated limits for these
vibrations shall be reduced for old buildings, eroded utilities and computer
buildings, to the limits estimated by the specialized agency in the blasting plan.
b) The maximum peak particle velocity of ground vibrations for the three mutually
perpendicular components for underground public utility and non-residential
structures shall not exceed 50 mm/sec.
c) Whenever there are some structures in the area which requires special vibrations
requirements contractor shall coordinate with owners of these structures to get the
approved limits.
78
General Specifications of Urban Roads Construction
Division 5- Earth Works
Table 5.3.1: Ground Vibration Limits for Residential and Building Structures
Type of structure
New buildings
Reinforced concrete or steel
buildings
Wells and water strata layers
Old buildings
Max. particle peak velocity (mm/Sec)

frequency (40Hz)
frequency below (40Hz)
or greater
19
50
50
100
25
50
13
50
d) Contractor shall not conduct any blasting operation within thirty (30) meter from
concrete structures which are newly completed (less than 7 days) without approval
from the Engineer.
e) The peak air pressure resulting from the blasting shall not exceed 128 dB in the
residential area.
4.
Vibration monitoring Instruments

Contractor shall provide the required vibration measurement systems to monitor
and record vibrations produced by blasting activities. These systems should be ready for
operation, calibrated and should fulfill the following conditions:
a) Measure, display and provide permanent records on strip chart of particle velocity
components.
b) Measure the three mutually perpendicular velocity components for the particle
velocity in the vertical, perpendicular and radial directions.
c) The systems should have a velocity frequency response varying between 2-150
Hz and be capable of measuring peak particle velocity of up to 250 mm/sec.
d) Calibration certificates and date for last calibration from an approved center
shall be attached.
e) The system shall be calibrated according to the periods approved from the
specialized agencies, providing that this period shall not exceeds one year,
regardless of the utilization type, and the calibration should be carried according to
regulations implemented in K. S. A.
f) The operation manuals, requirements and the degree of accuracy approved by the
manufacturers shall be attached with the proposed instruments.
g) The operation of these instruments shall be performed by trained and qualified
technicians and contractor shall submit the credited experience certificates of those
operators.
5.
Maintaining and Storing Blasting Materials and Equipments:

All the blasting, explosives storage, blasting instruments and their transportation
operations shall be conducted according to these general specifications, ministry of interior
regulations and authorized agencies in K. S. A. And it is not permissible for the contractor to own
or store any explosives at the project site or in his private property except after obtaining
acceptance from the relevant security authorities.
All blasting materials and equipments shall be provided with special records and cards including
production date, validity date, requirements for maintaining, storing and
79
transporting, requirements and methods for use. All these information shall be approved
and endorsed by the manufacturers and authorized agencies.
Contractor on his own responsibility shall keep supply and consumption records
for blasting materials, equipments and the used quantities and he shall be responsible for
any failure or damages may occur due blasting activity.
5.3.7.3.2
Work plan:
Contractor shall submit a study, prepared by an approved specialized authority on
the basis of the site investigation and the required geological studies, , Before not less than
30 days from commencement of executing blasting operations, it should includes method
of blasting, ways of security and protection, methods of protection and/or support for
surrounding structures and public utilities, protection and supporting for excavation sides
from any damages that may occur due to blasting operations. The study should be
attached with a copy of the manuals, instructions applied by the authorities, blasting
requirements and acceptance of the relevant authorities for the execution of the works.
Contractor has no right to start works before obtaining approval from the concerned
authorities and the Engineer for the work plan.
The work plan shall includes the following:
1- Control blasting sequence and schedule including the general method for
excavation lift heights, starting location, dates and the estimated rate of progress.
2- Written evidence of the licensing, experience, and qualifications, of the blasting
teams and names/experience of the persons who shall be responsible for loading
and firing of each shot.
3- Names and qualifications of the persons responsible for designing and directing
blasting operations performed by the contractor.
4- Name and qualifications of the blasting consultant proposed for performing
primary survey works before blasting.
5- Name and qualifications of independent blasting consultant proposed for use in
monitoring blast vibrations. A sample of a previous vibration analysis or report or
both shall be included with the qualifications. The report shall also includes an
evidence shows the ability of the consultant to analyze blasting operations.
6- A listing of instatements and devices which blasting consultant proposes to use to
monitor vibrations and control blasting together with performance specifications,
instruments user manuals supplied by the manufacturer.
7- A proposed form for the blasting daily record which will be approved by the
Engineer according to instructions for blasting issued by the authorized agencies in
the Kingdom of Saudi Arabia.
In addition the plan should include the following basic details:
1. A diagrammatic description of the typical blasting pattern to be used for the
required rock excavation, including the pre-splitting and control patterns, as
required. This description shall include the spacing, between holes in the pre-split
lines and production lines. And the methods of control the cap delays and time
separating between blasting of each row or hole.
2. description of loading plan for a typical production and pre-splitting blasting
including, for each type of hole the fuse and cap locations, the percent strength
80
and type of primer, the proposed hole diameter, name and quantity of explosive,
and anticipated location and depth of stemming.
3. Sub-drilling depth, explosive quantities, primer, and initiators, initiation sequence
including delay times and delay systems, and manufacturers data sheets for all
explosives, primers, and initiator to be used.
4. Specifications of stemming and metal covering grid materials any other materials
suitable for preventing rock throwing resulting from blasting.
The blasting plan shall -after its approval- form the basis for all blasting operations
in the project, this plan may be changed according to judgment of the Contractor or the
Engineer or the specialized authority, after stopping of the blasting operations.
Approval of the blasting plan does not relieve the contractor of full responsibility
for the blasting operation results, accuracy and adequacy.
When the blasting excavation method is approved the overburden materials
covering the rock shall be removed or cross-sectional trenches shall be drilled to the full
depth of the materials covering rock with a distance separate each section providing that
the space between each cross-section neither less than five (5) meters nor greater than ten
(10) meters to provide the possibility of forming the cross sections of the rocks in their
original position. Suitable self propelled equipments may be used to form these
cross-sections and any removed rock before the formation of these cross-sections shall be
considered as common excavations.
5.3.7.3.3
Execution
Blasting excavation shall be conducted according to all laws and regulations
implemented in the kingdom, an approval from the authorities shall be obtained and
blasting operations shall be performed in the presence of their representatives.
Back slopes and side formations for cutting location shall be constructed as
specified on the drawings or as instructed by the Engineer in a proper and safe way
without exposing the life of inhabitants or their property to danger.
The Engineer has the right at all times to stop the contractors blasting operations
when the applied method does not produce the approved excavation sides or does not
meet security and safety conditions or leads to exposing the population, buildings and
structures to danger.
Contractor shall inform the engineer with the blasting program before a period not
less than 24 hours and to inform him with the stand by condition before no less than 30
minutes from the blasting.
Warning signals shall be placed or applied for persons near the blasting area at
least before 3 minutes from starting of each blasting operation, and contractor shall use
amplifiers or horns which can be heard clearly from a distance not less than three hundred
(300) meter.
Prior starting of any blasting operation contractor shall cover the rock proposed for
blasting with special covers or earth layer or any material that prevents scattering of
81
rocks. The control method of rock scattering shall be subject to the approval of the
Engineer.
1.
Experimental Blasting:
Prior starting of the blasting works, Contractor shall prepare an experimental
section with sufficient length not less than thirty (30) meter for the purpose of verifying
the accuracy of the prepared blasting plans. All drilling, charging of blasting holes with
the specified quantities and locations, and controlled blasting operations shall be
conducted according to the approved work plan. The blasting and monitoring consultant
shall prepare a complete report contains all the records of monitoring and the results of
blasting.
The work plan should be revised whenever the experimental blasting results not
achieve the specified requirements and goals, the Contractor in such case shall submit to
the Engineer a modified plan prepared by the specialized authority or the blasting
consultant.
2.
Pre-blasting meeting:
A pre-blasting meeting shall be held prior to the start of any drilling or blasting
activity. The purpose of the meeting shall be to review the blasting procedure and
vibration monitoring requirements and to facilitate coordination between all parties
involved. Individuals attending the pre-blasting meeting should include Contractors
representatives, the ministry, blasting consultant, the security authorities, any utility
affected by the blasting operation and any other personnel the engineer deems appropriate.
3.
Drilling:
Prior the starting of the drilling and blasting operations, loose materials,
disintegrated rocks and large boulders on the surface of the rock subjected to blasting,
within the limits approved in the drawings shall be removed to a distance not less than ten
(10) meter far away from the outside of the expected rocks splitting or cracking limits, or
as directed by the Engineer.
Drilling shall be conducted according to the work plan and the blasting study
prepared by the specialized agency and the blasting consultant, which is approved by the
Engineer and authorized agencies. It shall be conducted using the suitable equipments
capable of drilling the holes within the approved dimensions, depths and slopes.
Except otherwise indicated in the special specifications, hole diameters should not
exceed arrange of thirty to fifty (30-50) millimeters in urban areas and seventy five (75)
millimeters outside these areas.
However, when conducting rock excavation in utility areas using blasting, the hole
diameters should not exceed one sixty (1/60) of the approved excavation width.
The distance between the holes in the same blasting line shall not be more than
ninety (90) centimeter according to the specified slopes and depth of the blasting layer to
be removed, while the excavation angle shall be maintained in all the holes so that the
deviation between any two holes does not exceed three hundred (300) millimeter in ten
(10) meters. Holes shall not deviate from their specified locations by more than two
hundred twenty five (225) millimeter and when the number of the deviated holes is
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increased, the height of layer to be blasted and the drilling procedure should be modified
to comply with the approved limits providing that the height of the blasted layer at any
time does not exceed ten (10) meters. Lines of splitting shall be specified for any next
layer in such way that the inside offset distance shall be six hundred (600) millimeter from
the previous pre-split face.
No payment shall be made for any additional excavation located outside the
approved line limits fixed over the blasted or over the next layer.
4.
Blasting:
Prior placing of the charge each hole shall be inspected and tested to its entire
length to ascertain the possible presence of any obstructions and each hole shall be cleared
to the whole depth from obstacles. All necessary precautions shall be exercised so as to
prevent depresses from falling in to the holes prior to loading and so that the placing of
the charge does not cause caving of materials in to the walls of the holes before reaching
its bottom. Adjustments shall be made to the distances between blasting holes, distribution
of explosives quantities and types, procedure and sequence of blasting according splitting
properties, composition and origin of the rock, so as to obtain the required side slope of
the excavation.
Continuous column cartridge explosives specially manufactured for presplitting
shall be used for all presplitting and maximum diameter of the explosive used in presplit
holes shall not be greater than the half of the hole's diameter and it is permissible for the
bottom charge to be larger than the line charge over it.
The upper portion of all holes from the top most charge to the hole's collar, shall
be stemmed with granular materials.
When the charge of the controlled blasting is fired with the detonation cord the
cord shall extend to the full depth of each hole and when full or fractional dynamite
cartridges are used with detonating cord, the dynamite shall be securely affixed to the
cord.
All the space in each blast hole not occupied by the explosive charge in shall be
filled with stemming materials. Stemming materials shall be clean stone chips having
gradation as indicated in Table 5.3.2 or any approved aggregate materials.
Table 5.3.2: Gradation of stemming materials
Sieve size (millimeter)
9.5 (3/8 inch)
4.75 (No.4)
2.36 (No.8)
percentage by weight Passing

100
20 - 25
0-10
Controlled blasting operations shall be conducted according to the work plan and
blasting plan approved in the study or that which has been amended after the experimental
blasting. All holes of controlled blasting can be detonate simultaneously or delayed
providing the hole to hole delay is not more than twenty five (25) milliseconds. The
detonation of the different charges shall precede each other within the section by a
minimum of twenty five (25) milliseconds.
83
The line of the blast holes immediately adjacent to the presplitting slope holes will
be (1.2) meter from an on plane approximately parallel to the plane of the presplitting
slope holes.
Contractor with the approval of the Engineer and blasting consultant can use
blasting to trim the edges resulted by the controlled blasting, providing that the difference
in delay between the trim line and the nearest production blasting shall not be less than 25
millisecond and not greater than 75 millisecond.
The Engineer has the right to halt blasting operations whenever that blasting
results are not satisfactory or if the Contractor did not take the adequate precautions to
perform the works according to the approved plan and the Contractor has no right to
resume the work before the agreement of the Engineer.
5.
Monitoring report:
Following each blast, the Contractor shall submit the blasting results monitoring
report to the Engineer. In the event the seismic vibrations caused by the Contractors
operations approached or exceed the established limits, the Engineer shall require the
Contractor to modify the blasting plan. The blasting consultant should assist the
Contractor in the design of the blasting operations to eliminate the problems and avoid
liability claims.
Within 24 hours following each blasting operation, the Contractor shall submit to
the Engineer a report shows the details of the operation as shot, including the information
required in the approved basting log and results of the monitoring at each instruments
location including the maximum peak particle velocity, vibration chart records during
blasting marked with the date, time, site, location of the equipments and location of the
seismograph and name of the operator.
6.
Removing or stabilizing of materials:

Contractor shall remove or stabilize all unsuitable loose materials, rock fragments
and pieces even if theses were outside the approved blasting line and limits according to
the Engineer opinion after any blasting operation. It is not permissible to drill for the next
operation until the removal works are completed.
Rock excavation shall be finished so that it produce level, uniform and stable
surface that comply with the dimensions, slopes and levels indicated in the drawings and
contract documents.
5.3.8 Structural excavations
When the special specifications or contract documents require structural
excavations such excavations shall be performed according to dimensions indicated in the
drawings or special specifications.
Contract shall take all the arrangements and procedures required for supporting
the excavation sides against failure, using the supporting methods indicated in the
contract documents or as directed by the Engineer. The Contractor shall prepare with or
without the assistance of a specialized agency, soil study and submit the suitable method
of supporting of excavation and work plan which should include execution method and
types/numbers of the equipments used to perform the excavation and
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supporting works. Contractor has no right to commence the work before obtaining the
written approval for the soil reports, supporting solutions and work plan. No additional
payment shall be paid for the Contractor for preparing these reports or supporting study,
except otherwise stated clearly in the contract documents.
The excavation dimensions shall be adequate for carrying out the specified work,
fixing the frameworks for concrete, insulation, and backfill works, according to the
particular specifications and this specification. The dimensions of the excavation should
not be less than the external dimension for the structure plus 0.5 m or the distance
specified in the study, plans and special specifications whichever the greater, and the
contractor shall provide safely entrances and exits for equipments and labors.
Contractor shall maintain the bottom of the excavation in dry state until concrete
casting and insulation works are completed. This can be performed either with pumping
or making special barriers or any other method accepted by the Engineer.
Contractor prior the starting of the work shall verify the existence of utility or
foundations or structures that may be affected with the excavation works. All the required
protection precautions shall be taken to protect the public utility lines and structures or
their foundations. When contractor encounters such utilities or structures he shall stop the
work and inform the Engineer, and he has no right to restart the work before approval of
the required solutions and measures is released by the concerned authorities and the
Engineer.
5.3.9 Finishing requirements:
The dimensions of excavation should comply with the cross section shown on the
drawings and in the other contract documents or as approved in writing by the Engineer.
These dimensions shall be sufficient for construction of all roadways' elements,
sidewalks, islands and the other elements indicated in contract documents.
Contractor shall measure dimensions, levels and slope of the excavation through
of the cross sectional level taken with distances of not more than twenty (25) meters,
providing that the number of sections is no less than five (5) for each (2000) m2 of the
completed works and the spot points in each section shall not be less than five (5),
including all the distinguished points, and excavation toe points at natural ground.
The levels of the bottom of the excavation shall not differ from the specified levels
by more than one (1) centimeter in common excavation or two (2) centimeter for rock
excavation, providing that this does not lead to any reduction in the thickness of the next
structural layers.
Slopes of cut shall be finished within variation limits of fifteen (15) centimeters
for common excavation or twenty (20) centimeters for rock excavation from the limits
indicated in contract documents or approved in writing from the Engineer.
Contractor shall control the quality of excavation through performing all the
required measures which insure that the used materials, methods and the completed works
meet the quality requirements specified in these specifications and other contract
documents.
85
The Ministry has a right to insure the quality by verifying that the contractor has
performed the quality control procedures in the correct way either through direct
supervision of quality control activities or carrying out quality assurance procedures
neutrally on a sufficient number of representative samples to judge the level of
construction and to decide acceptance or rejection of the executed work on the basis
detailed in division (17) of this specifications except otherwise indicated in the special
specifications and other contract documents.
1.
Quality control:
Contractor shall control the quality of materials and executed works, and monitor,
record and analyze results, draw quality charts for critical properties and perform all
measurements.
Contractor shall provide the Engineer with copies of all the measurements, reports
tests results and he shall apply all the articles stated in item 17.1.1 of this specifications.
Quality control works shall include the critical properties indicated in Table (5.3.3).
2.
Quality assurance:
The Ministry has the right at any time to insure the quality of the materials and
completed works through carrying out or ordering others under its direct supervision to
carry out the necessary tests and measurements, and checking the completed work for
each or some quality control items specified in Table (5.3.3).
Ministry has the right to review contractors quality control records and to
compare these records statistically with the results obtained by the adopted quality
assurance procedure and as specified in division (17) of this specifications. Also it has the
right to inspect contractors equipments, his technical staff, and methods of measurement
and execution, to insure the efficiency of Contractors technical staff and equipments and
degree of compliance of his measurements and execution methods with the approved
requirements.
Quality assurance procedures shall include confirmation of the correctness of
reports using measurements at random location and visual inspection.
Works shall be accepted with the prices specified in the contract or with lower
prices or might be rejected according to the quality levels through applying the statistical
method specified in division (17) of this specifications except otherwise specified by the
5.3.11 Measurement:
The completed excavation works shall be measured in cubic meters within the
excavation limits indicated in the drawings or other contract documents or as approved by
the engineer. Computation should be made using end area method or any other method
approved by the Engineer. It is not permissible to carry out any measurements located
outside the specified limits for the purpose of payment. Unless otherwise indicated in the
special specifications measurements for the structural specifications shall be performed
according to the external limits of the structure and no volumes shall be measured out of
these limits.
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Table 5.3.3: Excavation works quality control procedures

Work
Excavated
materials
Properties
All properties
required for
the work in
which
excavated
materials
proposed to be
used
Classifications
Constructed
Works
Test method
Test methods required

for approval of
materials at source for
target work.
Location of
samples
In the site of
the
excavation.
Number of samples
for approving material
required in work item
in which excavation
material proposed to
be used
In the site of
the
excavation
One test at starting

compaction of the
bottom and one test
each week or when a
change in the
properties of the soil
in the bottom of the
excavation is noticed.
AASHTO
M-145
DensityMoisture
Relationship
AASHTO
T-180
Field density
at the bottom
of the
excavation
AASHT T-191/
T-3 10-01
or any approved nondestructive test
Number of samples
Requirements
According to
materials
requirements
for the work in
which
materials is
proposed to be
used.
Item 5.3.6
One tests every

2000m2 or each daily
works which is the
lesser.
At work site
levels of the
bottom
Excavation
Survey measurements
Side slopes
One cross-section for

every 2000 m2 of the
excavations bottom
surface or one crosssection every 25m
interval which is
lesser.
Item 5.3.8
5.3.12 Payment:
Payment shall be made for actual quantities of completed and technically accepted
work within the limits and dimensions approved, and according to the contract prices or
reduced prices as a result of application of quality assurance procedures as stated in the
contract documents.
Paid amounts are considered as a full compensation for execution and finishing of
all works including study and supporting works, provision and operation of the machines
and equipments, labor, tests and measurements, interests, revenues, fees and payments to
third parties and all requirements to carry out the works according to drawings, this
specifications, special specifications and other contract documents.
Payment shall be made according to, but not limited to, one or more of the items
listed in Table (5.3.4) without conflict with contract documents.
Item No.
5.3.1
5.3.2
5.3.3
Table No. (5.3.4): Excavation work items

Work item
Common excavations
Rock excavation
Structural excavation (can be classified to
common and rock excavations)
Unit
Cubic meter
Cubic meter
Cubic meter
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5.4
Fill works:
5.4.1 Description:
This section includes construction of the natural ground level or the surface on
which the embankment will be constructed and hauling, wetting, spreading, grading and
compacting of technically accepted materials in layers to construct road embankment and
structures backfill and execution of road bed preparation according to the dimensions,
levels and slopes indicated in the drawings, special specifications and these specifications
and to maintain surfaces and performed layers until next layers are constructed.
5.4.2 Road embankment
The road embankment in this specification is the fill that constructed over the
natural ground or existing surfaces and lies below the bottom level of subgrade layer and
the road embankment is consists of performing of technically acceptable materials,
wetting, spreading and compacting it in layers according to limits, dimensions, thickness,
levels and slopes shown in the plans, contract documents and this general specifications.
The embankment dimensions shall be adequate for executing the road and all its elements
such as sidewalks, islands, and other elements and shall comply with the dimensions
indicated in the drawings and other contract documents.
Prior to starting of road embankment and roadbed preparation works the contractor
shall finish all site preparation works indicated in section 5.1 from this section or special
specifications and contract documents. All these works shall be tested and handed over to
the engineer.
Contractor prior starting construction of road embankment shall prepare the
surface on which the embankment is to be constructed and carry out the required tests to
verify suitability and capability of the native soil to bear the road embankment and
subsequent works and prepare the surfaces and grading them to receive the embankment
works.
When test results show that roadbed soil in its current state is not suitable for to
resist the pressure from the road and all its elements and traffic loading over it like Sabkha
or soil susceptible to swelling and failure, such soil shall be treated with the suitable
method and to depth required, using one or more of the following methods:
1. Mixing of unsuitable materials with high quality materials to improve their
properties.
2. Removal of unsuitable materials and replacing them with suitable materials.
3. Use of rock material.
4. Plowing to the suitable depth and stabilized with lime or cement.
5. Using of Geotextile materials.
6. Use surcharge embankment and sand drain when period and embankment
height allow this.
The required treatment method and depth shall be according to the technical report
prepared by a specialized agency. Contractor shall follow the treatment method specified
in the special specification and plans or the results of that study which is the
88
strictest. In any case the contractor shall perform a technical report prepared by
specialized agency includes, soil properties, treatment method, construction phases and
the specifications. The cost of this study is considered included on the contract item prices
except otherwise indicated in contract documents.
When the embankment height from the bottom of subgrade layer to the natural
ground surface is less than 60 cm and the test results of uppermost 30 cm of the local soil
shows that it conform to requirement of embankment material the contractor shall plow,
wet, spread the native soil to a depth of 20 cm from the surface and compact it up to 95%
percent compaction of the maximum dry density and at a moisture content not differ by
more than 3% from the optimum moisture content specified by Proctor test AASHTO
T-180.
When embankment is constructed on existing asphalt or concrete surface the
contractor prior to starting of embankment shall ensure that these surfaces and the soil
below has enough capacity to resist the changes resulted from road construction and
traffic loads over it, and if the soil below the existing pavement layers is not suitable these
soil shall be treated or substituted as specified above and when it is suitable the existing
surface shall be prepared according to the required embankment thickness up to the
bottom of the Subgrade according to the following, except otherwise indicated in the
special specifications, according to embankment height:
1.
Less than (20) centimeter:

The existing surface shall be removed using methods mentioned in section (5-1) of
this division, then the embankment layers under the removed surface shall be plowed to a
depth not less than 15 cm, wetted, spread, leveled, and compacted to not less than 95% of
the maximum dry density according to the modified Proctor test method AASHTO T-180.
2.
Between twenty and forty (20 - 40) centimeters:

The existing surface is scarified to a level which allows the stability of the
embankment materials over the surface using grader or any other equipment indicated in
the special specifications or accepted by the Engineer.
3.
More than forty (40) centimeters: Embankment is

constructed directly over the existing surface.
5.4.2.2 Materials:
Materials used in road embankment construction, shall be capable to form a stable
and balanced road embankment within the approved dimensions and side slopes. Soil type
used in embankment construction shall not be less than A-4 according to AASHTO
M-145 classification with a maximum size not greater than 8 cm and it shall be free from
organic, plant, decay materials, metal waste and debris.
Materials used in embankment construction at water flooded areas or areas with
high water table level, shall be durable or non-plastic materials of type not less than A-2-4
according to AASHTO M 145 classification.
The used materials could be from excavation or hauled from barrow pit areas and the
contractor prior starting hauling operations of any material needed to be used
89
shall submit a technical report attached with tests results of the material to be used
showing it conformity with the general and special specifications and he is not allowed to
start material hauling and construction before the approval of the engineer per material
type and source.
The initial tests for embankment materials before transported to the site shall
include classification (AASHTO M 145), and Proctor tests (AASHTO T-180) method for
determining maximum dry density and optimum moisture content.
Whenever possible the materials excavated within the project limits shall be used
in the road embankment, if they were suitable and compatible with the embankment
specifications.
It is permissible to mix excavated materials with each other or with a good quality
borrow pit materials to improve its properties and modify its classification. It is not
permissible to mix embankment materials within the right of way, and it shall be mixed at
specified locations accepted by the Engineer. The mixed material shall be verified for its
consistency and conformity to specifications according to tests results carried on
representative samples and the number of tests required shall not be less than the number
of tests required in source as shown in Table 5.4.3.
The following materials are considered as unsuitable for embankment:
1.
2.
3.
4.
5.
Materials which can not be spread and compacted in layers to the required density
regardless of their classification.
Milling materials from old pavement layers (RAP) are considered not suitable for
embankment in areas specified for planting or for backfilling over public utilities
or beside structures.
Material affected by water, that contain a high content of sulfates or chlorides
exceed (0.5%) by weight of soil according to AASHTO T (290-29 1) test are
considered unsuitable as backfill materials for concrete structures.
Materials which contain organic materials of more than 2% according to
AASHTO T- 194 test.
Materials susceptible to volume changes in which the shrinkage limit is more than
10%, and of relative swelling more than 1.5% or of a liquid limit exceeds 40% or
of a plasticity index greater than 25 %.
Sand materials of type A-3 according to AASHTO M 145 classification may be

used in embankments construction providing that it should be confined and protected
from erosion by using cohesive materials-classified as A-4 or better- and compacted to the
required density. It is not permissible to use sand materials A-3 in uppermost 30 cm of the
embankment
It is possible to use rock materials in embankment construction at specified
locations, and it is not allowed to use rock in embankment in the upper thirty (30)
centimeter of the embankment or in structure backfill or in the sixty (60) centimeter over
or under culverts and under public utility.
It is not permissible to use rocks with maximum dimension exceeds hundred (100)
centimeter in any layer of the embankment. The used rock materials shall be
90
dense, solid and sound, not affected with water and suitable for spreading and compaction
according to the specifications. The gradation shall permits the gaps between large rocks
to be filled with small ones. The soil type used for filling and leveling the surface of rock
layers shall be of class A-2-4 or better except otherwise indicated in the special
specifications.
5.4.2.3 Borrow pits:
Contractor shall take the accepted borrow materials from the borrow bit specified
in the drawings or contract documents or any other proposed and approved sites. All
borrow pit locations shall be outside urban area and it is not allowed to take borrow
materials from areas adjacent to the road in the urban areas or from the area within the
inlet or outlet of drains or from the flat or depression areas. Borrowing activities shall not
lead to any change in the direction of water flow or to deforming the natural general
environmental view of the area.
Contractor shall, before starting of the works in the borrow pits, obtain a written
release from public or private owners of the proposed borrow locations and submit a
technical report to the Engineer shows the test results of representative samples determine
the degree of compliance with the specifications and availability of the sufficient
quantities. Contractor has no right to start taking materials before obtaining the acceptance
of the Engineer.
Contractor shall follow environmental conditions and standard requirements
during barrowing operations and undertake all the required arrangement to follow the
environmental requirement and conditions during borrowing activities and shall take the
required arrangements to lessen dust due to these activities.
At the end of the borrowing works, Contractor shall level and compact borrow pit
site in such way that it shall be in conformity with the surrounding environment and
topography. The cost of this work shall be included in the costs of other embankment
item.
5.4.2.4 Water:
Whenever possible, the best type of water available in the project area shall be
used for materials wetting and mixing. It is permissible to use salty water, sea water and
Sabkha water, providing that the total content of salts in the mixed soil not exceed one (1
%) percent more than the allowed content in the soil having contact with the structures.
The use of such soil should not lead to failure when exposed to floods or submersion. The
verification process shall be base on test results carried on representative soil samples
after wetting it by that water.
5.4.2.5 Equipments:
Contractor shall provide all the machines and equipments required for excavation,
loading, transporting, wetting, processing, leveling compacting and finishing the
embankment materials to the required density, and compaction and finishing of the side
slopes. These equipments shall be in sufficient numbers and types for the embankment
construction according to, contract documents and these specifications within the periods
approved in the time schedule. The Engineer has the right to require the replacement of
any incapable machine or equipment for the work
91
execution. These machines and equipments shall include for example bulldozers, trucks,
graders, water spray tanks and rollers.
5.4.2.6 Construction:
Contractor, prior materials hauling and starting construction of embankment shall
finish site preparation as indicated in section (5-1) of this Division and prepare the
roadbed and handing over these works. Contractor shall furnish the control devices
required for traffic regulation during construction activities. Contractor shall submit to the
Engineer materials test results, work plan, list of machines and equipments intended to be
use. It is not permissible for the Contractor to commence construction works without a
written acceptance from the Engineer about embankment materials, work plan, time
schedule, machines and equipments.
Contractor shall choose the construction method and types of equipments which
do not brought any damage to the structures or near by public utilities. Contractor shall be
responsible for any damages arise due his works.
When constructing an embankment regardless of its height in rolling natural
ground or adjacent to existing road sides with side sloped exceeds one vertical to four
horizontal the sloped section shall be cut in horizontal step shape with a width not less
than 1.5 meter which should be enough for movement of spreading equipments and it
shall be wetted and compacted to the required degree of compaction.
The depth of step shall not be less than 20 cm and the embankment in these areas
shall be constructed to the full width of all road and its elements in echelon forms in
layers with thickness not exceeding 20 cm and it shall be compacted up to required
compaction degree which comply with layer level, to satisfy the required bond between
embankment layers for the full width of the road and its elements and prevent the slippage
along the tangential line.
In case of slope construction as horizontal trenches, the end of these trenches shall
cut off in order to obtain the natural grade complaint with the tangential line for this slope,
and this requires making leveling using graders and compact their using steel rollers to get
the suitable compaction ratio. The material excavated from the step forming whenever
comply with specifications can be used in embankment construction and no measurement
shall be taken for step forming works for purpose of payment unless otherwise indicated
in the special specification.
Whenever an embankment construction located in soft areas not suitable for
equipments passing, and when embankment levels and adjacent area allow, Contractor
shall construct rock or aggregate layers which are not affected with water. The total
thickness of these layers shall not be more than the thickness required for movement of
construction equipments without considerable deformations. No additional payments shall
be paid for this item. The Engineer has the right, if necessary, to advise the Contractor to
use light machines and equipments.
When constructing an embankment below water level the materials used shal
composed of solid rock or aggregate which are not affected by water. Embankment
materials shall be spread in one layer for the full required width up to the approved level,
while the embankment part over water level shall be executed after filling the
92
voids between rocks with materials of smaller size and constructing a capping layer
separates the rock layer and other embankment layer. The thickness of this capping layer
shall not be less than thirty (30) centimeter, so that it prevents embankment material and
subsequent works material to penetrate in to the rock layer.
Contractor shall, except otherwise indicated in the special specifications, construct
the embankment according to the requirements indicated in the following paragraphs:
1.
Soil embankment:
Embankment are classified in these specifications as soil embankment when the
percentage by weight of rock pieces with maximum size more than fifteen (15) centimeter
exceeds 25 %.
Materials shall be transported, by trucks or any other equipment, in such a way
that prevents contamination on the used roads, and shall not cause any interruption to
public traffic. The loads of these trucks shall be discharged in the form of heap,
distributed on the surface over which the embankment shall be constructed, in such way
that it gives a thickness not more than the approved thickness for each layer.
It is possible to supply materials either dry or wet, and it is permissible to spread
materials heaps, initially, using bulldozer but the spreading for the full width shall be
only by graders or equivalent machines.
These materials shall be uniformly wetted during mixing, with adequate quantities
of water, until the moisture content shall be more than the optimum moisture, to
compensate for expected evaporation.
The thickness of any soil embankment layer before compaction shall not exceed
(20) centimeter for the upper embankment layers specified as 30 cm for local roads and
(60) cm for the arterial, collector, industrial area roads and parking areas for heavy trucks
below the bottom level of the subgrade layer. While the thickness of any layer which lie
below that levels before compaction shall not exceed twenty (30) centimeter, regardless of
material classification.
Compaction shall be made by rollers having weight and type suitable to the type of
material used, to achieve the required compaction level. The soil moisture content during
compaction shall not differ from the optimum moisture content specified by Modified
Proctor test (AASHTO T-180), by more than ( 2-3) percent.
Soil-aggregate materials which contain a small amount of clay shall be compacted
using vibratory rollers, but soft soil materials which contain a high percent of clay shall be
compacted using tire wheeled rollers or Sheep foot Rollers.
When constructing an embankment in confined areas for which large rollers can
not be used, the compaction equipments (including manually operated equipments) and
layer thickness shall be chosen to achieve the required density for the full layers depth.
Compaction shall continue until the required density is achieved. The required field
density shall be measured as a ratio from the maximum dry density obtained by
93
modified Proctor test (AASHTO T-1 80), for the full depth and width of the layer of the
road embankment and its elements. The field density shall not be less than 95% for
embankment layers which lie within the upper 30 cm specified for the roadbed in local
roads and 60 cm in collector and arterial roads measured from the bottom of subgrade
level, or 90% for embankment layers lie below the upper specified depth.
The density for each layer shall be determined by sand cone method according to
(AASHTO T- 191) test or the nuclear method according to AASHTO T 310-01 or any other
approved non-destructive test. The minimum number of readings when using nuclear or
non-destructive method at each location shall be not less than three (3) taken at each area,
and the average of these three readings is considered as the field density of that location.
The minimum lower limit of compaction is considered for determining payment
factor using statistical as the above mentioned compaction degrees minus 2%.
2.
Sand embankment:
Cohesion less sand materials which are classified as A-3 according to AASHTO
M-145 shall be not be used for construction of upper 30 cm of the road embankments. The
site conditions shall allow the using of such embankment materials according to these
specification and the special specifications.
Sand embankment sides shall be confined between cohesive materials classified as

A-4 or better in a form of steps, for their protection against erosion due to winds and
water during construction or pavement life. The width of these steps shall be sufficient to
accommodate construction equipments. It is possible, if the embankment side slopes were
not more than 25% and the site conditions allow provision of the required support for
compaction process, to increase the sand layers width initially, then cut to the final width,
and covering the side slopes/surface with cohesive protection layer having thickness not
less than thirty (30) centimeter and classified as A-2-4 or better. In this case it is
permissible to compact the protection layer in direction perpendicular to road center line.
It is permissible if it is possible to fulfill the required degree of compaction to
spread the sand embankment in layers with a thickness up to fifty (50) centimeter and
compaction is initiated using wet or dry methods using self propelled vibratory rollers or
trailed with chain bulldozers, the pressure vibratory rollers shall not be less than 14000
kg/vibration with a rate of hundred (100) vibrations per minute. It is preferable if the site
conditions allow that to transport sand materials by scraper.
Measuring of density and evaluation of compaction, in non-cohesive drained soil for
which compaction does not lead to forming a clear curve of moisture/density relationship,
shall be done by minimum index density test and specific gravity test for cohesion less
free drained soil according to ASTM D 4254 method or any other approved method and
the soil dryness and looseness shall be verified during the test.
The field density and moisture content in compacted sand soil is determined using
sand cone method according to (AASHTO T-191) test or the nuclear method (AASHTO
T-310-01) or any other approved nondestructive test.
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The test shall be done by removing the upper 25 cm from the constructed layer
and measuring the density of the other 25 cm remaining bottom layer of sand
embankment. When using nuclear method or any other nondestructive method three
reading shall be in each location shall be taken and the average of these reading is taken
as the density of that place
The compaction of sand embankment shall continue until the following minimum
limits of field density are achieved:
74% for the 30 centimeters lying within the roadbed.

70% for layers below that level.

Contractor shall determine the method of compaction and the number of passing
required by using the available compaction equipment on the basis of an experimental
section which may be a part of the project works. Values obtained shall be considered as a
basis for the work whenever that materials or equipments are not changed.
3.
Rock embankment
Embankment materials are classified as rock materials if the percent of rock sizes
which have a maximum dimension of more than fifteen (15) centimeter at a certain site
constitute more than 25% of the total volume of the materials used.
Rock embankment shall be limited to the parts shown on the drawings and in the
contract documents. It is not permissible to use rock embankment within the upper 30
centimeter of embankment below the Subgrade layer, and public utility lines areas or
backfill of structures or at areas where structures can be constructed later. But it can be
used if an aggregate embankment layer thickness of not less than 60 centimeter is
constructed to separates the rock embankment from the structures.
It is possible to use the following construction methods according to the percent of
rocks with maximum dimension exceeds fifteen (15) centimeter and the available
equipments:
1.
When the percent of rocks with maximum dimension exceeds fifteen (15)
centimeter is less than 25%, materials shall be spread in layers with a thickness
before compaction not exceed 20 centimeter and all the rocks with a maximum
dimension of more than 20 centimeter shall be removed. Spaces between large
rocks shall be filled with earth materials of type A-2-4 or better according to
AASHTO M-145.
2.
When the percent of rocks with maximum dimension exceed fifteen (15)
centimeter constitute more than 25%, or when the Engineer decides that the used
materials can not be spread in layers of 20 centimeter before compaction then
materials are spread in layers with a thickness does not exceed 11/3 of the maximum
size for the materials used or 100 cm whichever is lesser.
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Rock layers spreading shall be performed using heavy bulldozers in such a way
that insures a uniform distribution of the large rock pieces throughout the width, and small
pieces fill spaces between large pieces. All projected rocks shall be removed.
The thickness of rock embankment layers before compaction shall not exceed the
values indicated in Table 5.4.1 according to the available roller.
Table 5.4.1: Thickness of Rock Embankment layer according to available rollers
Maximum layer thickness before
compaction (Cm)
40
Minimum Weight of Roller

(kg)
2300-2900
60
2900-3 600
80
3600-4300
100
4300-5000
Compaction of rock layers shall be performed by using heavy rollers and it shall
continue until the resulting settlement between consecutive passes becomes negligible and
not exceeding one (1) cm or 1 % of the layer thickness under compaction which is the
lesser, it is possible to be use the following numbers of passes and type of equipment, if
the thickness of rock embankment not exceed thirty (30) centimeter:
1.
2.
3.
4.
Four passes when using steel roller which has a weight of not less than 45
tons.
Four passes when using vibratory rollers having a dynamic power of not less
than 180 KN, and vibration frequency not less than 16 HRZ.
Eight passes when using the common steel roller weigh about 20 tons.
Eight passes by vibratory rollers having a dynamic power for each vibration
130 K N and a vibration frequency not less than 16 HRZ.
The above number of passes shall be increased with the increase of the compacted
layer thickness by 4 additional passes to the number mentioned in (1 and 2) above, or
eight (8) additional passes to the numbers mentioned in (3 and 4) above, for each 15
centimeter increase in the compacted layer thickness .
Settlement Observation
When the roadbed (below rock embankment) is weak and susceptible to
settlement, Contractor shall observe the settlement during a period not less than one
month as follows:
1. After completion of the rock embankment to a uniform level surface, Contractor shall
measure the levels at five cross sections (minimum 5 points) at longitudinal interval
not more than 30 meters these measurements shall be linked with a reference control
point.
2. The measurements shall be taken at suitable time interval until the daily average
settlement does not exceed (0.5) mm for a period of one month. It is not allowed for
96
the Contractor to construct any subsequent layers (Subgrade, Subbase, aggregate base)
except after achieving these specific criteria.
5.4.3 Roadbed preparation:
The roadbed in these specifications is defined as the soil on which the treated or
untreated subgrade shall be constructed. The roadbed shall consist from all or part of the
following elements according to location and design level:
1.
2.
3.
4.
The natural ground level.

Bottom of the excavation.
The existing road surfaces.
The upper part of road embankment.
Unless otherwise indicated in the special specification or other contract documents

the roadbed shall be considered as the upper 30 cm for the local roads and 60 cm for
arterial and main collector roads and industrial areas roads and heavy trucks parking areas
measured from the bottom level of subgrade layer.
The roadbed preparation shall consists of all required works to bear adequately the
soil pressure fluctuation resulting from construction of the subsequent layers and traffic
loading, this works shall consist of all the areas that sustain the road and all its elements
like sidewalks and median within the dimensions, limits and levels indicated in the
drawings and other contract documents.
The road bed material shall be class A-4 or better according to AASHTO M-145
with California bearing ratio CBR grater than 3 % and swell under load equal to the
weight of layer constructed on it shall not be grater than 1 %.
The embankment lie within the road bed shall be constructed using the same
method used for the construction of the road embankment as indicated in paragraph
5.4.2.6 in this section with materials satisfying the required specified above. The material
shall be spread, and compacted in layers its thickness not exceeds 20 cm at moisture
content during compaction not differ by more than 2 % from the optimum and the
compaction shall continue until reaching a degree of compaction of 95 % of the maximum
dry density of the according to modified proctor test AASHTO T- 180.
When the roadbed extension is in the natural ground or in the existing road surface
less than or equal 15 cm and the native soil satisfy the requirements of the roadbed
material, the soil shall be pulverized up to a depth of 15 cm, wetting, re-spread and
compacted up to 95 % degree of compaction of the maximum dry density specified by the
modified proctor test. If the existing soil is not suitable it shall be treated using one of the
methods stated in paragraph 5.4.2.1.
5.4.4 Structural Backfill:
This work consists of backfill for structures such as culverts, retaining walls _ and
bridge abutments, including material requirements and method of construction.
5.4.4.1 Materials:
Materials used in structural backfill shall be selected materials of A-2-4 type or better and
its plasticity index shall not be more than 5 when tested according to
97
AASHTO T-90 test, which are not affected by water, free from organic materials and the
percent by weight of sulphates and carbonates is not more than 0.5 % according to
AASHTO T-(290-291). The backfill material shall not contain rock fragments having
maximum dimension of more than 8 centimeter.
The aggregate materials used in backfill for structures shall achieve the gradation
in Table (5.4.2) or any other gradation indicated in the special specifications.
Table 5.4.2: Gradation of materials used for structures backfill
Sieve size, mm (sieve No)
75 (3 inches)
19 (3/4 inch)
2.36 (No. 8)
0.075 (No. 200)
Percent Passing by weight, %

100
60-100
35-80
0-12
It is permissible, if approved by the Engineer, to use dune sands in structural

backfill providing that the Contractor shall proves the possibility of using these materials
in regard of its confinement, compaction and protection from erosion of water and winds
and should not cause any adverse effects on the structure.
Materials and construction methods for the upper part of backfill layers which are
similar in depth from the road surface to the pavement layers depth (Subgrade, Subbase,
and aggregate base) shall achieve the requirements indicated in these general
specifications and special specifications.
Before commencing construction of structural backfill, Contractor should
complete all concrete and insulation works, testing and handing over these structures.
Concrete strength, at the time of starting backfill works shall be adequate for resisting
loads and pressures arising from discharging, spreading, and compaction of backfill
materials. This strength should not be less than 80% of the design strength unless
otherwise lower percent is specified in the special specification and the time elapsed since
the casting of concrete should not be less than 72 hours. Contractor shall obtain a written
permission from the Engineer for starting backfill works.
Contractor shall select construction method and the types of equipments capable of
executing backfill works without inflict any damage to the structures, according to the
requirements of these specifications and the special specifications.
Contractor shall be responsible for any damage arising from construction method
or equipments movement and he shall carry out on his expense all repairs including
re-construction of the damaged structures.
Backfill shall be executed according to the dimensions and thickness indicated in
the drawings, contract documents and special specifications or these general
specifications.
Backfill materials shall be spread in layers with thickness suits the used compaction
equipment and should not exceed 15 cm. Contractor shall use light
98
compaction equipments including manually operated in areas where rollers do not reach,
to prevent damage to structures. It is preferable, to construct the backfill parallel at the
two sides of the structure. The compaction of backfill martial shall continue until field
density reaches the compaction level required in the special specifications or 95% of the
maximum dry density of modified Proctor test whichever is greater. The field density test
should be carried out as indicated in paragraph (5.4.3.5) of this section. The minimum
acceptable limit of compaction level for determining payment factor by the statistical
method is the compaction level above minus 2%.
5.4.5 Compaction Experimental Sections:
Contractor, when required by the special specifications or ordered by the Engineer
shall construct a test section before commencing the execution of road embankment using
the materials, construction method, machines and equipments approved in the work plan.
The length of test section shall not be less than 200 meters and it may be a part of the
project. The construction of test section aims to verifying the possibility of maintaining
the required specifications, assessing the suitable moisture content for compaction,
number of coverage and the resulting density. The Contractor granted permission for the
commencement of construction works when test results are technically acceptable,
otherwise the necessary modification for the work plan or equipment should be made.
In the latter case Contractor shall remove the test section or reconstruct it until the
achievement of the required specifications. The Engineer has the right to require
construction of any other test sections whenever he notices a significant change in the test
results or in the method and equipment of the construction.
5.4.6 Maintaining of Embankment:
Contractor shall take all the necessary requirements and arrangements for the
protection of the constructed embankment from damage due to storm water or any other
reasons. At the end of each working day, Contractor shall finish the leveling, compaction
and formation of the last layer according to the slopes that permits water drainage and
prevent water collection on the surface. And construct temporary drain for water drainage
from embankment when necessary.
Contractor shall, on his expense, repair all damaged parts results from his failure
to maintain the constructed works, and he has no right to claim any additional payment.
Contractor shall remove the works executed by using of unacceptable materials
and replace them with other suitable materials and re-construction the embankment
according to the special specifications and this specification without any additional
payments. Contractor has the right to commence construction of the subsequent layers
before carrying out handing over of embankment works.
The executed works shall be compatible with the dimensions and levels indicated
on the drawings and specified levels staked by the Engineer. Contractor shall execute the
works within the following tolerance limits:
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- Side Slopes:
Road embankment side slopes shall be finished according to the lines, dimensions
and slopes shown on the drawings or approved by the Engineer and should not deviate
from specified values by more than:
1. Ten (10) centimeters for the upper meter of the embankment.
2. Twenty (20) centimeters for the remaining embankment part.
The side slopes for island and middle trenches shall be finished with 1 vertical to 6
horizontal (1:6) in such way that it should not deviate in the bottom of the embankment
from the slope indicated on the drawings or specified for the stakes by more than one
centimeter. And the levels of drainage trench should not deviate from the approved level
by more than 5 centimeters.
-Final Surface:
Contractor shall carry out the survey works for dimensions and levels of the final
surface of the embankment in cross sections of twenty five (25) meters intervals.
Dimensions and levels shall be measured at least in 5 points including toe of embankment,
these levels considered as a basis for calculating quantities after the approval of the
Engineer.
Embankment surface level shall be finished so that it does not exceed the level
indicated in the drawings and approved by the Engineer by more than 2 centimeters or be
less than 4 centimeters. Any shortage in the embankment level at isolated areas shall be
compensated with materials from the next layer materials during its execution.
5.4.8 Works Acceptances:
Contractor shall apply quality control works using all required procedures to
insure that materials, construction methods and e finished works are in compliance with
quality requirements indicated in these specifications and other contract documents.
The Ministry has the right to carried out the required quality control either,
through direct supervision upon quality control procedure or applying neutrally quality
assurance procedures on representative samples with adequate numbers to accept or reject
constructed works according to section 17 of this specifications except otherwise
indicated in the specifications and other contract documents.
1.
Quality control:
Contractor shall control the quality of materials and executed works, and monitor,
measurements indicated in Table (5.4.3). Contractor shall provide the Engineer with
copies of all the measurements, reports tests results and he shall apply all the requirements
stated in item 17.1.1 of these specifications.
2.
Quality Assurance:
The Ministry has the right at any time to insure the quality of the materials and
completed work through carrying out or ordering others under its direct supervision to
carry out the necessary tests and measurements, and checking the completed work for
each or some quality control items specified in Table (5.4.3).
compare these records statistically with the results obtained by the adopted quality
assurance procedure and as specified in division 17 of these specifications. Also it has the
right to inspect contractors equipments, his technical staff, and methods of
100
measurement and execution, to insure the efficiency of Contractors technical staff and
equipments and degree of compliance of his measurements and construction technique
with the approved requirements.
5.4.9 Measurement:
Embankment quantities shall be measured in cubic meter. Actual and
acceptable embankment quantities should be calculated using the average end
area method except otherwise indicated in the special specification and contract
documents. No measurements for payment shall be taken for the purpose of
payment for the works performed outside the areas approved in the drawings or by
the Engineer.
Embankment quantities should not include any quantities for which payment is
included in other work items such as preparation of roadbed, Subgrade, embankment in
extra excavation areas and replacement of soil in road foundation, structural backfill and
embankment around utilities. Quantities of these work items shall be calculated and paid
according to the contract documents.
Table 5.4.3: Quality Control Procedure for Embankment works
Work
Properties
Soil
classifications
Test method
Location
of sample
3 tests on different
samples from each
source, when source
is approved or
M-145
AASHT
Raw
materials
Moisture
Density
relationship
Classifications
Materials
in use
AASHTO T- 180
ASTM D 4254
At source
AASHTO M-145
MoistureDensity
relationship
ASHTO T 180
ASTM D 4254
on site
Constructed
works
Sampling frequency
AASHT T-191,
Degree of AASHTO T3 10-01
Compaction
or any approved
non-destructive test
levels and
dimensions of
Survey
works
measurements
Side slopes
changed or a change
is noticed in material
properties or
constructed works
One test at the start
of hauling the
materials then, one
test each week or
5000 m.3 of the
supplied materials
whichever is lesser,
or when a change is
noticed in the
executed works or
when the source is
changed.
A test every 2000 m 2
or every daily works
whichever is lesser,
for each layer.
Measuring 5 crosssections each work
day or for every 2000
m2 whichever is
lesser
Requirements
Items
5.4.2.2
5.4.3
5.4.4.1
Items
5.4.2.6
5.4.4.2
Items
5.4.4.2
5.4..3
5.4.4.1
Items
5426
5.4.4.2
Items
5.4.2.6
5.4.4.2
section
5.4.7
101
5.4.10 Payment:
Payment shall be made for the actually executed and technically accepted works
within the approved limits and dimensions according to contract prices or lowered prices
due to applying of quality assurance procedure as indicated in the contract documents.
Paid amounts are considered as a full compensation for preparing, supplying,
mixing, hauling, spreading, compacting of materials and finishing the works, provision
and operation of machines, equipments, labor and tests, measures and benefits, revenues,
fees, third party payment and all requirements to execute the works according to
drawings, special and general specifications,.
Payment will be made according to one or more of the items indicated in Table
(5.4.4) as an example but not limited to if not contradict with the contract documents:
Table 5.4.4: Fill works Items
Item No.
5.4.1
5.4.2
5.4.3
5.5
Payment item
Roadbed preparation
Embankment works
Structures backfill
Payment unit
m2
m3
m3
Subgrade:
5.5.1 Description:
This section consists of materials requirements and works required for the
Subgrade construction. The Subgrade layer is the layer that lies directly under the Subbase
or aggregate base or asphalt layers.
This section includes the following subsection according to sub grade classification:
Untreated Subgrade
Lime-treated Subgrade
Cement-treated Subgrade
Prior starting of Subgrade construction, Contractor shall insure the finishing and
handing over of site preparation, excavation, fill, roadbed preparation, public utilities
works and structures' backfill, according to the approved specifications.
The Subgrade shall be constructed on the prepared surfaces according to the
requirements of the roadbed preparation, and the bottom of excavation which are
indicated in sections (5.3 and 5.4) of this division.
5.5.2 Untreated Subgrade:
5.5.2.1 Description:
This subsection includes requirements and methods for Subgrade construction
using available materials which conform to the requirements of the special specifications
and these general specifications without any additions to improve their properties. It is
permissible to use the natural soil available at site from the excavated
102
materials or brought from borrow pits. The works include supply of materials conforms to
these general specifications and special specifications, spreading and compacting them in
layers according to the thickness, levels and slopes shown on the drawings and other
contract documents, reducing dust and maintaining the Subgrade up to the time of laying
the subsequent layers.
5.5.2.2 Materials:
The materials used in untreated Subgrade construction shall be in conformity with
the requirements indicated in the special specifications or these general specifications.
The used materials shall not be less than (A-2-4) according to AASHTO M-145
classification or the type indicated in the special specifications. When the subsequent
layers are asphalt or when executing the Subgrade in areas with high water table shall not
be less than (A-1-b). The California Baring Ratio (CBR) for the soaked sample used in the
Subgrade shall not be less than 25 % and the thickness shall not be less than 30
centimeters.
Whenever excavated materials shall be used, , when they are suitable or it is
possible to improve them by mixing with other soil materials to conform to the
requirements for the untreated Subgrade materials in these general specifications or
special specifications providing that the decision shall be taken according to the test
results of representative samples.
When the excavated materials are not sufficient or do not achieve the required
specifications, Contractor shall choose an other borrow pits and obtain the necessary
release for using them and he has to clear and arrange these locations after completion of
borrow works according to the conditions indicated in section (5.4) Embankment
Works of this division.
Contractor prior starting hauling of the materials from the source/sources by at
least two weeks from the date expected, shall submit a technical report shows the
proposed material sources, the approximate quantities and the test results on
representative samples for each source. These tests shall include:
1.
2.
3.
Classification according to (AASHTO M-145).

Moisture-Density relationship according to (AASHTO T- 180)
California Baring Ratio (CBR) for soaked materials according to (ASTM
D-1883) or any other strength index required by the special specifications.
Contractor shall obtain the Engineers written approval for the materials and
sources prior starting hauling of the materials. All the hauled materials and the
constructed works before obtaining the Engineers approval should be rejected, removed
and transported without any additional payment. The Engineers approval for the source is
considered as preliminary approval of the material and does not release Contractor from
the responsibility for the quality of the materials and constructed works.
Waters used in mixing the Subgrade materials shall be clean, free from any
impurities and it should not increase the total percent of salts in the soil to more than
(1)%.
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5.5.2.3 Equipments:
Contractor shall provide the sufficient number of necessary equipments required for
the Subgrade construction, and the qualified staff for operating and managing these
equipments, within the specified times in the approved work plan and time schedule and
according to the drawings, special specifications and these general specifications All the
equipments shall be in good condition and of types and capabilities suitable to type of
work and operation conditions and shall includes:
1.
Excavation and transportation equipments
2.
Spreading and leveling equipments.
3.
Tankers provided with water sprayers.
4.
Rollers with types and weights suitable for materials used and layers
thickness.
All the used equipments shall conform to the environmental, noise and vibration
requirements implemented in urban areas and their movements should not lead to any
damage to the near by buildings, structures or utilities. Contractor shall be responsible for
any damages resulting from using unsuitable construction methods, machines and
equipments and he shall repair in his expense all the damaged properties.
Contractor, prior to starting of the Subgrade construction by not less than15 days,
shall submit a report to the Engineer includes the work plan and time schedule, a
description for the equipments includes, their numbers, technical conditions and
capabilities to construct the works according to the plan and time schedule.
Contractor shall prepare a traffic control plan and shall take all the required
measures for the protection of pedestrians and the neighborhood.
The approved materials shall be transported through approved roads network
without traffic interruption, and transportation shall be done using trucks having a closed
metal covered boxes to prevent dust proliferation and roads contamination.
Vehicles loads shall be deposited on the prepared surfaces and distributed almost
equally to give the required Subgrade layer's thickness. The deposited materials shall be
spread using bulldozers and leveled by graders. The layer's thickness after compaction
shall not more than 15 centimeters. The untreated Subgrade with thickness exceeds 20
centimeters shall be constructed in two equal layers.
Materials can be supplied either dry or wet conditions. Water shall be added to the
soil and mixed until the moisture content not differ by more than 2% from the specified
optimum moisture content determined using modified Proctor test for same material.
When it is found that moisture content is higher than the limits the soil shall be pulverized
and dried until the moisture content becomes within the required limits for compaction.
Immediately after completion of spreading, wetting and leveling of the materials in
a uniform surface with the required thickness, slopes and cross-sections indicated in the
drawings or other contract documents, compaction shall be starting using the suitable
equipments like static or vibratory steel rollers or pneumatic tiered rollers. It is not
allowed to use sheep foot rollers for aggregate layer compaction. Compaction shall
continue until the ratio of field density determined by AASHTO T- 191 test or AASHTO
104
T-310-01 test, to maximum dry density determined by modified Proctor Test AASHTO T180, is not less than 95% if the subsequent layers are aggregate layers and not less than
100 % if the subsequent layers are asphalt layers.
The field density shall be measured using sand cone method according to
AASHTO T-191 or nuclear method AASHTO T-310-01 or any other non-destructive
method. However, when the nuclear method is used measuring shall be done in 3 different
locations for each location. The average of the three readings is considered as the field
density of that location.
The minimum acceptable limit for the degree of compaction for determining
payment factor using statistical method is the percent of compaction specified minus 2%.
5.5.2.5 Maintaining of the Constructed layers:
Contractor shall take all the required measures and precautions to protect and
maintain the uniformity of the constructed Subgrade layers, their surfaces and slopes from
any damages and shall keep the layers within the required compaction level until the
laying of the subsequent layer.
At the end of each daily work, Contractor shall form and compact the Subgrade to
a uniform cross-section suitable for water drainage, and take the required arrangements to
drain waters and prevention of their collection on the road surface. And he shall protect
the neighboring buildings and structures from any waters damage.
The Contractor shall be responsible for maintaining the stability of all the
Subgrade layers and replace all the sections removed or eroded by water and/or wind as
directed by the Engineer.
It is not allowed to leave the constructed Subgrade layer exposed for a period
exceeds two weeks after being tested and accepted by the Engineer. If this occurred,
Contractor prior to construct the next layers shall perform the required tests to verify
moisture and percent of compaction and carry out the necessary repair works on his own
expense. Contractor shall wet the Subgrade surface with water in the times and with the
quantities specified as directed by the Engineer, before the construction of the subsequent
layers.
The Engineer has the authority to stop all the other works in the project until the
Contractor carries out the proper maintenance for the constructed and accepted Subgrade.
And he has the absolute power to re-test and evaluate the Subgrade layer.
5.5.2.6 Finishing requirements:
The construction of untreated Subgrade layer shall be performed with the
conformity of dimensions, slopes and thickness indicated in the drawings and special
specifications. The variation between the executed layer thickness and the required
thickness shall not exceed 2 centimeters or 10 % of the approved thickness whichever is
lesser.
The levels of finished layer's surface shall not differ from the specified levels by more
than 10 millimeters if the subsequent layer was an asphalt layer or 20 millimeters
105
if the subsequent layer an aggregate layer. Cross-sections levels shall be taken at five
points in 25 meters interval, providing that the number of the sections is not less than 5
each 2000 square meters of the executed layer.
Unevenness shall be verified visually and by measuring with a straight edge of 3
meters long at five locations. The clearance between the straight edge bottom and the
layer's surface at any two neighbored support points shall not exceed 20 mm.
5.5.2.7 Works Acceptance:
Contractor shall apply the quality control for untreated Subgrade works and
performing all the required measures to insure that the used materials, construction
methods and the final works conform to the quality requirements stated in these general
specifications and the other contract documents.
The Ministry shall apply quality assurance for the production and verifying the
Contractor quality control procedures either by direct supervision of the constructed layer
or by carrying out neutrally and independent quality assurance procedures on sufficient
numbers of representative samples to judge the construction level and to accept or reject
the executed works, according to the principles stated in division 17 of these general
specifications except otherwise indicated in the particular specifications and other contract
documents.
1.
Quality control:
Contractor shall perform quality control for materials and constructed works and
he shall monitor records and analyze the results and draw quality charts for critical
properties. Contractor shall carry out all the tests and measurements indicated in Table
5.5.2.1.
Contractor shall provide the Engineer with copies of tests promptly and apply all
the items indicated in item 17.1.1 of these general specifications.
2.
Quality Assurance:
The Ministry has the right, to apply or ordering performing of quality assurance
for the materials and constructed works, under its direct supervision, and it has the right to
test the materials and inspect the constructed work for all or some of quality control items
specified in Table 5.5.2.1.
The Ministry has the right to review Contractors quality control records and to
compare those records statistically with the results of the applied quality assurance
procedures as specified in Division 17 of these general specifications. And inspect
Contractors laboratory, equipments and technical staff to insure the efficiency of
Contractors staff and inspection, testing and construction methods whether they are
conforming to the approved testing and construction method.
5.5.2.8 Measurement:
The un-treated Subgrade shall be measured in cubic meters or according to special
specifications, for the executed and technically acceptable works within dimensions and
levels shown on the drawings or according to the engineer's instructions.
No measuring shall be made for the purpose of payment for the works outside the
limits shown on the drawings, special specifications or specified by the Engineer.
106
5.5.2.9 Payment:
Payment shall be paid for actually and technically accepted constructed works and
quantities within the approved limits and dimensions according to contract unit prices or
reduced prices as a result of applying quality assurance procedures if stated in the contract
documents.
The paid amounts are considered as a full compensation for material excavation,
transporting, wetting, mixing, compacting and finishing of the work, in addition to the
provision and operation of machines, equipments, labor, tests, measurements, benefits,
revenues, fees, third party payments and all requirements to construct the works according
to drawings, special and general specifications,.
Payment shall be made according to one or more of the items indicated in Table
(5.5.2.2) if not contradict with contract documents:
Table 5.5.2.1: Quality control procedures for untreated Subgrade
Work
Raw
materials
Materials
at use
Properties
Soil
classification
CBR
Test method
Sampling frequency
AASHTO M-145
ASTM D 1883
Densitymoisture
relationship
AASHTO T-180
Classification
AASHTO M-145
Moisturedensity
AASHTO T-180
Relationship
Degree of
AASHTO T-191,
Compaction AASHTO T-3 10-01
Thickness
Core samples
Dimensions
and levels
Location
of samples
At source
Three tests on different

samples from each source,
when source is approved or
changed, or a change in the
materials or constructed
works is noticed.
5522
At project
site
Three tests at starting of

production, test for each
produced 1000 cubic meter
or when a change is noticed
in the properties of the
executed works
5.5.2.2
A test every 2000 square

meters of each constructed
layer or each work day
5.5.2.4
Measuring every 2000

meters or each work day
5.5.2.4,
5.5.2.6
Survey measures
At project
site
Constructed
works
Cross section every 25

meters or 5 sections every
Surface
smoothness
Item No.
5.5.2.1
Straight edge
Requirements
2000 square meters

whichever is greater
5 measurements at different
sites each 2000 square
meter or between the cross
sections for measuring
levels and dimensions.
5526
5.5.2.6
Table 5.5.2.2: Untreated Subgrade Works Items

Work type
Unit
untreated Subgrade
m3
107
5.5.3 Lime Treated Subgrade:

This subsection consists of furnishing, mixing spreading, leveling, and compacting
the materials of lime treated Subgrade to the required compaction degree according to the
thickness, levels and dimensions shown on the drawings and according to the special
specifications and these general specifications. It also includes construction method and
protection work for constructed layer until the laying of the next layer.
5.5.3.2 Materials:
1.
Soil:
Soil materials can be native soil of the site or other barrow materials brought from
outside the site. The soils wherever its source shall, meet the following requirements:
1.
2.
3.
4.
Positively response to the lime treatment and improved with lime.

Free from organic materials and all other undesired materials.
Clay lumps shall be pulverized to a degree that allows it to pass through the
mixing machine and permits it's mixing with lime.
The percentage of Sulphates shall not exceed 1%.
The applicability of the soil to be treated with lime shall be decided on the bases of
technical study prepared by specialized agency in which a comparison between test results
of untreated and treated soils for the target properties shall be made. The soil is considered
suitable for lime treatment when its plasticity index is equal to or grater than 20 %. The
treatment is considered effective if results of average plasticity index of five (5) soil
samples after the lime treatment using the same percent of lime is reduced by not less than
35 % compared with the average plasticity test result for five (5) untreated samples from
the same soil. The suitability of the soil for lime treatment shall be verified on the basis of
Appendix (A) of ASTM M 2163.
Prior starting the treatment process, the percentage of Sulphates shall be
determined in the soil to be treated by using the approved standard methods. In case the
results of tests showed the existence of soluble Sulphates in the soil then, the treatment
process shall be done according to mellow time indicated in Table (5.5.3.1) below.
Table No. 5.5.3.1: Mellow Time according to Sulphate Percent *
Percent of Sulphates %
0.0-0.3
0.3-0.5
0.5-0.8
0.8-1
Note*:
Suggested mellow time

No need for additional time
One day
Two to three days
Double treatment
When the sulphates percentage exceeds (0.8) percent reference shall be made to the Engineer
and the design authority to obtain more construction requirements.
2. Double treatment shall be performed as follows; by adding half of the specified hydrated lime
percentage and mixing it with the soil and wetting for 5 days at moisture content higher than the
optimum moisture content and the other half of liquid hydrated lime is added and mixed and
compaction.
108
2.
Lime:
Lime used in treatment shall be hydrated lime or quick commercial lime that
conforms to the requirements of (ASTM C 51) designation produced in approved factories
and it shall be free from lumps and achieve the gradation requirements indicated in Table
(5.5.3.2).
Table No. 5.5.3.2: Lime Gradation
Percent
Passing %
Sieve size
Hydrated lime
Quick lime
19 mm (3/4 inch)
100
100
0.63 mm (No. 30)
95-100
0.15 mm (No. 100)
30-100
0.075 mm (No. 200)
75-100
Dry sieve analysis
(ASTM C 110)
Test method
(ASTM C 136)
Calcium Hydroxide percentage in the hydrated lime shall not be less than 85 %.
And the quick lime shall contain not less than 94 % of Calcium and Magnesium oxide
(CaO+MgO) and not less than 90% total available Calcium oxide (CaO) as determined by
(ASTM C 25) test.
It is preferable to use hydrated lime and it is not permissible using of quick lime in
urban areas without a special permission and Contractor shall be responsible when
allowed to use quick lime to provide the required protection measures. And he is
responsible for any damages, which may inflict individuals or properties as a result for
using this type of lime.
Contractor can supply the lime specified for use from more than one approved
source providing that the materials of each source shall be used separately. Also
Contractor, when supplying lime, shall submit a guarantee certificate endorsed from the
manufacturer with production date, validity date, storing and using method.
The lime should be stored in specific and moisture- isolated loose and dry places until
time of using in dry state to allow easy distribution and it shall be free from lumps.
3.
Water:
The water used in mixing shall be free from harmful materials such as oils, acids,
alkaline, clay, silt and organic materials. It shall not contain more than 1000 unit per
million of chloride (Cl) or sulphates like (So4). If required by the special specifications or
the Engineer, water shall be tested to verify its suitability according to (AASHTO T-26)
test.
4.
Asphalt curing membrane:

Except otherwise the special specifications indicates, the asphalt material used as a
curing membrane shall be from asphalt emulsions type (SS-1h or CSS-1h) and shall achieve
the requirements specified in Division 7 of these general
specifications.
5.5.3.3 Equipments:
Contractor shall submit to the Engineer with the design job mix formula a list of the
equipments he intends to use. These equipments shall be capable of executing the
109
works according to the work plan, time schedule and shall be able to produce and execute
a subgrade layer conforming to the requirements stipulated in the special specifications or
these general specifications. This list shall include, for example, graders with accessories
required for pulverizing and plowing earth materials, lime distributor, mixing and
spreading equipments, compactor and water distributor, asphalt distributor and any other
equipment required for construction the work in accordance with the special
specifications and work plan.
Pulverizing and plowing equipments shall be capable of plowing soil to the
required depth and pulverizing it to the required sizes.
Also, the lime distributor shall be capable of distributing lime in a uniform way
throughout the width of the area to be treated and equipped with the quantity control
systems which provide controlling of distributed quantity of lime according to the ratio
identified in the approved job mix formula and it shall be provided with equipments
preventing the lime scattering during its distribution. The sides of lime distributors shall
be covered with a special cover to prevent scattering.
The mixing equipments shall be self propelled and equipped with a mobile mixing
chamber or a mixer equipped with one or more wide mixing screws and they shall be
capable of picking the soil and mixing it with lime and water and spread in a uniform and
a regularly way to the depths indicated on the drawings or the special specifications.
The grading machines used shall be capable of spreading and leveling materials
according to the approved slopes and levels. Water and asphalt distributors shall be
susceptible to calibration and capable of spraying materials with the required ratio.
Compaction machines shall be capable of compacting layers to the compaction
degrees indicated for the full depth of the layer. They may include smooth wheel
pneumatic rollers and vibratory rollers and it is preferable to use grid or foot ship rollers
for breaking the large particles and clay lumps.
Contractor may use one machine which is capable of carrying out a group of the
works required such as plowing, pulverization and applying lime and water in the
approved ratios and depths providing that the Contractor proves their capability to
produce the work as required in the specifications.
The Engineer shall review and approve proposed Contractor's equipment list or
requires more additional equipments prior or during construction if the executed work is
not in conformity with the specified requirements.
5.5.3.4 Job Mix Design Formula:
1.
Mix Design Requirements:
The lime treated Subgrade layer materials shall achieve the following quality
requirements, except otherwise special specifications and the approved technical report
prepared by the specialized agency, indicate different requirements:
~ Swell
potential shall not exceed 1% when the treated material is soaked with water and
it is allowed to swell according to ASTM D 3668.
110
The unconfined compressive strength for cylindrical samples shall not be less than
one (1) mega Pascal when tested according to ASTM D 5102 after the 28 days
curing period.
The percent of hydrated lime shall not be less than 5% of the dry weight of soil.
2.
Acceptance procedures of Job Mixture formula:

Contractor, prior starting lime treated Subgrade works by 30 days, shall submit to
the Engineer a technical report prepared by an approved specialized agency shows
material proportions, construction, wetting and curing method. The report shall be based
on actual test results on the soil, lime and water specified for use in producing the lime
treated Subgrade.
As a minimum, the report shall include the following information:
1.
2.
3.
4.
5.
Type and percent of lime to be used.

Classification of soil before and after treatment.
Maximum density for the treated soil.
Optimum moisture content during mixing and compaction.
Strength index such as (CBR) or unconfined compression test for soil before and
after treatment and the value of free expansive as indicated in the special
specifications. Also the report must clarify the following :
a. Construction method including lime application and curing method.
b. Any special requirements for mixing, curing, compaction and testing.
c. List for machines and equipments proposed for construction.
The Engineer shall review the design job mix formula and verify if it contains all
the required information. In case the information was not complete, the J.M.F should be
returned to the Contractor within 7 days, for completing the lacking information and
resubmit the design job formula. However, if the information were complete the Engineer
shall check and insure whether the treated soil achieves the requirements. Indicated in the
special specifications. If it doesnt achieve those requirements the report should be rejected
and the Contractor shall submit a new job formula. But if the mixture achieves the
requirements the Engineer shall issue a written acceptance for the job mix formula which
is considered only as preliminary. The final acceptance shall be issued on the test results
of field samples during construction.
5.5.3.5 Experimental section:
Contractor shall, when special specifications indicate that or the Engineer requires,
construct an experimental section at least 200 meters long for the purpose of verifying the
possibility to construct the works according to the job formula, construction method and
the proposed machines and equipments. Contractor shall perform all the required tests on
the executed layer in the experimental section and to submit a copy of their results to the
Engineer for evaluation. If the Engineer found that, during construction or from the test
results, there is a need for carrying out some modifications in the work plan or
replacement of some equipments and machines or modifying the mixture to fulfill
specification requirements, he shall conveys his written comments to the Contractor. The
Contractor shall satisfy all the comments and required modifications including
reconstruction of the rejected executed layer. However, if the experimental section results
were conformed to the requirements then the design job formula, work plan, percent of
lime distribution, water content and methods of
111
distribution, leveling and compaction should be approved. The Contractor shall abide by
with the approved construction method from experimental section up to the finishing of
works, except otherwise a change is made in the design job formula or in the work plan.
Contractor shall perform the treatment works according to the drawings, special
specifications, and design job formula and he shall finish the treated layer according to the
approved dimensions, levels, slopes and thickness and approved curing method. The
Engineers acceptance for the job formula, equipment list and experimental section
results, does not release the Contractor from his full responsibility for execution the work
according to the drawings and special specifications.
Construction shall be carried out according to the constructed experimental section
results using the approved design job mix formula, machines and equipments, percent of
lime and water, mixing, spreading, compaction and approved methods of protection.
1.
Plowing and Pulverizing of Soil:

The soil materials proposed for lime treatment shall be plowed and pulverized. All
rock materials with a size of more than 5 cm, deleterious and organic materials should be
removed. At the end of this phase a loose material, free from any lumps and particles size
exceed 5 centimeter shall be obtained, so that it completely pass through the mixing
machine.
Plowing and pulverizing shall be performed to a depth equal to the layers
thickness shown on the drawings and special specifications after mixing with lime,
applying of water, leveling and compaction. The resulting thickness shall not be less than
the specified thickness by more than two (2) centimeters.
When using mixer which requires material's collection before spreading, these
materials shall be collected in heaps of suitable sizes suiting the power of mixer obtains a
consistent mixture. Otherwise the materials shall be formed according to the approved
dimensions, thickness and required cross sections.
When the Subgrade thickness is more than thirty (30) centimeters, treatment shall
be performed in two layers of approximately equal thickness. so that the upper layer shall
be on site then it will be removed and stored in such a way that maintains its moisture
content. The bottom layer shall be treated, maintained and compacted at site then the
stored treated materials shall be spread, mixed and compacted over the finished treated
lower layer.
2
Application of lime:
Lime shall be applied at the percent approved in the design job mix formula
according to the construction method specified in the work plan and the results of the
experimental section. The percent of lime added should not vary from the percent
specified in the approved design job mixture formula by more than ten (10) percent of the
approved percent, it is permissible to apply lime in one batch or two b atches by using the
approved equipments and machines providing that each batch of lime shall be well mixed
with the soil.
112
Hydrated lime can be applied by one of the following methods:

- Dry method:
Lime can be distributed by machines and equipments like self discharging vehicles
which are equipped with a transfer screw that distributes lime on the surface intended for
treatment, or a mobile mechanical spreader which distribute the lime to a close distance
from the surface.
Also lime can be distributed using bags in form of rows at specified interval to get
required and uniform percent of lime. It is possible to distribute the lime in one batch or
more batches with the required mixing after each batch according to the approved work
plan. The required measures shall be taken to prevent lime dispersal due to winds by
immediate wetting with water and Contractor shall stop work when wind speed leads to
lime dispersal.
- Wetting method:
Lime and water shall be mixed to obtain an emulsion in which the percent of solid
particles is not less than 30 % then the emulsion is sprayed by particular trucks or rotary
mixers. Lime distribution in both cases shall be uniform throughout the area intended for
treatment by repeating the applying process until the lime and percent of moisture
required for treatment is achieved.
The following requirements shall be followed at all times:
- No spreading of lime or lime-treated material shall be made when the temperature
during spreading or the expected temperature within 48 hours is less than 4
degrees Celsius (4 C).
- Lime distribution shall be limited only to areas that can be mixed in the same
working day. It is not permissible to leave a distributed lime without mixing with
soil and water for more than six hours.
- Parts which have been spread without mixing for more than 6 hours or parts for
which test results showed a shortage in lime content out side the tolerance limits,
Contractor in his expense shall retreat these section by adding all the originally
required lime quantity.
- The application of quick lime if allowed to be used should be only by the dry method
and it shall be mixed properly with soil before adding water and all safety
conditions shall be followed.
~
3.
Mixing:
Immediately after completion of lime distribution water shall be added in a ratio of
five (5%) percent more than the optimum percent and the mixing of materials shall start
immediately after that.
Lime mixing with soil shall continue until a uniform mixture is obtained for whole
depth of the constructed layer. It is possible to mix the treated soil with lime by using
equipments equipped with plowing and scarifying devices. These equipments shall be
capable of plowing and scarifying materials for the whole depth.
When the special specifications and the approved job mix formula state that the
lime application should be in batches, Contractor shall mix lime with the soil and water
and initially compact these materials and let them for a period not less than 3 days, then
he shall apply the second application of lime, and the required percent of water and mix
113
these materials properly until a uniform mixture for the whole depth of the layer under
progress is obtained.
When the Contractor faces difficulty in materials mixing, he shall execute the
preliminary mixing, spreading and compaction to lessen water evaporation and maintain
the layer for a period of not less than 48 hours, then the moisture shall be adjusted so that
it doesnt differ from the optimum moisture content by more than 2 % and remixing
materials properly until a uniform mixture is obtained then leveling the layer and finishing
the compaction.
When the special specifications and the job mix formula indicate a special
mellowing period according to Table (5.5.3.1) or the approved job mix, the lime and
water shall be added and mixed initially and kept wet during the specified mellowing
period, the layer is re-plowed and pulverized then water is added, and the layer shall be
mixed, leveled and compacted and the lime treated material shall be left, after the
preliminary mixing operations and before compaction, for a period varies between 24 to
48 hours to allow more mellowing.
If the Contractor could not execute the mixing process in the same day, he shall
treat the surface with preliminary compaction by rubber wheeled rollers before the end of
the working day providing that the work sequence will continue next day.
When quick lime is used for the treatment of the Subgrade, the applied water
quantity before or during mixing should be adequate to fully hydrate lime, the heat arising
from hydration shall not decrease percent of water in the final mixture.
When lime treated Subgrade required to be re-constructed after 7 days from the
final compaction, a percent of lime which shall not differ from the basic percent, by not
more than 2%, shall be added to the mixture and mixed in a uniform way and all the
phases of construction shall be repeated.
4.
Construction of Joints:
To achieve required joint between successive working days, Contractor shall plow
a part of the previous constructed treated layer in the past day for a distance not less than
half (0.5) meter remix and wet after adding 50% of the approved lime content to that
plowed area and re-construct this part with the new day work.
5.
Compaction:
The Subgrade lime treated layer shall be compacted after the wetting and applying
the final formation processes according to dimensions, levels and thicknesses shown on
the drawings or specified in the special specifications. The individual layers thickness
shall not exceed 30 cm, and when the required thickness is more than 30 cm the mixture
shall be spread and compacted into two or more layers of approximately equal thickness.
Moisture shall be maintained during spreading and compaction process so that it does not
differ from the optimum moisture content by more than 2%.
The compaction process shall be executed by using the approved compaction equipments.
The preliminary compaction shall be started by using rollers capable of
114
penetrating and kneading the material like grid wheel rollers or sheep foot rollers.
However, the final compaction process shall be performed by steel or pneumatic wheeled
rollers, provided that final number of passes shall not be less than 2.
Areas can not be reach with rollers shall be compacted by compaction equipments
chosen by the Contractor and accepted by the Engineer such as vibrating plate or any
other capable equipment. Consideration shall be given to equipment capability to compact
to the whole depth and to achieve the required density. When it is necessary, the specified
thickness may be changed for each layer to suit the used compaction equipment.
Lime treated Subgrade shall be compacted, up to a density of not less than 95% of
the maximum dry density specified by (AASHTO T-99 method C) test except otherwise
indicated in the special specifications. All compaction and finishing processes shall be
finalized within a period not more than 12 hours from the final mixing.
Compaction degree shall be determined for each constructed layer using the sand
cone method according to (AASHTO T- 191) or the nuclear method according to
(AASHTO T3 10-01) or any other approved non-destructive method. When using the
nuclear or non-destructive test method, three readings shall be are taken for each location
in different direction and the average for the three readings is considered as the field
The minimum acceptable limit for the compaction degree to determine the
payment factor using statistical method is the indicated compaction degree minus 2%.
The unconfined compressive strength or the approved strength index for the
constructed works shall be determined using core samples and the allowed minimum limit
for calculating pay factor shall be 80% of the value obtained in the design job mix
formula or the minimum limit of the strength specified in the special specification
whichever is greater.
Verification shall be carried out for the percentage of lime added to uncured
samples using (ASTM D 3155) test and the percent of the lime used shall not differ from
the approved percent by more than 10% of the rate specified in the job mix formula,
providing that the difference shall not exceed (0.5%) whichever is lesser.
6.
Curing:
The surface of the constructed layer shall be maintained in wet condition until the
next layer is laid otherwise Asphalt curing membrane should be executed.
When required, the asphalt curing membrane shall be executed during one day
from completion of the final compaction, by applying a continuous uniform asphalt
emulsion in rate of (0.7-1.4) litter per square meter through out the width with the same
method of prime coat distribution as indicated in Division (8) of
these general specifications.
Curing period shall not be less than 7 days and vehicles and machines are not
allowed to pass on the lime treated Subgrade before the end of the curing period except
water distribution tankers, providing that their passing should not result any
115
deformations on the surface of the layer. the equipment is not allowed to move over the
asphalt curing membrane before 72 hours after its distribution.
5.5.3.7 Safety requirements:
Contractor prior starting of the construction of the lime treated Subgrade, shall
provide all the required instructions, requirements and arrangement of safety from the
lime manufacturers and to be aware of the aid operations. Accordingly, Contractor shall
prepare a special program for training employees and submit a report to the Engineer. It is
not permitted to start the works before the approval of the Engineer for the safety plan and
verification of the employees training. During lime applying, particularly quick lime,
warning signs shall be placed for pedestrians and neighboring residents.
Contractor shall, during construction processes, apply all safety regulations and he
shall impose on the employees the use of safety equipments such as gloves and protective
masks. In case the Contractor fails to apply safety requirements all construction activities
shall be stopped and Contractor shall be responsible for any damages arising from his
failure to apply safety regulations.
The lime treated Subgrade shall be constructed according to the dimensions,
grades and thickness shown on the drawings and special specifications. The difference
between thickness of the constructed layer and the required thickness shall not exceed 2
cm or 10% of the approved thickness whichever is lesser. Measuring of each layer shall
be performed after verifying the degree of compaction using core samples from each
layer. The field density holes can be used for this purpose.
The final surface levels of the constructed layer shall not differ from the specified
levels by more than 10 mm if the next layer was asphalt or 20 mm if the next layers were
aggregate. The final cross-sections levels shall be measured at 25 meters interval
providing that the number of the sections shall not be less than 5 every 2000 square
meters of the constructed layer. Measuring shall be performed at least in 5 points in each
cross-section.
Verification for unevenness of the layer surface can be done visually or by
measuring with a metal straight edge 3 meters long in 5 locations and the clearance
between the bottom of the edge and the layer's surface between any two contact points
shall not exceed 20 mm.
5.5.3.9 Works Acceptances:
Contractor shall apply the quality control for lime treated Subgrade works and
Contractor quality control procedures either by direct supervision of the constructed
layer or by carrying out neutrally and independent quality assurance procedures on
sufficient numbers of representative samples to judge the construction level and to accept
or reject the executed works, according to the principles stated in division 17 of
116
these general specifications except otherwise indicated in the special specifications and
other contract documents.
1.
Quality control:
Contractor shall perform quality control for materials and constructed works and
he shall monitor records and analyze the results and draw quality charts for critical
properties. Contractor shall carry out all the tests and measurements indicated in Table
5.5.3.3. Contractor shall provide the Engineer with copies of tests promptly and apply all
the items indicated in item 17.1.1 of these general specifications.
2.
Quality Assurance:
The Ministry has the right, to apply or ordering performing of the quality
assurance for the materials and constructed works, under its direct supervision, and it has
the right to test the materials and inspect the constructed work for all or some of quality
control items specified in Table (5.5.3.3).
procedure as specified in Division 17 of these general specifications, inspect Contractors
laboratory, equipments and technical staff to insure the efficiency of Contractors staff
and the inspection, testing and construction methods whether they are conforming to the
approved testing and construction method.
Works shall be accepted according to unit prices specified in the contract or by
reduced prices or rejected according to the quality level results from applying the
statistical method indicated in Division 17 of these general specifications, except
otherwise indicated in the special specifications.
The lime treated Subgrade shall be measured in cubic meters after being laid and
compacted to the specified thickness and within the dimensions and levels shown on the
drawings or according to the Engineers instructions.
No measuring shall be made for the purpose of payment for the materials laid
outside the limits shown on the drawings, special specifications or specified by the
Engineer.
5.5.3.11 Payment:
reduced prices as a result of applying the quality assurance procedure if stated in the
contract documents.
transporting, wetting, mixing, compacting and finishing of the work, in addition to the
provision and operation of machines, equipments, labor, tests, measurements, benefits,
revenues, fees and third party payments and all requirements to construct the works
according to drawings, special and general specifications.
(5.5.3.4) if not contradict with contract documents.
117
Table 5.5.3.3: Quality control procedures for lime treated Subgrade works
Work
Properties
Soil
classification
Test method
Location
of Sample
AASHTO
M 145
Raw
materials
At source
Lime
Lime percent
Materials
during
use
Soil
classification
after
treatment
Moisture/
density
relationship
unconfined
compressive
strength
Field density
Executed
Works
Thickness
Dimensions
& levels
Surface
leveling
Item No.
Manufacturers
guarantee
certificate from
manufacturer
3 tests at production starting

and one test every 10,000
square meter production or
noticing a change in the
properties of the executed
works.
AASHTO
T-99
AASHTO
T-220
Survey
measuring
Measuring with
straight edge
3 tests on different samples

from each source when the
approving source and design
job mixture formula or
change of source or noticing
a change in the properties of
the executed works, and 5
tests on different samples at
different intervals for each
5000 cubic meters from each
source during execution.
and whenever the source is
changed
AASHTO
M 145
Core samples
Requirements
Item
5.5.3.5
At commencement of supply
AASHTO
T-232
AASHTO
T-191/T-310-01
or any other
approved nondestructive test
Sampling frequency
At site
Item
5.5.3.2
Item
5.5.3.5
5.5.3.7
Item
5.5.3.5
Item
5.5.3.5
3 tests at production
commencement and one test
each 10.000 square meter
from the executed works or
when a change is noticed in
executed works.
Item
5.5.3.7
Every 2000 square meters of

each executed layer.
Item
5.5.3.7
One measuring for each 2000

square meters of the executed
layer and it is possible to use
field density holes.
Measuring in five cross
sections each 2000 square
meters cross-section each 25
meters whichever is greater.
Five measures each 2000
square meters or between
cross sections
Item
5.5.3.9
Item
5.5.3.9
Item
5.5.3.9
Work type
Unit
5.5.3.1
_ Lime
treated
____________________
Table
5.5.3.4:
Items
forSubgrade
lime-treated
subgrade layer worksm 3
5.5.3.2 _ Lime(whenspecifiedinseparatepayment) ________________ Ton
118
5.5.4 Cement Treated Subgrade:

This section consists of material requirements and construction methods for
cement treated Subgrade, it includes preparation of the surface, provision of the materials,
mixing with water, spreading, and compaction of these materials to the required density
and maintaining the constructed layer, according to the thicknesses, levels and dimensions
indicated on the drawings and in conformity with the special specifications and these
5.5.4.2 Materials:
1.
Soil:
The soil material used in cement treated Subgrade shall be from the local soil or
barrow materials. It shall be of a type positively response to lime-treatment and improved
by cement, free from plant or organic materials and unsuitable materials. The total percent
of chloride and sulphates by weight of the soil according to AASHTO T - (290-29 1) test
shall not exceed 1%. The soil shall be pulverized until particle's size becomes less than 5
cm and the percent of the retained on sieve No. 4 (4.75 mm) shall not be more than 45%.
The applicability of the soil to be treated with cement shall be decided on the bases
of technical study prepared by specialized agency in which a comparison between test
results of untreated and treated soils for the target properties shall be made. The soil is
considered suitable for cement treatment when its plasticity index is less than 20 %. The
treatment is considered effective if results of average target property value of five (5) soil
samples after the cement treatment using the same percent of cement is improved by not
less than 35 % compared with the average target property value for the five (5) untreated
samples from the same soil.
2.
Portland Cement:
The Portland cement used shall be Portland V sulphate resistant type and shall be
conforming to Saudi standard specification SASO 570 or ASTM C150 except otherwise
special specifications allow for another type.
3.
Water
The water used in mixing shall be in compliance with the requirements of section
(5.5.3) of these general specifications.
4.
Asphalt curing membrane:

The asphalt material used as a curing membrane shall be from asphalt emulsions
type (SS-1h or CSS-1h) conform to the requirements of Division (7) of these general
specifications.
5.
Additives:
The Retarders compounds and other chemical compounds shall be effective and
conform to the requirements specified in specification (ASTM C 494); the addition of
these materials should not lead to an adverse effect on any required properties of the mix
in treated layer.
119
5.5.4.3 Job Mix Design Formula:

1.
Requirements of the Mix:

Unless otherwise indicated in the special specifications, the unconfined
compressive strength, after 7 days for the soaked cylindrical samples of the cement treated
soil, shall not be less than (2.75 M.Pa) according to ASTM D 5102. When the special
specifications require durability test for the cement treated soil, the percent of loss by
weight of cured samples for a period of 7 days after being exposed to (12) cycles of soaking
and drying according to ASTM D 559 test, shall not exceed the values showed in Table
(5.5.4.1), unless otherwise indicated in the special specifications.
The percent of cement used shall not be less than (3.5%) by weight of soil.
Table 5.5.4.1: Loss of weight in the soaking and drying test
Soil classification
A-1, A-3, A-2-4, A-2-5
A-2-6, A-2-7, A-4, A-5
A-6, A-7
Percent Loss by weight

14
10
7
2.
Acceptance of Job mix formula:

Prior starting construction of the cement treated Subgrade by not less than 30 days,
Contractor shall submit to the Engineer a technical report prepared by a specialized and
qualified agency include the job mix formula, the work plan and a list of the machines and
equipments proposed for construction. The job mix formula shall include materials
sources, properties, material proportions, and curing methods. The report shall be based
on actual test results on representative samples of soil materials, cement and water
proposed to be used in cement treated Subgrade.
The report shall include the following:
1. Source and properties of all materials proposed for producing cement treated mixture
including additive materials, percent, and methods of application and mixing.
2. The proposed percents of cement, water, and additives.
3. The mixture density at the proposed proportions of cement and water on the basis of
(AASHTO-134) test.
4. The quality properties of the mixture (unconfined compressive strength) and any other
properties indicated in the special specifications.
5. Equipments and machines list.
6. Mixing, spreading, compaction and curing methods.
The Engineer shall review the design job mix formula and verify if it contains all
the required information within 7 days and return it to contractor for completing the
lacking information or study it and verify that the proposed mix achieves all the required
requirements. If it was found that specifications were not achieved, he resubmits it to the
contractor with his comments. Then contractor shall resubmit a new job formula. But if
the design job formula was technically acceptable, the engineer shall issue his written
acceptance and inform the contractor.
120
When the contractor changes materials or if testing results and execution prove
that specifications were not achieved or that the mix is not suitable for construction,
contractor in such case shall carry out all the required modifications to obtain a workable
mix that achieves specifications.
Contractor has no right, by any means, to start production and construction before
receiving the written approval of the job mix formula by the Engineer. Acceptance of the
formula is considered as preliminary until verification is made of the possibility for its
production and execution on site. Also, this acceptance does not release the contractor
from his responsibility for producing a cement treated specimen layer according to special
specifications or these specifications.
5.5.4.4 Weather limitations:
Cement application and mixture production or construction shall not be performed
when the temperature is 5 degrees Celsius or expected to reach this temperature in the
next day following the day of mixing and spreading or when it exceed 35 degrees Celsius.
These limits can be exceeded with a written approval from the Engineer if the contractor
takes the required precautions to maintain the mix and executed works for reducing water
evaporations and damping of the mix using ways that do not affect the quality of treated
layer or its efficiency after construction. The contractor shall be responsible of any results
arise from that and he shall carry on his expense all repair works when required without
any additional payments, including the sections that does not conform to the specifications.
It is not permissible to construct the cement treated subgrade during rainfall or when speed
of the wind exceeds 25 km /hr or at any speed the Engineer decide that it may affect the
cement distribution during on road mixing or during sand or dust storms. The contractor
is responsible to maintain the road surface on which the treated subgrade will be
constructed in a technical acceptable condition in all weather and he shall remove all
materials, mixes and works constructed in unsuitable weather conditions, and he has no
right to claims any additional payments for that.
5.5.4.5 Traffic Control:
Contractor shall take all the necessary arrangement to control traffic movement
during construction and diverting the public traffic movement when necessary. He shall
assign and construct the required paths for pedestrians. Contractor shall prohibit passing of
all machines and equipments on the cement treated Subgrade throughout the curing
period which should not be less than 7 days, excluding asphalt curing membrane and
water distributor equipments.
Those equipments shall be chosen so that they should not lead to any damages to
the Subgrade and the Contractor is responsible for any damages which occur to the
Subgrade due to private or public traffic or due to any other reason.
5.5.4.6 Equipments:
Prior starting the Subgrade treatment works, Contractor shall submit to the
Engineer the design job mix formula, the work plan, and list of the machines and
proposed equipments to be used. Those equipments and machines shall be in the
numbers and productivity required for constructing the works according to the time
schedule prepared by the Contractor approved by the Engineer in conformity with the
contract period. The machines and equipments shall includes:
121
1. Plowing and pulverizing machines and equipments capable of plowing and scarifying
the soil to the approved depths and dimensions.
2. Cement distributor which are capable of distributing cement in the specified rates and
possible to be calibrated and controlled.
3. Soil, cement and water mixing equipments which are capable of uniformly mixing all
materials for the full depth.
4. Mobile mixers capable of picking the soil and mixing it with cement and water and
re-spreading the mixture.
5. Batch or continuous central plants capable of producing the mixture and susceptible to
calibration and control for all the mixture contents.
6. Spreading and leveling equipments capable of spreading and leveling materials
according to the slopes and levels approved on the drawings and special
specifications.
7. Compaction equipments capable of compacting the mixture to the required density
and suitable for the site including mechanical small compaction equipments or manual
equipments for compaction in areas where common rollers can not reach.
8. Water distributor equipments that can be calibrated.
9. Curing membrane equipments that can be calibrated.
The selection of suitable equipments shall be made according to the approved
work plan and construction method.
5.5.4.7 Experimental section:
When the special specifications state or the Engineer requires, Contractor shall
construct an experimental section not less than 200 meters long (it may be from the
project works) for the purpose of verifying the possibility construction the cement treated
Subgrade according to the job mix formula using the proposed machines and equipments
and to insure that the constructed layer conform to the requirements of the special
specifications and the contract documents.
Contractor shall perform all the measurements and tests for the constructed
experimental section and submit the results to the Engineer. The Engineer shall evaluate
the results and verifies the construction method and he shall inform the Contractor with
his written comments. Contractor shall carry out all the required modifications including
the job mix modifications in any phase of the construction works or replace some
machines and equipments, to achieve the requirements of the specifications. Contractor in
his expense shall remove the unacceptable constructed works and replace them with
suitable ones if the results of the experimental section were not acceptable.
However, if the results of the experimental section were acceptable, the Engineer
shall approve the results and the Contractor shall follow the job mix formula, plan,
machines and equipments used throughout the construction period. These results are
considered as a reference for subsequent works evaluation and the Contractor has no right
to make any modifications without permission from the Engineer. The Engineer's
acceptance for the experimental section results, approval of the job mix formula and plan
does not release the Contractor from the responsibility for producing and constructing
cement treated Subgrade conforming to the approved specifications.
122
The Contractor shall construct the cement treated Subgrade according to the
thickness, dimensions, levels and slopes shown on the approved drawings and special
specifications using materials, job mix formula and construction methods approved by the
Engineer.
Construction shall be carried out according to the following phases:
1.
Plowing and pulverization:

Prior starting of cement treated Subgrade construction, Contractor shall prepare
the surface on which the treated Subgrade shall be laid and execute the proof rolling to
determine weak areas and treat them. And he shall provide a sound and stable surface
capable of sustaining the construction equipments and receiving the cement treated
Subgrade.
The soil to be treated shall be plowed and pulverized, whether it is the site material
or supplied material from outside, throughout the depth of the layer to be treated so that it
achieves the materials requirements indicated in this section or as specified in the special
specifications and the approved job mix formula.
All the pieces and lumps larger than 5 centimeters in size or larger than the
maximum size specified in the special specifications shall be removed by picking or
broken to the required size or screened.
2.
Application of the cement:

Cement shall be added to the material to be treated according to the type and
percent approved in the job mix formula and construction method used in the
experimental section. The applied cement content shall not vary from the approved one by
more than 10% of cement percent or (0.5%) which is the least. when the contract
documents and the job mix formula indicate using of additives Contractor shall apply the
additive materials according to the manufacturers recommendations and the approved
method in the work plan.
Cement may be applied to the soil according to the site and construction method
by one of the following ways:
-
In-place mixing:
When performing the mixing directly on the road cement is distributed uniformly
with the specified rates on the surface of the soil to be treated by special mechanical
distributor. It is also possible to distribute cement bags on the surface to be treated in form
of rows such that the cement content after distribution shall be equal to the approved
percent then the bags are opened and the cement distributed towards lateral direction and
distributed on the surface by equipments which provide the possibility of uniform
distribution.
When the soil type and depth of the layer to be treated allow that, it is possible, to
use machines that pick the soil from the surface with the specified thickness and mix it
with cement and re-distribute it on the surface in the dry condition or in the form of a
ready mix after applying water.
123
In all the cases of dry distribution, consideration shall be made to weather

conditions like wind speed and surface moisture such that no lost of cement occur due to
winds or to prevent forming of cement lumps due to humidity or surface moisture. The
period from cement distribution on the surface and finishing of its mixing with the soil
shall be as short as possible.
Cement shall be distributed only on surfaces where it is possible to finish their
mixing, soaking and compacting by the end of each working day, considering the elapsed
period between applying water, spreading, leveling, compaction and surface finishing.
Contractor shall be responsible for the results arising from breaching any of these
conditions.
-
Plant Mixing:
When mixing is performed in a central mixer cement shall be applied in a dry
state to mixing chamber. Plants shall be equipped with a silo for cement, and cement
feeding is done through special lines provided with the required control systems to
control the applied cement quantity and automatic stopping when the specified quantity is
added.
3.
Mixing:
Contractor shall mix the soil with cement and additive materials uniformly
throughout the area and depth of the layer to be treated. Both the cement application and
mixing methods shall be approved.
When mixing in central plants it is possible to use the continuous twin shaft or
batch mixers whereas the soil is mixed with cement in a special mixing chamber.
Soil-cement mixing time shall be controlled to produce a uniform mixture before addition
of water, and then water is added the mixing shall be continued until a uniform mixture is
obtained.
When the continuous central twin shafts mixers are used the mixing chamber shall
continue after addition of water for a distance not less than 1.25 meter to complete
mixing. Such mixers shall contain a silo provided with discharging gate which opens and
closes automatically and with a capacity of not less than 20 tons for storing mixed
materials.
Mixers, whatever their type, shall be equipped with a calibration system capable
of adding soil, cement and water in the required quantity by volume or by weight.
When using batch mixers, the required tests shall be performed to determine the
mixing time before commencing the mixture production.
Mixing may be executed on the road either by mixers which pick the soil from
the surface and applying cement, mixing with the soil, adding water, complete mixing
and spread the ready mixture on the road when the treated soil and the available
equipments allow this. Or by machines that plow the soil, mix it with cement using dry
method rolling and rotating by a shaft provided with a screw plow, introducing water and
mixing until a uniform mixture is obtained with the required moisture and cement
contents.
124
Mobile mixers shall move in a speed conform to the speed recommended by the
manufacturer according to the treatment depth and the quantity to be mixed and, at all
times, mixing shall continue until a uniform mixture is obtained for the full depth.
The moisture content of the produced mixture shall be higher than the specified
optimum moisture content by 2% according to (AASHTO T-134) test method. The
cement content shall not differ from the specified content in the job mix formula by more
than 10% of the specified content providing that the difference should not, be more than
half percent (0.5%).
4.
Spreading, compaction and finishing:

Immediately after finishing mixing, the materials shall be loose and easily spread
and leveled in a surface that conforms to the grades and levels indicated in the drawings
or special specifications.
The compaction of the mixture shall be started immediately after finishing the
spreading and leveling process, the period between the addition of water and the
subsequent processes shall not exceed the values indicated in Table (5.5.4.2) below.
Table 5.5.4.2: Maximum Periods between Work Phases
Work phases
From water addition to starting of compaction
Between addition of water and finishing the
preliminary compaction
Between addition of water and completing
compaction and finishing works.
Maximum period between

phases, hours
1
2
2.5
When the separating period between compaction of adjacent parts exceeds 2 hours
or when joining between previously constructed and new parts the joining process shall be
made according to method specified in the construction joints below.
The thickness of the compacted layer shall not exceed 20 cm and construction
shall be performed in layers of approximately equal thicknesses when the required
thickness is more than that.
Each layer, unless the special specifications otherwise state, shall be compacted by
using suitable machines and equipments. Preliminary compaction shall be executed by
using sheep foot rollers or grid rollers and the final compaction shall be executed by
smooth wheel or steel wheeled rollers. Compaction shall continue up to a density not less
than 100% of the maximum dry density specified by AASHTO T-134 test, and at
moisture content which should not differ from the optimum moisture content by more
than 2%.
Areas which are difficult for the rollers to reach shall be compacted up to the
required density for the full depth by the method and equipments accepted by the
Engineer.
Contractor shall take all required precautionary measures to eliminate formation of
random cracks, through controlling used cement percentage, such that it does not
125
exceed the approved minimum limit in the design job formula, control of water
percentage, carrying out work in the suitable weather conditions when temperatures are
getting lower, making the required provisions for construction in hot weather, and care
about moistening during curing period. When some random cracks appear, he shall
complete the necessary repair works according to the instructions of the engineer and fill
cracks with the suitable material. Except otherwise special specifications stipulate for a
specific type, fill materials shall be compliant with ASTM D (3405, 3406) and contractor
shall not be paid any additional amounts as a result of that.
Compaction degree shall be determined for each constructed layer using the sand
cone method according to (AASHTO T- 191) or the nuclear method according to
(AASHTO T-310-01) or any other approved non-destructive method the compaction
degree shall be determined by taken field density as a percent of maximum dry density
specified according to AASHTO T-134. When using the nuclear or non-destructive test
method, three readings shall be taken for each location in different direction and the
average for the three readings is considered as the field density of that location.
The minimum acceptable limit for compaction degree to decide payment factor by
the statistical method is the indicated compaction degree minus 2 % percent.
The unconfined compressive strength for constructed layer shall be determined by
taking core samples. The minimum allowed limit for calculating the payment factor is
90% of the value obtained in the mix design or the minimum of the specified strength in
the special specifications whichever is greater. The test is performed by using (ASTM D
1633) method.
Cement percentage shall be verified by test AASHTO T-144 and cement
percentage used for treatment shall be compliant with the percentage determined in the
mix design or special specifications and it shall not vary from it by more than 10% of the
specified percentage in the design mix. The difference shall not, by any means, exceed
0.5%.
5.
Construction Joints:
At the end of each working day and when the period between laying of the
adjacent treated layers is more than two hours a lateral or straight linear joint shall be
constructed by cutting a part of the treated layer to a distance not less than (8) cm for the
whole depth in a vertical surface and removing the cut materials, cleaning and protecting
the joint until the new materials are placed. Consideration shall be made to wet this
surface carefully immediately before placing the new materials.
6.
Curing:
The cement treated Subgrade shall be maintained in a wet condition using
emulsified asphalt membrane or spraying or covering it with sack, wetting and covered
with plastic sheet. These sacks shall be wetted with water at least two times daily and
recovered with plastic sheet, or the surface can be soaked with water confined over the
surface. The curing shall continue for a period not less than 7 days unless otherwise the
special specifications allow.
Curing membrane execution shall not be started before the hardening of the layer to such
extend that it is able to sustain passing of the curing membrane equipments
126
and this period shall not be less than 24 hours from finishing. The asphalt curing
membrane shall be executed from emulsified asphalt composed of equal percent of water
and asphalt with application rate range (0.9-1.13 Litter/m2) and the actual rate shall be
determined from the experimental section results.
The Contractor shall be responsible for any damages which may arise as a result of
his failure in curing the executed layer and he shall carry out all the required repair works
without having the right to claim any additional payments.
The cement treated Subgrade shall be constructed in accordance with the
dimensions, slopes and thickness shown on the drawings and special specifications. The
difference between the constructed layer thickness and the required thickness shall not
exceed 2 cm or 10% of the approved thickness whichever is lesser. The thickness of each
constructed layer shall be measured after achieving of required degree of compaction
using core samples from each layer and it is possible to use the field density holes for this
purpose.
The final surface levels of layer shall not vary from the specified levels by more
than 10 mm if the next layer was asphalt or 20 mm if the next layers were aggregate. the
measurements of cross-sections levels shall be taken on the final surface at an interval of
25 meters providing that the number of the points at each cross-section not be less than (5)
for every 2000 square meters.
Smoothness of layer surface shall be verified visually and by a metal straight edge
3 meters long in five locations, and the space between the bottom of the edge and the
layer's surface between any two contact points shall not exceed 20 mm.
5.5.4.10 Works Acceptances:
Contractor shall apply the quality control for cement treated Subgrade works and
Contractor quality control procedures either by direct supervision of the constructed layer
or by carrying out neutrally and independent quality assurance procedures on sufficient
numbers of representative samples to judge the construction level and to accept or reject
the executed works, according to the principles stated in division 17 of these general
specifications except otherwise indicated in the special specifications and other contract
documents.
1.
Quality control:
Contractor shall perform quality control for materials and constructed works and he shall
monitor records and analyze the results and draw quality charts for critical properties.
Contractor shall carry out all the tests and measurements indicated in Table (5.5.4.3).
Contractor shall provide the Engineer with copies of tests promptly and apply all the items
indicated in item 17.1.1 of these general specifications.
127
2.
Quality Assurance:
The Ministry has the right, to apply or ordering performing of the quality
assurance for the materials and constructed works, under its direct supervision, and it
has the right to test the materials and inspect the constructed work for all or some of
quality control items specified in Table (5.5.4.3).
procedure as specified in Division 17 of these general specifications. And inspect
Contractors laboratory, its equipments and technical staff to insure the efficiency of
Contractors staff and the inspection, testing and construction methods whether they are
conforming to the approved testing and construction method.
Table 5.5.4.3: Quality control Procedures for the cement treated Subgrade works
Work
Raw
materials
Properties
Soil
classification
Cement
Materials
during
use
Cement
content
Mixture
density
unconfined
compressive
strength
Loss in
weight, after
wetting and
drying
Test method
AASHTO
M 145
Location
of Sample
At source
Guarantee
certificate from
manufacturer
AASHTO
T-144
AASHTO
T-134
ASTM
D 5102
unconfined
compressive
Construct
ed Works
At mixing
location
ASTM
D 559
strength
T 310 01)
or any other non
destructive test
ASTM
D 5102
Thickness
Core sample
Dimensions
and levels
survey
measurements
Surface
smoothness
Measured with
straight edge
properties is noticed, and five tests

on different & timely diverse
samples for each 5000 cubic meter
from each source during
construction.
At the beginning of supply and
whenever source is changed.
AASHT-191,
AASHTO
Degree of
Compaction
Sampling frequency
Three tests on different samples
from each source. When the
source and design job mix formula
are approved or change of source
or when a change in the executed
mixture or executed work
At the site
3 tests at production
commencement, and one test each
5000 cubic meters, or noticing a
change in the executed works
properties.
Requirements
Item
5542
Item
5.5.4.2
Item
5.5.4.3
Item
5.5.4.3
Item
5.5.4.3
The indicated rate for nonconfined compressive strength, but

test is performed when the special
specifications state this.
Item
5.5.4.3
A test at supply commencing and a

test each 2000 square meters or
one working day whichever is
greater
Item
5548
Each 10000 square meters from

each constructed layer
Measurement each 2000 square
meters
Measuring of dimensions & levels
of lateral sections each 25 meters
or 5 sections each 2000 square
meters whichever is greater
5 measurements each 2000 square
meters
Item
5548
Item
5.5.4.9
Item
5.5.4.9
Item
5.5.4.9
128
The cement treated Subgrade shall be measured in cubic meters or according to
special specifications after being laid and compacted to the specified thickness and within
the dimensions and levels shown on the drawings or according to the Engineers
instructions.
When special specifications stipulate a special item for cement, the cement
quantity used in the cement treated sub grade shall be measured in tons. No measurement
shall be made for the purpose of payment for the materials laid outside the limits shown
on the drawings, special specifications or specified by the Engineer.
5.5.4.12 Payment:
reduced prices as a result of applying the quality assurance procedure if stated in the
contract documents.
transporting, wetting, mixing, spreading, compacting and finishing of the work, in
addition to the provision and operation of machines, equipments, labor, tests,
measurements, benefits, revenues, fees and third party payments and all requirements to
construct the works according to drawings, special and general specifications,.
(5.5.4.4), if not contradict with contract documents.
Table 5.5.4.4: Items of Cement Treated Subgrade Works
Item No.
5.5.4.1
5.5.4.2
5.5.4.3
5.6
Work type
Surfaces preparation
Cement (when the special specifications state
payment for it separately)
Cement treated Subgrade
Unit
m2
Tons
m3
Civil Works in Utilities Projects:
5.6.1 Description:
This section consists of excavation and backfilling works for public utilities
projects within a new road or existing roads. The transferring or removing or extending of
different utilities such as water supply lines, sewage water, electricity, communication and
their components and accessories, bedding layers, protection layers around pipes and
handing over of these works shall be carried according to specifications approved by the
concerned authorities under direct supervision by their representative. And contractor
shall be qualified for the execution of such works.
Civil works which include excavation, backfilling and highway paving layers will
be carried out according to the general specifications for civil works in public utilities
projects issued by the Ministry of Municipal and Rural Affairs and special specifications
or these specifications.
129
5.6.2 Preliminary works:

Before starting the execution of the public utilities works, the Contractor shall
inspect site and carry the required survey works to determine the routes and levels for the
lines of the required utilities to be constructed. Also he should locate all structures,
obstructions and existing facilities within his work area according to section (5-1)
requirements (site preparation) of these general specifications or special specifications.
5.6.3 Trench Excavation:
This work includes excavation for utilities according to the dimensions and levels
shown on the drawings and contract documents, support for excavations sides, transfer of
excavated material to storage locations for the purpose of using them later, if they comply
with the materials requirements of the work based on the test results of representative
samples or shall be transported and disposed at the approved locations.
Contractor shall, before starting excavation works, specify work sites and
excavation route by paint marks or stakes or any other method which is approved by the
engineer. These marks shall be clear and distinct and engineer shall verify the suitability
of the route before allow the contractor to start excavation. Contractor should have
completed traffic control works, barriers, signals and warning lights and signs with
barriers and walkways and traffic lanes. Based on the results of investigation and survey
works, contractor shall set out the work plan, time schedule and method and details of
excavation, buildings and structures support, protection or transferring the near by utilities
and to determine the locations at which unsuitable excavation material shall be disposed
attached with a written approvals to use these locations. He shall obtain the excavation
license from the concerned authorities such as the secretariat or Municipality or the rural
affairs locality according to delegated authorities and submit work plan, time schedule,
details and approvals to the engineer for acceptance. The contractor is not allowed to start
excavation before receiving the written acceptance of the engineer.
When excavation for utilities are being executed at the same time of road
embankment construction or prior that, the excavation works should be carried out before
fill works and it is not allowable to start fill works for embankment before the completion
of excavation works for the public utilities and extension of lines, their accessories and
components and handing over these works to the accepted concerned utilities client.
Backfilling work shall be done according to these general specifications except otherwise
stipulated in the special specifications.
When utilities excavation are being executed at the same time of road excavation
or prior that, excavation works for utilities shall be executed after the completion of
excavation works for the road and its elements except otherwise stipulated in the special
specifications, When levels of public utilities lines are below excavation levels of the road
and its elements then public utilities excavation quantities are calculated starting from the
bottom of the road excavation.
When executing public utilities in existing road the Contractor shall start with
cutting asphalt by the mechanical saw and it is not permissible to use jack hammer and
equipments which cause vibration and convulsion to the paving layers. Asphalt cutting
shall be done in two phases:
130
1.
Stage one:
Cutting is carried out according to the excavation width specified in the drawings or
other contract documents or according to the engineers instructions. Cutting shall be
straight and vertical to the road surface and continues until it reaches the earthy layer
then the paving layers milled and/or removed.
2.
Stage two:
Cutting is done after the spreading, compaction and handing over of backfilling
layers and before starting execution of following layers (Subgrade and/or Subbase and/or
Base layers) and cutting width shall be specified for this stage outside the previous
cutting limits not less than fifteen (15) centimeter from each side of trench excavation or
not less than total thickness of the existing pavement layers whichever is greater.
When cutting some parts of the pavement layers which have been subjected to
localized deformations or cracks or deteriorations, the cutting width shall be increased in
these areas up to their external limits in addition to 15 cm at each side to the cutting
width indicated in the above paragraph. And length of the additional cutting distance in
these areas will not be less than five (5) meter.
When the excavation width is grater the half of lane width and less than total
width of complete lane, the contractor shall remove in second stage all the asphalt layers
for the full width of lane and reconstruct it.
Excavation shall be carried out by using the suitable equipments such as special
trench excavators or any other equipment complies with the soil condition, location and
depths of excavation proposed by the contractor and accepted by the engineer. The
asphalt layer shall be protected from the effect of excavation equipment chains by
covering these with rubber pieces or by putting rubber tiers under. Excavation shall start
from the sides if site conditions and excavation depths allow that or excavation from
inside. The excavated material will be transported by using metal boxed trucks, also
equipments and trucks should not come near to excavation sides and the wheels and
chains of equipments should be at a distance no less than one(1) meter from the upper
end of the excavation.
The movement of working equipments or general traffic should not lead to
disturbing the stability of the trench sides, neighboring structures, buildings and utilities.
And the Contractor shall be responsible for any damage or affect arising from his work to
these items.
The trench sides shall be supported in clay, sand or loose soils and in the
saturated soil by using suitable methods accepted by the supervising engineer. Table
5.6.1 shows guide for values of maximum vertical excavation depths without support in
the absence of underground water according to soil types.
Table 5.6.1: Maximum Vertical Excavation Depth without Support
Type of soil
Maximum Excavation Depth (meter)
Sand or dry aggregate
0.3
Wet san d
0.6-1 . 0
Drained sandy clay
1.0-3.0
Drained clay
2.0-3.75
Consistent aggregate (Conglomerate)
3.0-4.0
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The dimensions of the bottom width of excavation should determined based on the
specification requirements approved by the utility authority and should not be less than
the distance required for the installation of pipes and the execution of all required works,
using approved machines and equipments and it should not be more than the pipes
external diameter plus sixty (60) centimeter from each side except otherwise stipulated by
At manhole areas excavation dimensions shall be determined so that the manhole
pre-cast elements or the form required for cement concrete cast in place can be installed.
When excavation is being carried out in rock soil it should be completed according
to a suitable excavation method which is accepted by the engineer by using ripping.
When blasting is required it should be necessary to obtain all the approvals and to
take all the security and safety arrangements as indicated in section 5-2 "rock excavation"
in these general specifications or as indicated in the special specifications. Excavation
should continue up to a depth no less than fifteen (15) centimeter below bottom level of
the pipe at both ends of the pipe in order to execute the required foundation layer of the
pipe.
When executing utilities in existing highways and roads daily excavated parts
should not exceed the distance in which public utilities may be installed during one work
day or one hundred fifty (150) meters whichever is greater. The contractor is not allowed
to start excavation in the next part before completing installation work and backfilling in
the current part except otherwise stipulated by the special specifications or as directed by
the Engineer, based on traffic control plan during construction.
When excavation is being carried out at intersection a cross highways and roads
Contractor shall take all arrangements to carry out the works in the possible shortest time
and he shall execute temporary bridges which allow continuity of traffic and pedestrian
movement if the site conditions do not allow organization of traffic or pedestrian
movement on a part of the road width.
Contractor shall take all the required arrangements to drain water from excavations
according to plan prepared by contractor and accepted by the engineer, such as the sheet
pilling or pumping or wells filled by free drained materials. Contractor shall take the
required arrangements for preventing surface water from reaching the excavation.
Contractor shall whenever the special specifications or the client advice the lowering of
water table during construction - submit a technical study prepared by an approved
specialized firm, shows the proposed method, material specifications, specification and
method of construction and the way of water draining. And the Contractor shall carry out
work execution on the basis of this study.
The water level shall be lowered up to a depth not less than one (1) meter below
the foundation level of the utility under construction except when the special
specifications and the study allow lesser values. When the special specifications stipulate
that the required lowering is temporary then should be maintained up to the completion of
the utilities installation, and their elements, backfilling and final handing over.
132
Excavation should continue up to the levels and depths shown on the drawings
which should be sufficient for installation of utilities and their bedding foundations and it
should provide the minimum thickness of protection layer under pavement that stipulated
in the utilities specifications approved by the client.
The bottom of the excavation should be leveled in compliance with the approved
levels and slopes. Contractor shall keep the bottom of the excavation clean and free from
loose unsuitable material and water up to handing over of the excavation works by the
engineer and construction of utilities foundation, pipe installation, manholes and other
elements, and fill protection around the pipes.
When excavating to depths below than the approved depths Contractor shall
correct levels by filling the excavation with technically accepted materials (no less than
Group A-1-b) except otherwise the special specifications stipulate for better materials, and
the Contractor shall level and compact these materials up to a compaction degree not less
than 90% of the maximum dry density according to modified Proctor test AASHTO T180 for the same used materials providing that it would not lead to any reduction in the
utilities foundation layer thickness indicated in the public utilities specifications approved
by the client. When soil under excavation is not compliant with foundation soil
requirements for the construction of utilities it should be excavated and replaced or treated
to the depths specified by the client.
5.6.4 Backfill:
Backfill works shall be started after the preparation and completion of public
utilities foundations, installation of pipes, completion of manholes and other elements
related to public utilities, execution of the protection layer around pipes and handing over
of public utilities to the clients representative.
Preparations for public utilities include protective compaction for the bottom of
the excavation by plowing, wetting or drying soil layer up to a moisture content of not
more or less than 2% of the optimum moisture content and compacted to not less than
90% of the maximum dry density determined by modified Proctor test for compacted soil
except otherwise recommended by the special specifications for higher compaction levels.
The weak areas or areas that do not meet the approved compaction rates shall be treated to
fulfill the required specifications.
Public utilities bedding layer should be executed with the specified thickness and
materials which comply with the specifications approved by the client. These materials
shall be spread, leveled and compacted to no less than the required compaction degree for
the road at the specified level or ninety percent (90%) of maximum dry density whichever
is higher. The resulting surface shall provide a sound and stable foundation to bear pipes
and following works in accordance with the levels and slopes shown on the drawings
and/or other contract documents and it shall be leveled so that pipe lie completely at all
points.
It is not allowed to start backfilling works around concrete structures
(manholes-inspection champers, foundations etc.) before all works executed using cast
in place concrete reach not less than eighty percent (80%) of the strength indicated in the
contract documents and until these elements be capable of resisting loads and forces
133
arising from the spreading and compacting fill materials and the movements of machines
and equipments.
Before starting backfilling works all the areas, where failure or deformation
occurred in the excavation slopes, shall be treated by increasing limits of cutting up to the
deteriorated or deformed areas and the loose material shall be removed out and substituted
by using backfill materials comply with the proper back fill materials used in utilities
excavation.
Thickness of the protection layer around and above pipes shall be determined
according to the clients specifications and whichever the case this thickness should not be
less than the values indicated in Table (5.6.2) except otherwise indicated in the
specifications approved by the client.
Table 5.6.2: Minimum thickness for the protection layer
Minimum protection layer thickness
Pipe Diameter (millimeter)
(millimeter)
50 or less
150
Greater than 50
300
Vitrified clay pipe
600
Protection layer of pipes and utilities elements unless otherwise indicated in the
special specification or approved specification to the concerned authorities, shall be
executed on both sides of the pipes and elements and to full width of the trench using
granular material of no less than Group (A-1-b) and its maximum size shall not be more
than three fourths of an inch (19 millimeter). The grading indicated in Table (5.6.3) can be
used for the protection of sewage water pipes except otherwise stipulated in the special
specifications and specifications approved by the client.
Materials used for fill around pipes shall not contain organic materials or salts
affect harmfully the pipes or its connections like sulphates and chloride more than one (1)
percent by weight and shall not contain any clayey materials having plasticity index more
than six (6) percent. Except otherwise stipulated in the special specifications and
specifications approved by the client.
Before starting execution of protection layer for public utilities all loose materials
and debris shall be removed from the bottom of the excavation.
Pipe protection layer materials shall be spread simultaneously on both sides of the
pipe in layers having thickness as determined in compliance with the compaction
equipments, providing that the thickness shall not exceed fifteen (15) centimeter. These
materials should have been wetted in advance up to moisture content that not vary by
more than two percent (2%) from optimum moisture content. And it shall be compacted
by suitable compaction equipments, such as small rollers or manually operated plate
rollers without causing any damage to pipes or their elements or manholes, and
compacted up to ninety five percent (95%) of maximum dry density determined by
modified Proctor test for the same material (AASHTO T- 180). The process of spreading
and compaction of the materials continues up to covering pipes with the protection layer
according to the approved thickness. Contractor shall take all the necessary precautions to
protect pipes and their various elements and manholes from damage and he shall
134
repair any damage which may occur to the pipes or their elements or manholes and other
elements as a result of his work on his own account without having the right to any
additional cost for these repairs.
Table 5.6.3 Gradation of Protection layer material
Around Sewers Pipes
Sieve size (millimeter)
Percent passing by weight, %
(3/4 inch) 19
100
(3/8 inch)9.5
85-100
(No. 4) 4.75
70-100
(No. 16) 1.18
20-65
(No. 30) 0.63
0-45
(No. 100) 0.15
0-10
(No. 200) 0.075
0-5
Fill material classification over the protection layer, shall be not less than A-2-4
and its plasticity index not more than ten (10 %).
The moisture content in the materials used for backfill shall not differ by more
than two percent (2 %) from optimum moisture content. It shall be spread throughout the
excavation width, in equal layers of thickness no more than fifteen (15) centimeter, then
compacted to not less than 95% of the maximum dry density determined by modified
Proctor test (AASHTO T-1 80).
Contractor shall use machines and equipments capable of carrying out backfill
works according to specifications and to accomplish the required degree of compaction
for full depth of compacted layer and when necessary the layer thickness may be modified
so that it complies with the used compaction effort to fulfill the required degree of
compaction.
The Contractors equipments and the method of execution should not cause in any
damage on the public utilities or their elements. Contractor shall be fully responsible for
damage arising from his work and he will carry out all repairs and pay all the required
compensations on his own account.
Contractor is not permitted to execute the new layer of backfill before completion
of compaction tests and receiving acceptance from the Engineer for the results of
compaction tests of the previous layer.
Backfill works shall continue up to the level of the Subgrade layer or pavement
layers or islands or natural ground level according to the site condition.
Contractor shall carry out all the required tests to verify the properties of the
materials used in the protection layer or backfill and it is not permissible to supply any
materials before obtaining the written acceptance from the Engineer on the basis of test
results. This acceptance is considered as preliminary and the final acceptance is made on
the basis of test results for representative samples of the actually supplied materials.
Contractor shall transport unsuitable materials, remove all constructed layer by using
unacceptable materials, and re-construct all rejected works according to specifications
135
using acceptable materials. Contractor has no right to claim any additional cost for
correction of the works.
The contractor shall put warning strips on the top of every backfill layer and he
shall the type and depth of service clearly to prevent any damage on it during work
construction.
5.6.5 Pavement Re-construction:
Prior to starting pavement construction in trench areas the contractor shall
complete all installation of utilities and their elements and complete backfill works
according to the special specifications and the specifications approved by the client. All
these works shall be finished and handled over to representatives of the client and the
Engineer and the Contractor will provide the Engineer with a copy of all the tests and
handing over minutes to obtain his acceptance for commencing construction of pavement
layers.
Contractor after receiving acceptance of the engineer for commencing execution
of the highway pavement layers he shall carry out the second stage of pavement cutting
indicated in item 5.6.3 of this section.
Contractor shall remove the resulting materials and old non-asphalt materials up to
Subgrade level and replacing them with new materials which are in compliance with the
specifications for each layer (Base, Subbase and Subgrade). Contractor is prohibited from
using any of the old materials before verification their conformity to quality requirements
and gradation with the approved specifications for each layer in which these material
suggested to be used based on test results carried on representative samples of these
materials.
The Subgrade and the new pavement layers shall be completed according to the
dimensions, slope, levels and material specifications indicated on the drawings and special
specifications or according to item 5.5 requirements of this section for Subgrade layers
and sections (6.3 and 6.4) of these general specifications except otherwise indicated in the
Base course layer, Subgrade layer and Subbase layer shall form sound and strong
layers which are bonded with similar old layers and no separation should appear between
them.
The prime coat and tack coat layers shall be executed using the materials and in
compliance with the construction requirements stipulated in Division eight (8) of this
The joints between the old and the new asphalt layer shall be treated by cleaning the
cutting faces of the old asphalt, and correction of cutting faces so that they become
straight and vertical using suitable equipments then the cutting faces shall be sprayed with
liquid asphalt before executing the asphalt concrete layers.
Asphalt concrete layers, longitudinal and transverse joints shall be constructed
according and the material quantity of the new asphalt mix shall be controlled to give
adequate thickness and result in smooth road surface.
136
All used materials in asphalt works shall meet material requirements stipulated in
section seven (7) of these general specifications but asphalt concrete mix should comply
with the requirements stipulated in Division eight (8) of this general specifications except
otherwise indicated in the special specifications.
Contractor shall apply quality control for civil works of utility projects by carrying
out all the necessary procedures to insure that used materials, construction methods and
completed works fulfilled the quality requirements indicated in the special specifications
of the client, special specifications and these general specifications or other contract
documents.
The Ministry shall apply the quality assurance by verifying Contractor's quality
control procedures either through direct supervision or by carrying out quality assurance
procedures separately with adequate numbers of representative samples and accepting or
rejecting the constructed works, according to the detailed principles in Division 17 of this
general specifications except otherwise specified in special specification or other contract
documents.
1.
Quality Control:
Contractor shall apply quality control on materials and constructed works and
monitor records, analyze results, draw quality charts for critical properties and carry out
all tests and measurements indicated in Table (5.6.4).
Contractor shall submit to the Engineer with copies of all tests immediately and
apply all the items indicated in sub-section 17.1.1 of these general specifications.
2.
Quality Assurance:
Ministry at any time has the right to insure the quality of materials and constructed
works through carrying out or ordering others under direct supervision to test materials
and check constructed works for all or part of the quality control items specified in Table
(5.6.4).
procedure as specified in Division 17 of these general specifications, inspect Contractors
laboratory, equipments and technical staff to insure the efficiency of Contractors staff
and the inspection, testing and construction methods whether they are conforming to the
approved testing and construction method.
5.6.7 Measurement:
Excavation, backfill, Subgrade layer, aggregate layers and asphalt layers shall be
measured according to related sections of these general specifications except otherwise is
stipulated in the special specifications. Measurements for public utilities works are carried
out according to special specifications or as what is approved by the client.
5.6.8 Payment:
Payment shall be made for actually constructed works within the approved limits
and dimensions in accordance with the contract prices or reduced prices as a result of
quality assurance as indicated in the contract documents, the payment for public utilities
works will be according to the special specifications or what is approved by the client.
137
The paid amounts are considered as a full compensation for production,

transportation, spreading, wetting and compacting of the materials whatever their source,
provision and operation of machines and equipments, labor, tests, benefits, revenues and
all the required things for carrying out the works according to drawings, special and
general specifications and the special specifications and other contract documents.
Payment will be made according to one or more of items or items indicated in Table
(5.6.5) or as specified in the contract documents.
Table 5.6.4: Quality Control of Civil Works In Public Utilities Projects
Work
Description
Excavation
works
Measurement
s
Public
utilities
works
All quality
control
requirements
approved by
the client
Gradation
Backfill
materials
and filter
layers
Bedding
and
backfill
works
Reconstruc
tion of
Subgrade
layer and
pavement
layers
Densitymoisture
relationship
Testing Method
Survey
measurements
for dimensions
and levels
According to
what is indicated
in the special
specifications of
public utilities
AASHTO
T-(27,1 1)
Sampling
location
Repetition of sampling
Requirements
On site
Survey measurements every

25meter
Item
5.6.3
On site
and before
backfilling
According to the clients

specifications or this
specifications which is
stricter.
Values
approved by
the client
AASHTO
T-180
At source
Qualitative
properties
stipulated in
the special
specifications
Testing methods
stipulated in the
special
specifications
Field density
AASHTO
T-310-01,
or any other
non-destructive
method
and All
quality
control for
related works
Measuring and
testing methods
indicated in
section 5.5 ,
division 6 and 8
On site
Three tests on different

samples at approval of each
source, when the preparing
job mix formula and when
observing a change in the
produced mix properties or
the executed works. And
five tests on different
samples timely separate for
each 5000 cubic meter from
each source during
completion.
One test each 150 linear
meter or for every daily
production from each layer
whichever is lesser and one
test at each side of the
manholes
The number of samples and
measurements indicated in
related sections and items
considering that the lot for
quality control is equal to
150 linear meter
Item
5.6.4
Section
5.4
Sections and
items
concerned
Table 5.6.5: Items of Civil Works in Utilities Projects

Item No.
5.6.3
5.6.4
5.6.5.1
5.6.5.2
5.6.5.3
5.6.5.4
5.6.5.5
Work Type
Excavation
Backfill
Subgrade layer
Subbase layer
Aggregate Base course
Prime coat
Asphalt concrete
Measurement unit
m3
m3
m3
m3
m3
m2
m3
138
5.7
Water drainage:
5.7.1 Description:
This section consists of material requirements and construction methods required
for surface drainage and under drain at road areas, streets and their ancillary elements. It
includes the following items:
- Surface drainage.
- Under drain.
- Edge drains.
- Filtering layers.
- Culverts.
The drainage works shall be constructed on the base of technical study prepared by
specialized agency shows specifications and type of material used, method of construction
and contractor qualifications, when the drawings or special specification require using of
prefabricated materials that needs special experience like, Geotextile or Geocomposite
then the material shall conform to types and requirements indicated in the drawings,
special specifications or t technical study and the construction shall be executed according
to the instruction of the fabricated agency and under its supervision if necessary.
The contractor shall be qualified in field of construction of these works according
to approved experience certificate, otherwise he shall made a subcontract with other
experience contractor according to requirements of subcontracting items and conditions of
contract.
Contractor shall construct all works according to the dimensions, levels and slopes
shown on the drawings and indicated in the special specifications. All concrete works
related to surface and under-drains works shall be executed by using sulphates resisting
cement (type five), unless otherwise indicated in the special specifications.
Contractor shall furnish the required materials and elements conforming to the
requirements indicated in special specifications, standard specifications and the approved
standard specifications issued by the Saudi Arabian Standards Organization.
Contractor shall submit source guarantee certificate for all manufactured materials
supplied to the project, shows types, sources and approval of the sources by the concerned
authorities, manufacturer quality control programs, diameters, dimensions of those
materials and their specifications, properties, copy of standard specifications, frequency
and methods of sampling and testing of materials and manufacturing elements, copies of
tests results showing conformity to the specifications, instruction of construction and
connection method shall be attached.
The surface and under-drain water drainage system, unless otherwise indicated in
the special specifications and approved instructions shall be, separated from the sewage
drainage system and it is not allowed to connect these system with sewage drainage
system.
Contractor shall verify that the information for water drainage works fulfill the
purpose and submit a technical study prepared by a specialized agency including the
hydrological and hydraulic study conform to the road classification and the project area.
139
Study shall contain storm water draining from the road surface, culverts and lowering of
water table, in addition to diameters and types of the drainage network, drainage inlets
and manholes attached with the special specifications, drawings and all details. Contractor
has not right to start construction of these works before obtaining approval of the study
from the Ministry or its representative. No additional payments should be paid to the
Contractor for these drainage studies, unless otherwise indicated in the contract
documents.
5.7.2 Surface drainage:
This works consists of furnishing all materials, elements, equipments, machines
and construction of the works required for surface drainage from roads, streets and their
elements. Also, they include construction of slopes, construction of drains, drainage
basins and manhole systems and inlets according to special specifications, drawings,
contract documents or these general specifications.
5.7.2.1 Surface slopes:
Contractor shall finish the entire road and streets surface layers and all elements
such as pavements and islands according to the longitudinal and cross slopes indicated on
the drawings, special specifications and/or specified by the Engineer which allows the
draining and direct the water towards drain's inlet or side drains. Slope values shall
comply with type of pavers used. All the surfaces of the pavement layers and the upper
surface of the Subgrade layer shall be leveled and free from depressions and corrugations
which interrupt flow of water, and lead to water collection. Contractor shall give high
attention to achieve the specified smoothness and slopes starting from the Subgrade up to
upper layers. The minimum longitudinal and transverse slope shall not be less than the
values indicated in Table (5.7.1) unless otherwise indicated in the drawings and special
specifications.
Table No. 5.7.1: Minimum Slope Limits
Type of pavement
Asphalt or cement concrete
Concrete brick pavement
Macadam pavement
Minimum slope limits %

transverse slope
Longitudinal slope
2
0.5
3
1
2
1
5.7.2.2 Surface Side drains:

Contractor shall execute the surface drains required for collected water from the
road surface, its elements and directly neighboring area and to transfer it towards draining
inlets of the catch basins or towards culverts. The side drains shall be constructed in the
form of gutters according to the shapes, dimensions, slopes and locations shown on the
drawings and special specifications.
Gutters shall be constructed using cast in place cement concrete or pre-cast
concrete and they can be combined with the curb or separated from it according to the
drawings and special specifications. The construction of gutters shall be according to the
quality requirements, construction method and construction joints using the method and
the materials indicated in the special specifications and the drawings or Division fourteen
(14) and Division fifteen (15) of these general specifications. Contractor shall construct
the required drain inlets in the gutters or curbs at the specified locations and
140
according to the dimensions, levels and shapes shown on the drawings and special
specifications.
The surface of the gutter shall be finished according to the dimensions and slopes
indicated in the drawings and special specifications and the level of its surface shall be
verified by an straight edge 3 meters long placed parallel to flow lines and the clearance
between the bottom of the straight edge at any two adjacent contact points shall not
exceed 6 mm. This verification shall be performed at site immediately after finishing
casting, leveling and compacting, before the concrete hardening so that faults may be
repaired directly. Contractor shall remove all the parts that do not achieve the required
level and slopes without having the right to claim any additional payments.
When the special specifications require construction of catch basins, Contractor
shall execute these basins according to the dimensions and shapes using the materials and
construction method shown on the drawings, special specifications and manufacturer's
instructions. Those drains shall be covered using the suitable covers conform to the
technical requirements indicated in the special specifications and the drawings or in
paragraph (5.7.2.3.1) of this section.
The gutters and surface drains shall not lead to any interruption or danger to the
traffic on the road and all the constructed elements should be capable to restrain the traffic
loading.
5.7.2.3 Surface drainage systems:
Contractor shall furnish materials and construct the surface drainage network to
drain surface water through the inlets and catch basins. This works include provision of
pipes, joints, joint's materials, manholes, inlets and catch basins. And it includes,
construction and finishing of excavation, casting, installation, backfilling works and
execution of all the measurements and tests, according to the dimensions, levels, depths
and sites shown on the drawings, special specifications and contract documents or these
5.7.2.3.1 Materials:
All used materials and elements in the construction of the drainage systems shall
be in accordance with those indicated in the drawings, special specifications and contract
documents. Contractor prior supplying and using materials, shall, submit the origin
guarantee certificates approved by the manufacturer and the Ministry or Saudi Arabian
Standards Organization (SASO). These certificates shall indicate the conformity of the
materials and elements to the approved specifications and shall include the recommended
construction and installation methods. The Engineer has the right to take samples from the
materials for testing, and Contractor shall replace any unsuitable materials with other
technically acceptable quality on his own account.
1.
Inlet, Manholes and Catch Basins:

The inlet, manholes and catch basins shall be constructed from cast-in-place
reinforced or pre-cast concrete or non-reinforced concrete or from bricks and tiles in
accordance with the special specifications and drawings and according to the dimensions
and levels and locations specified in the drawings, special specifications and contract
documents.
141
Prior starting construction, Contractor shall verify the road surface levels and
determine the actual locations for inlets and catch basins so that they lie in the lowest
level of the transverse cross section. Inlets and catch basins shall be constructed at the
lowest points of the longitudinal section of vertical sag curve, at road intersection and at
car parking areas if not indicated in the drawing or special specifications. Water flow
across road intersection shall be prevented.
When the manholes, catch basins and inlets are constructed using in-place cast
concrete, this concrete shall be composed of aggregate-sulphate resistance Portland
Cement mixture and shall achieve the requirements indicated in Table (5.7.2) unless
otherwise indicate the special specifications.
Pre-cast concrete elements shall conform to the requirements of the standard
specifications indicated in Table (5.7.3) according to the material's type.
Table 5.7.2: In-place cast concrete requirements
or inlets, catch basins and manhole works
Requirements
minimum Cement content in the mixture, Kg./m3
maximum water cement (W/C) ratio %
maximum slump, mm
maximum entrained air content %
minimum unconfined compressive cubes strength after 28 days (M.Pa)
minimum aggregate percent passing 37.5 mm sieve %
Limits
350
0.5
125
4
30
100
Table 5.7.3: Standard Specifications of Pre-cast Elements

Materials
Standard specification
Pre-cast cement concrete
ASTM C 478
Concrete bricks
ASTM C 139 or ASTM C 55 (1st. class)
2.
Covers of Inlets, manholes and catch basins:

Contractor shall provide and construct manholes, inlets and catch basins covers
conforming to types, shapes and dimensions indicated in the special specifications and
drawings. The manufacturing of the manholes, inlets and catch basins covers shall be from
grey iron or cast iron or Structural steel and shall comply with the standard specifications
indicated in Table (5.7.4) according to materials.
Table 5.7.4: Standard Specifications of inlets, manholes and catch basins covers
Cover material
Grey iron
AASHTO M 105
Cast iron
AASHTO M 103M
Structural steel
AASHTO M 183M
3.
Drain pipes:
Contractor shall furnish the pipes with the types, diameters and materials conform
to the special specifications and the specified specifications approved by concerned
authorities or these specifications and laying, install and construct the
142
network system according to the locations, dimensions, levels and construction methods
indicated in the drawings, special specifications and manufacturer instructions.
Pipes with internal diameters less than 30 cm shall not be used in constructing
drainage system. The actual diameters, line, slopes, location of inlets and manholes shall
be identified in the drawings and special specifications.
Pipes shall conform to the standard specifications indicated in Table (5.7.5) unless
otherwise indicated in the special specifications or when no approved specifications are
available in the Kingdom of Saudi Arabia.
Table 5.7.5: Surface drainage pipe specifications*

Pipe types
Standard specifications
Non-reinforced cement concrete pipes ASTM C 14, ASTM C 14M
Reinforced cement concrete pipes
ASTM C 655, ASTM C 655M, SASO 1911
Iron pipes covered with cement mortar ASTM A 849, type C
Corrugated metal pipes
AASHTO M 36
Asphalt coated corrugated metal pipes AASHTO M 190 (D)
PVC pipes
ASTM D 3033, AASHTO M 3034
PVC, ABS
ASTM D 2680
ABS pipes
ASTM D 2661 (PS 46,SDR 35)
High resistant verified clay pipes
ASTM C 700
*(Codes between two brackets refer to category).
Table 5.7.6: Standard Specifications of Joints according to
Materials and types of Pipes
Pipes
joint
Rubber gasket
Cement mortar
ASTM C 443
ASTM C 270
Rubber gaskets
ASTM D 1869
Cement mortar
Plastic asphalt slurry applied in cold
state, air tight pre-shaped plastic
gasket applied in the cold state.
ASTM C 270
Reinforced concrete
Non-reinforced
concrete pipes
PVC plastic pipes
ASTM F 477
Table 5.7.7: Gradation of bedding layer materials

Sieve size (mm, No.)
(1 1/2 inch) 37.5
(1 inch) 2.54
(No. 8) 2.36
(No. 200) 0.075
Percent passing by weight

100
90-100
35-80
0-8
143
Joints Materials:
Contractor shall provide the required materials for constructing joints according to
drawings, special specifications and contract documents. The used materials and
construction methods shall be capable of joining drainage pipes and elements with each
other tightly without any water seepage unless otherwise specified in the special
specifications. These materials shall conform to the used pipe's materials diameters,
manufacturer instructions, and the standard specifications stated in Table 5.7.6 unless
otherwise indicated in the special specifications and contract documents.
Contractor, prior starting of supplying materials for the joints, shall submit
samples from the proposed materials with the technical specifications and construction
methods brochures prepared by the manufacturers or a specialized agency showing the
suitability of the proposed materials for the works to be executed and their conformity
with the approved specifications. Contractor has no right to commence supplying and
execution before obtaining the Engineer's approval.
5.
Bedding layer under pipes:

The bedding layer under the pipe lines shall conform to the gradation requirements
indicated in Table 5.7.7, unless otherwise stated the special specifications.
The plasticity index of the bedding layer for all types of pipes shall not exceed (8)
% percent according to AASHTO T-190 test.
Aggregate bedding layer shall be constructed on the full width of excavation and
with a thickness not less than (15) centimeters under the pipes with diameters up to (30)
centimeters and not less than (20) centimeters under the pipes of diameters more than (30)
centimeters.
When the bottom layer of excavation is silt or clay soil a sand layer separating
between the bottom of excavation and the bedding layer with thickness not less than 10
cm shall be constructed.
When the special specifications indicate to construct bedding layer using cement
mortar, the bedding shall be constructed for the full width of excavation and with
thickness not less 10 cm. The mortar shall compose of cement-aggregate mixture using
cement content not less than 300 kg/m3. The 28 days cube strength shall not be less than
25 M.Pa and water-cement ratio shall be within the lower limits to provide enough
workability of the mix and the slump shall not exceed 75 mm.
5.7.2.3.2 Construction:
1.
Excavation:
Excavation works shall be performed for the pipes and manholes at site to the
depths specified in the drawings, special specifications and the Engineer's instructions
according to requirements in section (5.6) of this Division, unless otherwise indicated in
Sides of the excavation shall be vertical unless otherwise allowed. When inclined
excavation sides are allowed, excavation in the lower part shall be vertical for a height not
less than 30 cm over the top of the pipe. The additional required excavation for the joints
and gaskets shall be made after preparing excavation bottom. Unsuitable
144
materials which are not suitable of providing a stable foundation for the pipes during
construction or operation shall be removed and replaced with suitable materials, according
to the requirements of section (5.6) of this Division.
The excavation width, for all pipes having diameter less than one (1) meter, shall
not be less than the pipe external diameter plus 15 cm and it shall not exceed the external
diameter of the pipe plus the radius of the pipe or 30 cm whichever is grater from both
side. However, for pipes with diameter more than one (1) meter the minimum limit for
excavation width shall provide a distance between the external sides of the pipe and the
excavation side slope or support elements of not less than 30 cm and not more than 60 cm.
Contractor shall store excavated suitable materials for use in the subsequent works
and to dispose the west and unsuitable materials according to section (5.3) of this division.
2.
Construction of Manholes, Inlets and Catch Basins:

Excavation in manholes areas, inlets and catch basin construction areas shall be
carried out according to the specified dimensions and levels in conformity with the
requirements of section (5.6) or according to special specifications. The excavation
dimensions shall be sufficient for constructing all works such as framework, concrete
casting, installation of joints and pre-cast or manufactured elements as indicated in the
drawings and the special specifications. Bottom excavation levels shall be verified such
that the upper surface levels of the manholes, inlets and catch basins, after installation of
the frames and covers, shall conform to the surface levels of the road.
Prior staring of construction works, the surface on which the foundation will be
executed shall be leveled and compacted so that it provides a level foundation conformed
to the approved levels and capable to sustain the following works. When using pre-cast
elements an aggregate layer 10 cm thick shall be constructed leveled and compacted
below the pre-cast foundations.
Installation of the pre-cast concrete elements shall be carried out using the suitable
machines and equipments which are capable of lifting and inserting elements to the
specified depths and locations without causing any damages to elements and excavation
side slopes or other elements. Special care shall be taken for the inlets and pre-cast joint
elements for pipe joining and it should be compatible with the diameters and directions of
pipes.
When constructing these works using in-place cast concrete all the concrete works
shall be carried out with framework, using the concrete type which achieves the quality
requirements indicated in the drawings and special specifications. All the concrete
production, casting and curing works shall be performed according to the requirements of
division (14) of these general specifications unless otherwise indicated in the special
specifications and contract documents. The construction of the joint's inlet and installation
of elements shall be performed according to indicated dimensions, sites and levels, and it
is not permissible, by any means, to prepare these inlets after casting the walls, and the
elements of joints shall be installed so that they pass the full thickness of the walls and
projected to enough distance sufficient for pipe connections.
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General Specifications of Urban Roads Construction _____________________ Division 5- Earth Works
Joints between pre-cast pieces shall be filled by using cement mortar or rubber
sealing materials or sealants materials or any other type according to the special
specifications and contract documents. When using cement mortar the mortar shall be
composed of cement-sand mixture in the proportion of 1 cement to 2 sand, and it is not
permissible to use any mortar have been mixed after 30 minutes and it is prohibited to
remix it by adding water.
Joints shall be constructed with flexible gaskets such that they provide a flexible
air tight connection, but preformed sealant joints shall comply with AASHTO M-198
requirements and shall be performed according to the manufacturer's recommendations.
When constructing the walls using bricks the used bricks shall be conform to the
quality requirements indicated in the special specifications and drawings. The bricks shall
be soaked in water before installation for a period not less than 24 hours before use and
they shall be installed on a layer of cement mortar conforms to the above mentioned
requirements. The executed walls shall be proper, level and compliant with the
dimensions and levels shown on the drawings and indicated in the contract documents.
During construction the required inlets of joints shall be left for subsequent connection of
the pipes or immediately installing the required joint elements of required dimensions,
locations and levels specified on the drawings and indicated in the special specifications.
The walls shall be coated with the cement mortar which is composed of cement and fine
sand mixture in the proportion of one to one (1:1). A layer of water proofing materials
shall be executed when the special specifications indicate that.
Special care shall be taken for all concrete and cement constructed elements by
maintaining wetting, preventing evaporation and providing the required conditions to
prevent appearance of any cracks. When such cracks are noticed, Contractor shall take the
required measures to fill them using the approved and technically acceptable materials
without any additional costs for this work and if the Contractor failed, according to tests,
to achieve that, he shall remove unacceptable constructed works and re-construct it on his
own expense according to approved specifications.
Contractor shall not start installation of manhole frames and covers before
finishing road pavement layers. The manholes, inlets and catch basins shall be covered
with metal sheets capable to sustain loads resulting from the machines and equipments
used in construction of asphalt layers. These plates shall be removed after completing
construction and the frames and covers should be installed. High care shall be taken to
insure that the covers and frames surfaces are compatible with the pavement surface.
The covers and frames shall be installed on a reinforced concrete bed constructed
according to the drawings and special specifications. It is not allowed to start the
installation before the end of the concrete curing period and reaching the required
strength which shall not be less than 80% of the indicated design strength after 28 days.
When inconformity of the cover and frame surfaces with the final surfaces of the
pavement is noticed Contractor shall modify the manholes, inlets and catch basin levels
by cutting the concrete or adding the suitable thickness for the constructed concrete
according to the used technical methods without having the right to claim any additional
costs for this work.
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3.
Pipe installation and construction of joints:

Laying and installation of pipes shall be at the required locations and in
accordance with the slopes and levels shown on the drawings and contract documents by
using the technically acceptable methods and equipments. Installation shall be on a
prepared bedding layer so that it provides a complete and stable foundation for the full
length of the pipes.
Pipes shall be loaded, transported and inserted carefully to avoid any damage and
Contractor shall replace all the damaged or broken pipes with other sound pipes on his
expense.
It is possible, as directed by the Engineers, to repair galvanized steel pipes
according to AASHTO M-36 specification and when the asphalt coated layer is damaged
a new coating layer shall be executed by using materials conform to AASHTO M- 190
specification.
Pipes and all their elements shall be laid according to the manufacturer
recommendations and it shall be cleaned from wastes and ingredient materials before
laying process. Locations and levels of the pipes shall be verified by the approved
surveying methods. The deviation of the pipes from connecting line between two
manholes shall not exceed 12 mm from centre line, and shall not exceed the design level
by more than 3 mm. The gradients of the flow surface in the pipes shall not be less than
0.005, unless otherwise allowed by the special specifications,
The ends of the adjacent pipe shall be identical and with continuous flow surface.
The joints shall be made using the methods indicated in the manufacturer brochures and
by using the materials indicated in those brochures or special specifications.
When pipes are proposed to be laid on cement concrete bedding, prior construction
of such bedding, pipes shall be laid, leveled, fixed using seats of concrete pieces capable
to sustain the pipe weight. After the Engineer verifies the pipe stability concrete casting
shall be started from one side of the pipe with complete filling underneath until
achievement of required contact for the full length and the filling process shall not leads to
any damage, then casting is continued on both sides of pipe up to thickness specified on
the drawings or in the special specifications or according to the Engineer's instructions.
Joint connection between the pipes shall be executed using the materials and
methods indicated by the manufacturers or in the special specifications or the drawings or
as stated in this section. The joint method shall provide stability of the pipes as to each
other during construction. Also it shall insure non-leakage of water from the pipes unless
otherwise allowed by the special specifications.
4.
System Testing:
Contractor shall, in the presence of the Engineer, test the drainage system which is
composed of non-perforated pipes and sealant gaskets immediately after finishing
installations and connecting all the elements by using one of the following methods in
accordance with special specifications or according or as accepted by the Engineer:
147
a.
Static pressure water test:

This method is summarized in providing a water source through a vertical pipe;
this source shall be higher than the top of the pipe by a distance of 1.2 meters providing
that this height does not exceed the lowest pipe end by more than 6 meters. A suction
period in the pipes of one (1) hour shall be allowed then the leaking water shall be
measured by adding water to compensate for that leakage using measuring gradated tube
during half an hour, the measurements shall be taken in regular periods every 10 minutes
and recording the required water volume in each measurement to increase the water level
to the original level at the beginning of the measurements.
The quantity of the water required for compensation shall not exceed the
following quantities according to the diameters of the tested pipes:
-
0.06 liter per hour for each 100 meters for pipes with diameters up to 30 cm.
0.12 liter per hour for each 100 meters for pipes with diameters more than 30 cm.
b.
Pressure air test:

The system shall be tested after being airtight by applying on tested part an air
pressure equal to water column pressure 100 mm high through a U-shape tube then all the
system elements are inspected at this pressure by a soap solution and monitoring any
leakage of the soap bubbles. Contractor shall carry out the required repairs at all the
leakage points including replacement of the elements and pipes if necessary and he shall
repeat the test until he completely verifies that no seepage of the soap bubbles exists.
Then the air pressure shall be increased until it becomes equal to 100 mm water pressure,
the pressure should not decrease to less than 75 during 5 minutes.
Contractor on his expense shall repair all the defects that may occur as a result of
the test without having the right to claim any additional compensation for this work. It is
not permissible to allow the Contractor to start backfill before inspecting, testing, and
accepting the system and handing it over to the Engineer. Contractor is responsible for the
results arising due to his failure to adhere to this.
5.
Backfill:
Prior to start Backfill works all pipes' installations and their elements, constructing
manholes, finishing joints, testing shall be completed and approved by the concerned
authority. Also it is not allowed before the hardening of concrete and reaching a sufficient
strength of not less than 80 % of the design strength in order to bear the pressures arising
from backfill and compaction equipments.
Backfill shall be carried out using acceptable materials according to section (5.6) of
these general specifications and the special specifications. When the pipes are protected
from corrosion by any materials care must be taken to avoid any damage to the protection
materials and backfill shall be performed, regardless of its materials used, in a balanced
way on both sides of the pipes.
If settlement occurs in the pipes during spreading and compacting of backfill
materials, the materials shall be re-excavated, then a preparation of the lower layer under
the pipes, and re-laying of pipes shall be carried out, according to special specifications or
these general specifications. The Contractor shall be responsible for all
148
the costs resulting from these works and he has no right to claim any additional payments.
Backfill shall be constructed around drainage pipes and over them to a height not
less than 30 cm using compatible graded granular materials, in compacted layers not more
than 15 cm thick, using manual or mechanical compaction equipments, which do not
cause any damage to the installations and achieve the uniform degree of compaction for
the full depth of the layer, not less than 95% of the maximum dry density at a moisture
content not vary from optimum moisture content by more than 2 % according to modified
proctor test AASHTO T- 180.
When the special specifications require using of cement treated backfill materials
or cement concrete around pipes it shall be constructed according to the special
specification requirements and the surfaces on which they shall be constructed should be
free from any deleterious materials and wetted before concrete casting. The quantity of
cement in the concrete mixture shall not be less than 150 kg/m3, and the cube strength
after 28 days shall not be less than 10 M.Pa, and slump shall not exceed 75 mm. The
mixture shall be used, within one hour after its preparation.
After completion of filling works around and over pipes and acceptance of testing
and compaction results then the construction of the remaining of the backfill works shall
be done according to the requirements of section (5.6) of these general specifications and
by using the technically acceptable equipments and materials providing that their
classification shall not be less than A-2-4 according to AASHTO M-145.
Each layer shall be compacted uniformly for the whole thickness up to compaction
95% degrees of compaction of the maximum dry density according to modified proctor
test AASHTO T- 180 at moisture content not vary from the optimum moisture by more
than the 2% as specified by modified Proctor test.
The contractor shall place warning strips on each layer of backfill and he shall
delineate type and depth of service clearly.
5.7.3 Under Drains Works:
This work consists of underground drainage using under drains pipes. It includes
supply of materials and construction of works according to the dimensions, slopes and
levels shown on the drawings and the special specifications or these general specifications
and the manufacturer's instructions.
5.7.3.1 Materials:
1.
Under drains pipes:

When the special specifications and contract documents require a construction of
under drain system, Contractor, shall provide the pipes, joints, materials, with a compliant
dimensions of holes and slots to construct the network according to the depths, locations,
levels, slopes, dimensions and the method for connecting the system with the other
drainage systems or to culverts or low areas according to the special specifications and
drawings.
149
The under drain system shall be constructed using concrete or verified clay pipes
or steel or PVC or corrugated aluminum pipes. These pipes shall be pre-perforated or it is
possible to use joints which allow the entry of water to the pipes, as required by special
specifications and drawings. Those pipes shall conform to the requirements of the standard
specifications stated in Table 5.7.8 unless otherwise indicated in the special specifications.
When the special specifications require the using of perforated pipes the
perforation of pipes shall be made with circular holes or in the form of slots according to
the special specifications. The diameters of the circular holes in the PVC pipes shall vary
between 5-10 mm in 4 symmetrical rows parallel to the pipe's axis and the distance
between adjacent holes in one row shall not exceed 10 cm. The opening of the slots shall
be made in two rows parallel to the axis and the slot width varies between 1.5-3 mm and
the distance between the slots is 20-30 times the slot width. For metal pipes the execution
of circular holes or slots shall be according to AASHTO M-36 test also the holes must be
open before treated and covering pipes.
The under drain pipes shall be manufactured from aluminum sheets of thickness
not less than 1.22 mm and any type of perforation can be use, while the steel pipes shall be
manufactured from sheets of thickness not less than 1.32 mm.
The asphalt coated metal pipes shall be covered by using asphalt materials
conforming to requirements of specification AASHTO M-(1 90, 243).
Table 5.7.8: Standard Specification of Under Drain pipes
Pipe types
Concrete pipes
Verified Clay
metallic-coated pipes
PVC
ABS
Aluminum corrugated pipes
AASHTO M (175M)
ASTM C 700
AASHTO M 36, AASHTO M 190
ASTM D 3033, ASTM D 3034 (SDR35)
ASTM D 2751
AASHTO M 196
2.
Under Drain aggregate (filter material):

The filter layer around the under drain pipes shall be constructed from free
drainage aggregate materials which allow the seepage of water and prevents passing of the
soil particles to the pipes. Unless otherwise indicated in the special specifications it shall
be from clean, crushed water resistant or natural aggregate, and the total density of the
aggregate shall not be less than (2.35) gram per cubic centimeter, the water absorption
percent shall not exceed 2.5% and abrasion according to Loss Angles test shall not exceed
40% for 500 cycles.
The materials used shall achieve the suitable gradation for allowing water seepage
and preventing soil particles passing. When choosing the gradation it shall be verified by
the following relationships or any other relations and requirements indicated in the special
specification:
150
a) The ratio between filter material gradation around the pipes and the
surrounding soil gradation:
1- The product of dividing the sieve size through which passes only 15 % of the filter
material D f (15) over the sieve size through which 85 % of the surrounding soil pass D s
(85) shall be less or equal to 5, according to the following relationship:
D f (15) / D s (85) ~ 5
2- The product of dividing the sieve size through which passes 50 % of the filter material
over the sieve size through which 50 % of the surrounding soil pass shall be equal or
less than 25, according to the following relationship:
D f (50) / D s (50) ~ 25
This equation must not be used if the surrounding soil is clay soil, and the sieve size
which pass passes 15 % of the filter material is 0.4 mm or more
3- The product of dividing the sieve size through which passes 15 % of the filter material
D f (15) over the sieve size through which 15 % of the surrounding soil pass D s (15) shall
be equal or greater than 5, according to the following relationship:
D f (15) / D s (15) ~ 5
b) The ratio between the filter material gradation and the under drain pipes
perforation openings:
The product of dividing the sieve size through which 85% passes of the fill material
around the pipes D f (85) over the drain slots width in the pipes shall be greater than 1.2
for slot opening pipes according to the following relationship:
D f (85) / Pipe slot width > 1.2
The product of dividing the sieve size through which 85 % of the fill material around
the pipes D f (85) over the diameter of drain holes in the pipe shall be greater than one
(1), according to the following relationship:
D f (85) / Pipe hole's diameter > 1
Such that:
Df = Sieve size through which the percent passing of the filter material is indicated
between two brackets.
Ds = Sieve opening through which the percent passing of the filter surrounding soil is
indicated between two brackets.
Pipe slot width - Drain slots width in the pipes
Pipe hole's diameter - Diameter of drain holes in the pipe.
No. 15, 50, 85 Represent the percent of passing from the sieve.
Filter layer shall be of good grading and its conformity index shall not exceed (D60 / D10 ~
20) except otherwise stipulate special specifications for a specific gradation of filter layer
material, it is possible to follow the gradation indicated in Table (5.7.9) and it is necessary
to verify it on the basis of the mentioned correlations, knowledge of surrounding soil
gradation, and shape/dimensions of pipe holes.
151
Unless otherwise specified in the special specification the gradation for the filter
layer it is possible, to use the gradation shown on Table (5.7.9), but it is necessary to
verify the gradation on basis of the above relationships using known gradation of soil
around and the shape and dimension of pipe slot.
When the under drains lie within traffic load distribution area the fractured faces of
the materials retained on the 4.75 mm sieve shall not be less than 90 %, the percent of
aggregate abrasion shall not be more than 40 % according to loss Angeles test for 500
cycles and total water absorption shall not exceed 2.5 % and the total density shall not be
less than 2.35 % g / cm3.
c) Geotextile:
In case the special specifications indicate the use of Geotextile or Geocomposite
material the used material shall conform to the type and requirements shown on the
drawings and special specifications and it shall be constructed in accordance with the
manufacturer's instructions. Unless otherwise the special specifications indicate the Geo
textile material shall achieve the requirements shown in Table (5.7.10).
Table 5.7.9: Gradation of the under drain filter material
Sieve size (mm, No.)
37.5 (1.5")
25.4(1")
12.5 (1/2")
4.75 (No.4)
2.36 (No.8)
2.0 (No. 10)
Passing percent, by weight

100
95-100
25-60
0-10
0-5
0-2
Table 5.7.10: Geo-textile Materials Requirements

Properties
Minimum Grab Tensile Strength, Newton
Minimum Puncture Strength, Newton
Minimum Tear Strength, Newton
Apparent opening size less than
or equal, (mm) according to
percent passing of surrounding
soil in No. 200 sieve.
Minimum Permeability, mm/Sec
Test method
Values
ASTM D 4632
ASTM D 4833
ASTM D 4533
500
200
200
50 % or less
0.6
ASTM D 4751
50-85%
0.3
ASTM D 4491
d) Under drain outlets:

Disposal of under drain water shall be performed according to the method, at the
specified location and using the materials shown on the drawings and special
specifications. Contractor shall submit source guarantee certificates which show
conformity of materials and elements with the approved specifications.
The under drain ends and outlets such as elbows, pipes and joints shall be
constructed using the same materials used in the construction of the drainage system and
their diameter shall not be less than 10 cm, it shall be connected with the system's
152
pipes and with each other using the materials and method recommended by the
manufacturer and the approved method for joining the pipe system considering that the
outlets and ends shall be non-perforated and it is not allowed to combine steel and
aluminum together.
When the under drain system is constructed in rolling areas the outlet ends shall be
carried out by using reinforced concrete in the shape of a vertical wall and wing walls
according to the special specifications and drawings and the slopes shall be protected from
erosion.
Excavation for the construction of the under drain works shall be performed
according to the requirements of section 5.6 of this Division, in accordance with the
dimensions, levels and depths shown on the drawings and special specifications
considering that the trench width shall not be less than the outer diameter of the pipes plus
a distance of 10 cm from each side, and the excavation width shall not be less than 25 cm.
The trench dimensions shall be adequate for laying the under drain pipes, the aggregate
filter layer and the geotextile according to the drawings and the special specifications. The
trench bottom shall be prepared according to the specified slopes such that it provides a
sound and stable support base for the drainage elements. After leveling and preparing the
trench bottom, aggregate bedding layer not less than 5 cm thick shall be executed.
When the drawings and special specifications require using geotextile material or
when carrying construction in soil type A-4, A-5, A-6, A-7 the used geotextile shall be
conform to the approved type and it shall be spread all over the excavated trench width so
that it accommodates all the elements of the drainage system and the filter material in
such way that it provides an overlapping in the upper part not less than 30 cm without
need for tension. The geotextile materials shall be spread along the whole drainage system
so that an overlapping of not less than 30 cm is achieved between adjacent pieces and the
overlapping shall be downstream.
All the loose, deleterious materials and any materials that may damage the geotextile shall be removed from the excavation bottom before spreading. The spreading of
the geo-textile material, laying of pipes and installation of joints and spreading the filter
layer materials shall be performed in such a method which insures that no damage shall be
inflicted on the geo-textile such as puncturing or tearing or any other damages. When such
damages are noticed, Contractor shall modify the work method or the used materials and
shall replace the damaged textile pieces with other sound pieces or spread new sound
pieces over the damaged pieces, providing that the spreading and approved overlapping
conditions should be achieved.
After spreading the geo-textile material the filter aggregate layer material shall be
spread considering that no damages occur to the geo-textile material or its stability on its
place.
Laying and installation of under drain pipes outlets and ends shall be performed
according to the locations, slopes and levels shown on the drawings, special specifications
and manufacturer instructions. The perforated side of pipes shall be in the bottom and all
the pipes, joints, ends and outlets shall be cleaned before starting laying
153
and installation process. It is not allowed to backfill over pipes and the system joints
before being tested, inspected and accepted by the Engineer.
The filter layer shall be spread in layers with maximum thickness not more than 15
cm around the pipes and all over the trench width with light tamping taking into account
that no damages occur to the pipe installations or the geotextile materials.
After the construction of the drainage system and the aggregate filter layer and
finishing it up to the levels shown on the drawings and in the special specifications, the
filter layer shall be covered with the previously spread geotextile to provide the required
overlapping.
After covering the pipes and surrounding filter material with geotextile and fixing
the ends, the trench backfilling shall be completed with a free drain aggregate material
unless, otherwise special in specifications that the backfilling should be for the whole
trench with the same filter material surrounding the pipes and covering with geotextile
material for the whole depth. Backfilling shall be constructed in layers not more than 10
cm thick compacted up to 95 % of the maximum dry density.
When the under drain lines lie within the pavement areas, the pavement layers
shall be constructed as soon as possible and it is not allowed to leave the under drain
trenches exposed for a period of more than 3 months after the completion of the under
drain system installation and backfilling. When this period is exceeded that the backfill
layers that mixed with the soil shall be removed and substituted with acceptable new
materials. However, when these lines lie outside the road a fill layer 30 cm thick shall be
constructed using soil type (A-4, A-5, A-6, A-7,) at the upper part of the trench to prevent
surface water seepage to the under-drain.
5.7.4 Edge drains:
When special specifications indicate the construction of the edge drains using
pipes for purpose of surface water draining from Base and Subgrade layers, the Contractor
shall furnish the materials and construct the works according to the requirements,
dimensions and locations shown on the drawings and in the special specifications.
5.7.4.1 Materials:
1.
Pipes:
When the special specifications require constructing edge drains using pipes, these
pipes shall conform to the types and diameters shown on the drawings and special
specifications or requirements of the specifications indicated in Table (5.7.8) under drain
pipes of this section, and they shall be installed and connected according to special
specifications and manufacturer instructions.
2.
Geo-composite:
When the special specifications indicate the use of geocomposite, it shall conform
to the special specifications and its construction shall be performed at the required
locations with the dimensions, levels and details indicated in the drawings, special
specifications and manufacturer instructions.
154
Contractor, prior starting the material supply, shall submit approved copy of the
source certificate, construction instructions and the technical specifications of the
materials and at least two samples of the material. The Engineer has the right, before
accepting material, to require carrying out the necessary tests in an independent approved
laboratory.
All materials and elements recommended by the approved manufacturer including
outlet drains, elements and ends shall be furnished.
The geo-composite, unless otherwise indicated in the special specifications, shall be
composed of the internal core and the outer part which is composed of filter fabric.
3.
The core:
The core shall be rectangular, flexible, hollowed, made of Polyolefin and strong
enough to resist vertical loads and pressures arising from installation, backfill and traffic
loads. It shall allow water entry and flow freely and shall conform to the requirements
stated in Table (5.7.11) unless otherwise specified in the special specifications.
4.
Filter fabric:
The filter fabric shall be made of non-woven polyolefin and free of chemical
treatments. The filter fabric should achieve the requirements indicated in Table (5.7.12)
unless otherwise indicated in the special specifications.
All the resistances shown in the table shall be considered as the average minimum
strength which can be obtained when testing with the weakest direction and the samples
shall be taken according to ASTM D 4354.
Table 5.7.11: Geo-composite core requirements
Properties
Maximum water absorption %
Test method
ASTM D 570
Fungus resistance
ASTM G 21
Limits
0.05 during 24 hours
Negative
(No growing fungus)
5.
Prefabricated drains from Geo-composites:

Underground or prefabricated edge drains shall be composed of geo-composites,
from core and filter fabric. After fabrication verification shall be performed to insure that
the drain dimensions conforming to the dimensions shown on the drawings and the special
specifications and that its thickness is not less than 19 mm. Also verification shall be
performed to insure that the filter fabric is bonded constantly with the core. The filter shall
achieve the requirements indicated in Table (5.7.13) unless otherwise indicated in the
6.
Drain outlets:
7.
Pipes and elements of the drain outlets shall bethe same types of
composed of the pipes used in the drainage system in accordance withial specifications,
the spec drawings and manufacturer's instructions providing that theybe perforated and
shall not their diameter shall not be less than 10 cm.
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Table 5.7.12: Filter fabric requirements

Properties
Minimum Permeability, mm/sec
Apparent Opening Size, mm
Minimum Grab tensile Strength, Newton
Minimum Puncture strength, Newton,
Minimum Tear strength, Newton,
Minimum Elongation, %,
Minimum Mullen Burst Strength, Kpa,
Minimum Seam Strength, KN/M
Minimum Unit Weight, kg/m 2,
Minimum UV Resistance, retained rays ratio
Fungus resistance
Test method
ASTM D 4491
ASTM D 4751
ASTM D 4632
ASTM D 4833
ASTM D 4533
ASTM D 4632
ASTM D 3786
ASTM D 4595
(wide slice method)
ASTM D3776
ASTM D 4355
ASTM G 21
Requirements
2
0.15-0.3
500
200
200
35
1000
14
0.14
80
Negative
Notes on Table 5.7.12:

1. Filter fabric section which lie in the pavement layers side is considered, after constructing the
overlapping, gluing or bonding, the critical permeability section. a section of filter fabric with the same
characteristics, i.e., as fabricated and installed, should be tested to ensure that the overlapped section
conform to the specified requirements. When the drain's filter fabric is not overlapped on the pavement
side, the Contractor may test a normal thickness of the filter fabric to determine its acceptability.
Table 5.7.13: Requirements of prefabricated drains from geocomposite

Properties
Minimum compressive strength (at
20 % maximum deformation), KPa,
Minimum Peel Strength, kg/mm of
width, (bonding fabric to fabric,
fabric to core, and fabric to
projecting elements)
Minimum In-Plane flow (cross
sectional area, Hydraulic
transmisity) m3/m2 of the width
Test method
Requirements
ASTM D 1621
(specimen dimensions
30x30 cm)
345
ASTM D-903
0.05
ASTM D 4716
(using a specimen at least
600 mm long)
0.003
Notes on Table 5.7.13

1.
2.
Peel strength shall be tested for all three cases using two flexible specimens (filter fabric) to test
fabric to fabric bonding and a flexible specimen with solid specimen (filter fabric material with
core) to test filter fabric bonding with core or projection. The specimens shall be jointed with each
other using similar method for fabricated and installed drain. Thickness of the used core shall be
equal to normal thickness for the core before covering with filter fabric. This represents a special
case from the 3 mm limit case specified in the standard test.
Rate of flow test shall be performed with a gradation of 10 % and a normal pressure of 70.0 K.Pa
for a period of not less than 100 hours.
Geo-composite edge drains or under drains shall be installed at locations and to the
depths shown on drawings, the special specifications and manufacturer instructions.
Contractor shall proof his previous experience in constructing such works or to sub-
156
subcontract a qualified agency. The Engineer has the right to request the presence of the
manufacturing company to supervise and verify that the construction in conformity with
requirements and instructions.
The edge drain trench shall be excavated at the locations and according to the
dimensions and levels specified in the special specifications and manufacturer
instructions. Before starting the construction drains the excavation bottom shall be
inspected, handed over and cleaned from all deleterious and loose materials.
The geotextile material shall be spread over the excavated bottom to provide
enough space for the coating and overlapping for collection pipes and/or the drain core
from geocomposites according to the specified condition, then the geocomposite drain
shall be fixed at the far end of the road edge from the trench and installation of all the
joint elements and outlets according to drawings, special specifications and manufacturer
instructions.
After completing the construction of the drains, all their elements and outlets,
verification and acceptance of construction, backfill shall be carried out using compacted
filter aggregate layers, these layers should be compacted using vibratory plates having
compaction power not more than 22 Kilo Newton, up to 90 % of the maximum dry
density determined by AASHTO T-99, unless otherwise indicated in the special
specifications, and all the necessary precaution shall be taken to avoid any damages which
may occur to the drains.
When the width of the excavated trench is less than 0.5 meter, the backfill shall be
performed using clean sand in one layer and compacted by using vibratory plates or water
submersion.
5.7.5 Filter layers:
When the special specifications, drawings and manufacturer instructions indicate
construction of filter bed or filter layers for the edge drains or backfill from untreated
cement or asphalt treated aggregate materials, the construction of such layers shall be
performed using the materials, methods, in the location and with the thickness indicated in
the special specifications and the approved drawings or these general specifications.
5.7.5.1 Filter layers from untreated aggregate:
The layers from untreated aggregate shall be executed by using the specified
gradation in the special specifications and it is possible except otherwise indicate special
specifications, to use one of the gradations indicated in Table (6.4.3) of section 6.4
"untreated base", and the materials shall meet the quality requirements stipulated in the
special specifications or in Table (5.7.15) of this section. Construction shall be carried out
according to the special specifications or the requirements for constructing the base or
backfill in these specifications. Untreated aggregate filter layer gradations shall achieve
with the gradation of aggregate sub grade over it the following correlations:
1- To prevent a drop in pressure in the filter layer
D1 5 f / D1 5 b > 4
2- To prevent leakage of material particles from sub grade to filter layer:
D5 0 f / D5 0 b < 25, D1 5 f / D 8 5 b < 5
D1 5 f / D1 5 b < 20,
157
Whereas:
Df, Db- Sieve opening diameter of filter material (f) or base (b)
Numbers: (85, 50, 15) Passing rate from sieve.
Filter layer material must be well graded and the percent of materials which passed sieve
No. (200) shall not be greater than 5% to forbid the internal movement of soft particles
and the maximum size of uses materials eight (8) cm as to forbid segregation .
5.7.5.2 Cement treated filter layers:
Cement treated filter layers shall be constructed according to the locations shown
in the drawings and the special specifications or these general specifications. If no specific
gradation or quality requirements are identified in these documents the construction shall
be performed according to the gradation indicated in Table (5.7.14) and the qualitative
requirements stated in Table (5.7.15).
The cement treated filter layers shall be constructed, maintained and finished
according to the special specifications or construction requirements indicated in section
(6.5) of these general specifications, considering that the cement quantity used shall not be
less than 150 kg/m3 of the mix. The cement used shall be sulphate resistance type unless
otherwise specified in the special specifications.
Table 5.7.14: Cement treated aggregate materials gradation for filter layers
Sieve size, mm (No.)
37.5 (1.5 inch)
25.4 (1 inch)
19 (3/4 inch)
9.5 (3/8 inch)
4.75 ( No. 4)
2.36 (No. 8)
0.075 (No. 200)
Percent passing, by weight, %

100
88-100
50-80
15-40
0-16
0-6
0-2
Table 5.7.15: Quality requirements of aggregate materials

Properties
Minimum Aggregate angularity for coarse
aggregate, %,
Maximum Los Angles abrasion, %
Minimum Sand equivalent, %
Minimum Total specific density of
aggregate, gram/cm3
Maximum water absorption of aggregate, %
Maximum Soundness by sodium sulphate %
Test method
Requirement
limits
ASTM D 5821
90
AASHTO T-96
AASHTO T-176
45
55
AASHTO T-85
2.35
AASHTO T-85
AASHTO T-104
2.5
15
5.7.5.3 Asphalt treated filter layers:

Asphalt treated filter layers shall be constructed according to the special specifications or
these general specifications according to the thickness and locations
158
indicated on the drawings and special specifications. When no specific requirements are
specified in the special specifications or the drawings, the construction shall be performed
according to the gradation indicated in Table (5.7.16), and the qualitative requirements
indicated in Table (5.7.15).
Construction and finishing of the asphalt treated filter layers shall be carried out
according to the requirements of asphalt treated base layers indicated in section (6.6) of
these general specifications, unless otherwise indicated in the special specifications.
Table 5.7.16: Asphalt treated aggregate materials gradation
Sieve size, mm (No.)
percent passing, by weight
25.4 (1 inch)
100
19. (3/4 inch)
90-100
12.5 (1/2 inch)
3 5-65
9.5 (3/8 inch)
20-45
4.75 (No. 4)
2.36 (No. 8)
0-10
0.075 (No. 200)
0-2
0-5
5.7.6 Culverts:
This work consists of furnishing of the materials, labor, and the required
equipments to construct the various types of culverts and their different elements such as
inlet/outlet wing walls, and protection and curing works according to the dimensions,
levels and using the materials shown on the drawings, special specifications, contract
documents or these general specifications.
5.7.6.1 Materials:
1.
Precast culverts:
When precast elements are used in the construction of box culverts, these elements
shall be produced by licensed and approved factories from the concerned authorities.
Contractor prior starting materials supply and culverts construction, shall, submit to the
Engineer a list of the materials he intends to supply and their sources attached with
approval of the manufacturer, the applied quality control system, the specifications of
materials and elements and test results of samples. The Engineer has the right to carry out
additional tests in an independent laboratory on the expense of the Contractor when
necessary. The Contractor shall submit the operation manual issued by the manufacturers
includes the instructions, methods and requirements of construction, joints and materials,
and he shall follow completely these instructions and requirements
Precast elements of pipe culverts may be from reinforced concrete or smooth or
corrugated metal pipes and they shall achieve the requirements of the standard
specifications indicated in Table (5.7.17) according to types unless otherwise indicated in
159
Table 5.7.17: Standard Specifications of Pipe Culverts

Pipe type
Un-reinforcement concrete pipes
Arched sections reinforced concrete pipes

Corrugated steel structural plates constructions
Corrugated steel pipes
ASTM (C 14, C 14M)
ASTM C 76, ASTM (C 655, 655
M), SASO 1911
ASTM C 1504
AASHTO (M 167, M 167 M)
AASHTO M 36, ASTM A 760
Polymer precoated corrugated steel pipes
AASHTO M 245, ASTM A 762
Reinforced concrete pipes
Pipes shall be reinforced with circular reinforcement and another layer of

reinforcement shall be added to the pipes with diameter more than 75 cm, of a length of
not less than 30 cm extended to distance not less than 20 cm into the projections,
provided that they do not exceed the length of those elements. The cube strength of
concrete shall not be less than 35 M.Pa and the cement content in the mix shall not be less
than 350 kg/m3. The concrete used in manufacturing the culverts and drain pipes shall
achieve all the requirements indicated in specification AASHTO M-170 unless otherwise
indicated in special specifications Taper of pipe joint ends shall not exceed 7 degrees to
connect the projection and not more than two (2) degrees for the gasket joint.
Joining process shall be performed using joint materials indicated in the special
specifications or recommended by the manufacturer. Before using any joint material
Contractor shall submit a technical report including type and composition of the proposed
material, method of construction and an approval certificate from the concerned
authorities.
The joints can be performed using the cold state flexible joint materials composed
of asphalt base, filler material and rapid solvent materials and it shall be consistent and
workable in the cold state to coat pipe ends up to 13 mm thickness. It shall be capable of
joining the pipes with each other according to the technical specifications.
Flexible joint gaskets can be used to join the projection and cavity pipes and they
shall be composed of strong rubber mixture with filler material and a small amount of
solvent.
Box culverts from pre-cast elements shall achieve standard pre-cast concrete
element requirements for box culverts according to standard specifications AASHTO M
259M or AASHTO M 273 M for culverts constructed with protective layer of not more
than 60 cm and subjected to road loads.
2.
Cast-in-Place Culverts:
Culverts and all their elements such as vertical walls and wings walls cast on site
shall be constructed using the materials indicated in the special specifications or the
approved materials in the job mix formula and the used concrete shall achieve the
requirements stated in Table (5.7.18) unless otherwise indicated the special specifications.
160
Unless the special specifications otherwise indicate, the aggregate shall achieve
the requirements indicated in Table (5.7.19). While the Cement shall be a sulphates
resistant type and shall achieve the requirements of standard specification ASTM C 150
unless otherwise the special specifications permit using of another type.
The water used for producing and maintaining the concrete shall be clean, pure
and free from impurities and harmful materials. It shall be tested according to AASHTO
T-26 test as directed by the Engineer.
The reinforcement steel used shall conform to the type and diameters shown on
the drawings and special specifications and shall achieve the specification requirements
specified in Division 14 of these general specifications.
When the special specifications indicate or the Engineer requires the use of some
additives or chemical admixture, these materials shall conform to the types stipulated in
the special specifications or the drawings or approved by the Engineer and they shall
comply with specification requirements indicated in Division 14 of these general
specifications.
Table 5.7.18: Culverts Concrete Requirements
Properties
Quantity of Cement, kg/m3
Minimum Compressive strength, M.Pa
Maximum water /cement ratio %
Slump, mm
Test method
AASHTO T-22,
Sample preparation according
to AASHTO T-23
AASHTO T-119
Limits
350
35
0.5
50-100
Table 5.7.19: Aggregate Requirements for Culverts Concrete

Requirements
AASTO M-6
Coarse
aggregate
AASHTO M-43
AASHTO T-112
0.5
0.25
AASHTO T-1 13
0.25
0.25
AASHTO T-1 13
Test method
Reference standard specification

Maximum percent of Clay
materials,%
Maximum percent of lignite, %
Maximum Percentage of
materials with density less than
1.95 gram /cm3, %
Total percent of above
undesirable materials, %
Maximum percent of material
passing Sieve 0.075, mm
Maximum Los Angles abrasion
(500 cycle), %,
Minimum Sand equivalent,
1.25
1.25
AASHTO T-(11, 27)
AASHTO T-196
40
AASHTO T-176
75
Materials which give
more dark color than the
be
rejected or the slurry
testing shall be required
for verification
in
Organic materials percentage
soft aggregate
Soft aggregate
AASHTO T-21
161
General Specifications of Urban Roads Construction _______________________Division 5- Earth Works
3.
Bedding layer:
The precast culverts, unless otherwise indicated in the special specifications, shall
be constructed on a cement concrete bedding layer with cement content not less than 200
kg /m3 and cube strength should not be less than 15 M.Pa. The aggregate used shall be
non-plastic and water-cement ratio should be in its minimum limits which allow
workability of the mix, and the maximum nominal diameter of the aggregate shall be 37.5
mm.
Culverts shall be constructed according to dimensions, levels and sites specified in
the special specifications, drawings or these general specifications. Contractor shall verify
the locations shown on the drawings in the field and determine the site and culverts skew
angle with the direction of the road axis to conform to the directions of water flow, unless
special specifications indicate diversion of the flow line and construction the required
works for that.
1.
Excavation and surface preparation:

Excavation works for the construction of culverts and their elements shall be
made by one of the following methods, according to the special specifications or as
accepted by the Engineer:
- First method:
In this method the works shall be performed by excavating to the required depth
of the bedding layer and the culvert foundation then the bedding layer is constructed and
its surface is prepared according to the drawings and special specifications, then culvert
works shall be completed, finished, tested and handed over before backfill execution.
- Second method:
This method is different from the first method only in the starting of construction
by performing road embankment up to a height near to the outer radius or height of the
culvert according to the requirements of embankment works indicated in section (5.4)
from this specification, and then an excavation shall be made for installing culverts
according to section (5.3). After that the surface is prepared and the bedding layer, culvert
and backfilling are executed.
In all cases the surface on which the culvert shall be constructed should conform to
the location, levels and slopes shown on the approved drawings after verifying the correct
location and elevation on site and taking the required levels by the Contractor and
accepted by the Engineer to verify the culvert location and crossing angle with the road.
2.
Installation of precast culvert elements:
Pipe culverts:
The bedding layer shall be executed all over the excavated width and its thickness
under the pipes shall not be less than 10 cm. And, it shall continue up to a height not less
than quarter (1/4) of the outer diameter of the pipe at the two sides of the culverts. At the
beginning the concrete shall be filled at one side of the pipe until complete contact and
no existence of spaces is verified then the filling is commenced at
162
General Specifications of Urban Roads Construction _______________________Division 5- Earth Works
the other side. The Contractor shall provide contraction joints at common interval known
in concrete practice.
The reinforced concrete pipes installation shall start from the lower side in to the
direction of the higher side, and the cavity shall be inserted into the projection in the
direction of water flow. When installing corrugated metal pipes consideration shall be
made to insure that the outer rings are aiming at the upstream direction and complete
contact for all the projecting elements during foundation preparation is provided.
During installation consideration shall be made for avoiding diversion of the
elliptical pipes axis of circular reinforcement, or the circular pipes of spiral reinforcement,
from the vertical position by more than 5 degrees. When using circular pipes provided
with holes for installation control consideration shall be made to have these holes on the
upper side and after the installation of pipes and before backfilling these holes shall be
closed with the materials recommended by the manufacturer.
Box culverts:
Precast elements of box culverts shall be installed on the previously prepared
foundations so that the openings shall be in the direction of flow and the installation shall
start from the culvert outlet, using the methods, machines and equipments capable of
controlling the process of lifting, lowering and adjusting the location of the elements and
avoid causing any damage to elements or prepared foundations or excavated slopes.
The construction of multi-opening culverts which composed of separated adjacent
cell elements shall be installed leaving a space between these elements of not less than 25
mm and not more than 50 mm. After the finishing of the installation of the elements and
completing the joining between each cell, this joint space shall be filled with cement
mortar composed of 1:2 cement-sand proportions for the complete depth and width and it
shall be cured by water.
Construction of Joints:
Joint between pipes and precast elements shall be constructed using the materials,
elements and methods indicated in the special specifications and the technical manuals of
the manufacturers considering that backfill works shall not be started before completion
of all the joints with the required verification and inspection.
When using flexible asphalt in the pipe's joint, the ends of pipes shall be cleaned
and dried before application of the material on the cavity side with a thickness about 13
mm and to a distance of not less than 2/3 of the joining section. After verifying the
conformity of the pipe ends the end of the second pipe (projection) shall be inserted in the
cavity by applying the required pressure to tighten the joint. The internal faces of the
pipes should be cleaned from the extra joining material. When using rubber gaskets the
protection paper shall be removed and ends of pipe should be pressed, and water
insulation joints should be constructed.
When special specifications specify the use of cement mortar joint the used mortar
shall be composed of the 1:2 cement-sand proportions and the works shall be constructed
according to special specifications with a thickness adequate for pipe connection. The
mortar layer shall be protected from quick drying and cracking by using curing methods
and materials. Before applying the cement mortar the pipe ends
163
shall be wetted properly with water and the pipes shall be kept exposed and the mortar
layer shall be covered by wetted sacks covered with plastic sheet to prevent water
evaporation and sprayed at least twice with water for not less than 3 days.
3.
Cast in Place Culverts:

Cast in place culverts, vertical walls, inlets and outlets shall be constructed
according to the levels, dimensions, by using the materials and at the locations indicated in
the drawings and approved specifications. Contractor shall verify the submitted drawings
for the cast in place culverts and complete all the details required for the construction and
to obtain the Engineer's approval.
Contractor, prior starting the construction, shall verify the culvert location and
angle of crossing to the road axis and to determine the actual location, carry out
excavation works up to the levels and adequate dimensions for the construction of the
bedding layer and placing and fixing the frameworks.
The bottom of the excavation shall be leveled according to the approved slopes
and levels and the bedding layer shall be constructed from aggregate materials with a
thickness not less than 10 cm, compacted and leveling such that a fixed and stable surface
is obtained to support the loads arising from subsequent works.
Contractor, prior starting concrete casting by a period not less than 30 days, shall
submit to the Engineer a technical report which describe:
-The design job mix formula includes the sources and qualities of aggregate materials,
cement, water, admixtures and chemical additives proposed for use.
-Proportions and method of material mixing
-Sites, types, method of operation and productivity of concrete mixers.
-When supplying from pre-mixed concrete factories, Contractor shall submit an
approved copy about the sites and specifications of these plants, their approval
certificate and the specifications of the concrete produced or which they are going to
produce for the project. Also he shall submit the test results of the concrete produced
in these plants and the supply time schedule.
-Test results for the raw materials and produced mixes using the proposed design job
mix formula.
-Time schedule and dates proposed for starting construction and the detailed program
for casting phases.
- A list of equipments and machines proposed for use.
The Engineer shall study the technical report and give his views about
completing all the required information and he shall return the report to the Contractor in
case there is a shortage in the information within 7 days. However, if the report included
all the information the Engineer shall study the information of the proposed design job
mix formula and the construction plan and issue a written approval or requires from the
Contractor to carry out the required modifications within 14 days.
The frameworks shall be according to the dimensions shown on the drawings and
by using metal or timber frameworks capable of supporting the pressure arising from
concrete and vibrating loads during casting. The concrete surfaces, after casting,
164
shall be leveled and smoothed, and free from any defects. Contractor shall be responsible
for the durability, stability and leveling of the frameworks.
Contractor shall install steel reinforcement at the locations, with the diameters,
spacing distances, and overlapping distances conform to the type and diameters of the
reinforcement steel approved on the detailed drawings and Contractor is not allowed to
start casting before the Engineer inspects, accepts and hand over the steel reinforcement.
The concrete casting shall be performed using the approved machines,
equipments, and work plan. Contractor shall perform all the required curing works until
the hardening of concrete and it reach the strengths indicated in the drawings, special
specifications and design job mix formula. The frameworks shall not be dismantled before
the passing of the period enough for the concrete to reach the adequate hardening to
support the subsequent loads providing that concrete strength shall not be less than 80%
of the design strength and the period shall not be less than 14 days. It is possible to follow
the periods indicated in Table (5.7.20).
Table 5.7.20: Minimum Periods for Forms dismantlin
Structure elements
Percent of specified 28
days strength, %
g
Number of
days,
50
50
80
14
80
14
90
21
Columns and wall faces (not yet

supporting loads)
Mass pier and abutments (not yet
supporting loads)
Box Girder
Simple span T - Girder, slab bridge, piers
cap not continuously supported, struts,
and top slabs of box culverts.
Arches, continuous bridge spans and rigid
frames
Contractor shall make all the required arrangements for concrete casting under hot
climate conditions and all casting works shall be performed with complete adherence to
the time interval between cement application and finishing casting.
Casting shall, whenever possible, be performed in one batch or with the least
number of joints and all the required arrangements should be made to eliminate the
possibility of structural joints formation and lessen their effect. The casting of the box
culvert bedding shall be performed in the beginning then construction of the remaining
elements shall start later after the elapse of 24 hours. The constructed concrete works shall
be maintained in wet condition during curing period which should not be less than seven
days by covering it with wetted sacks at least for two days and covering these sacks with
plastic sheets to minimize water evaporation or the moisture shall be maintained by any
method approved by the Engineer.
4.
Water proofing works:

Contractor shall perform water insulation works for all the surfaces in contact with soil
using the method and materials indicated in the special specifications and he is
165
not allowed to commence backfill works before culvert works being inspected, accepted
and handed over to the Engineer.
5.
Backfill:
Backfill works around the culverts, vertical walls, and inlet, outlet and wing walls
shall be carried out according to the details indicated in item (5.4) of section of these
general specifications, unless otherwise indicated in the special specifications.

Contractor shall apply quality control for drainage works by carrying out all the
required arrangements to ensure that the used materials, construction methods and the
executed works achieve the quality requirements, indicated in the standard specifications,
special specifications, these general specifications and other contract documents.
The Ministry shall apply the quality assurance works by verifying that the
contractor has carried out quality control procedures properly either through direct
supervision of the quality control procedures or by undertaking quality assurance
procedures neutrally on representative samples and with adequate numbers to judge the
execution to accept or reject the completed work according to the principles detailed in
Division 17 of these general specifications except otherwise specified in special
specification or other contract documents.
1.
Quality control:
Contractor shall apply quality control on materials and executed works and he
shall monitor records and analyze results and draw quality charts for critical properties
and carry out all the tests and measurements indicated in Table (5.7.2 1). Contractor shall
provide the Engineer with copies of all tests immediately and he shall apply all the items
indicated in sub-section 17.1.1 of these general specifications.
2.
Quality Assurance:
Ministry at any time has the right to assure the quality of materials and executed
works through carrying out or ordering others under its direct supervision to select
materials and check executed works for all or part of the quality control items specified in
Table (5.7.2 1).
Ministry has the right to review contractors quality control records and compare
these statistically with quality assurance results to insure quality according to what is
specified in division 17 of these general specifications. It has the right to inspect the
contractors laboratory and its equipments, its technical staff, methods of testing and
construction method to insure the efficiency of the contractors technical staff and
equipments and compliance of his inspection, testing and construction method with the
approved methods.
5.7.8 Measurement:
Drainage works shall be measured according to the approved measurement units in
the contract documents, for the actually constructed, technically accepted and handed over
works. Measuring shall not be performed for the purpose of payment outside the limits
and the sites shown on the drawings or approved by the Engineer.
Measuring shall be performed according to the following, unless otherwise indicated:
166
Table 5.7.21: Quality control Procedures for drainage works

Work
Pipes,
elements
and
materials
of joints
Properties
All the
properties
stated in the
approved
standard
specifications.
Gradation
Backfill
and filter
layers
materials
MoistureDensity
relationship
Qualitative
properties
System
installation
works
In-place
concrete
works
Excavation
works
Bedding
and
backfill
works
Systems
installation
All quality
properties
indicated in
special
specifications.
Test method
Source guarantee
certificate for
each material
according to type
and diameter.
AASHTO-T
(27,11)
AASHTO T-99
(C) and testing
methods
indicated in
division (6)for
aggregate bases
or cement and
asphalt treated
bases
Table ( 5.7.15 )
and section (5.6)
for backfill
Visual inspection
and testing
systems such as
non-perforated
pipes and gaskets
according to item
(5.7.2.3.2)
Measuring of
smoothness,
slopes and utility
levels
Test methods
indicated in
Division 14 rigid
pavement, unless
otherwise
indicated in the
special
specifications
Survey
measurements for
Measurements
dimensions and
levels
Field density
Location
of sample
AASHTO T310-01
At source
At site,
before
backfilling
At site
At
production
centers and
site.
Frequency of sampling
At the starting of materials
supply from each source and
when source is changed, the
materials specifications,
technical properties and
methods and rates of tests
and their results shall be
attached.
Requirements
The specified
requirements in
the acceptance
item of the
approved
standard
specifications

from each source for source
approval and when design
job mix formula or source is
changed or noticing a
change in the produced mix
or constructed works, and 5
tests on different and in
diverse intervals samples for
each 5000 cubic meters or
each source during
construction.
Between each two manholes

or two drain inlets
Survey measuring for levels

and coordinates between
each two manholes or drain
openings or grills or outlets
3 tests at commencing
mixture production and a test
each 2000 cubic meter
production or noticing a
change in material sources or
executed work properties
and one test each 50 cubic
meters or executing one day
works whichever is lesser
and from each element.
Success
Conformity
Properties and
limits approved
At site
Survey measurements each

25 m interval including at
least a starting, end
And middle points from each
element regardless of the
distance.
Conform to the
dimensions and
levels indicated
on the drawings,
special or
approved
specifications by
the Engineer.
At site
One test every 150 linear

meter or one day production
from each layer whichever is
lesser and one test at each
side of manholes and inlets
or culverts at each location.
Degrees of
compaction
indicated in
relevant items.
167
- Drain pipes installation works classified according to types and diameters in linear
meter.
- Under drain pipes installation works classified according to types and diameters in
linear meter.
- Geo-textile works for covering under drains in square meter.
- Filter layers works surrounding under drain pipes in cubic meters.
- Geo-composite drain works in square meter.
- Drain inlets, catch basins and manholes works including covers classified
according to types and dimensions in numbers.
- Pipe culverts works including inlet and outlet wing walls according to types, sites
and openings, in linear meter measured between external FACES of the vertical
walls at inlets and outlets.
- Box culverts works including vertical walls and wing walls in cubic meter.
- Excavation works in cubic meter for actually constructed works within the
approved limits and depths. The structural excavations for culverts shall not be
measured for the purpose of payment and its costs shall be included with the cost
of the culvert.
- Bedding works in square meter.
- Backfill works in cubic meter.
5.7.9 Payment:
Payment shall be paid for actually and technically accepted constructed works
and quantities within the approved limits and dimensions according to contract unit
prices or reduced prices as a result of applying the quality assurance procedure if stated in
the contract documents.
The paid amounts are considered as a full compensation for excavation, laying,
installation of pipes, casting and performing of the connection joints, inlets, manholes and
covers works. It is also for concrete works includes, transporting, wetting, mixing,
spreading, watering, vibrating and finishing of the work, in addition to the provision
and operation of machines, equipments, labor, tests, measurements, benefits, revenues,
fees and third party payments and all requirements to construct the works according to
drawings, special and general specifications.
5.7.22 if not contradiction with contract documents.
Table 5.7.22: Draina g e Works Items
Item No.
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.7.7
5.7.8
5.7.9
5.7.10
5.7.11
Work type
Excavation
Drain inlet, catch basin and manholes classified according to
types and dimensions.
Bedding layer
Drainage pipe (classified according to types and diameters).
Under drain pipe (classified according to types and diameters).
Filter layer around under drains pipes
Geo textile surrounding underground drains
Geo composite under edge drains
Pipe culver (classified according to types and diameters)
Box culvert
Backfill
Unit
m3
Number
m3
Linear meter
Linear meter
m3
m2
m2
Linear meter
m3
m3
168
5.8
Slope rip rap and protection:
5.8.1 Description:
This section includes embankment slopes, excavation, and backfilling protection
and rip rapping works at culvert inlets and outlets. It includes rip rap and protection works
by using loose or grouted rip rap and on site cast concrete or pre-cast concrete pieces or
with gabions and protection of rock excavation with metal grids. These works shall be
executed according to the sites and dimensions by using materials specified on the
drawings, special specifications and contract documents.
5.8.2 General requirements:
Before he commences rip rap and protection works, contractor shall prepare the
surfaces on which the work shall be executed by leveling and grading them according to
the approved cross sections, dimensions, and levels. He shall remove all undulations on
the surface and compact them if necessary, until a smooth surface capable of receiving the
intended rip rap works is provided.
Foundation trench shall be constructed below the slope intended for rip rapping
according to the dimensions shown on the drawings and contract documents. The trench
width shall not be less than double the intended rip rap or protection layer thickness.; and
its depth shall not be less than double that thickness or 60 cm whichever is lesser. This
trench shall be filled with materials capable of forming a stable foundation for rip rap and
protection works and it shall be from the approved or better type of rip rap materials. Rip
rap and protection works shall start from the bottom of the slope regardless of the rip rap
type used.
5.8.3 Stone rip rap:
This work includes provision of materials and execution of the works required for
rip rapping slopes by using loose or grouted stones or gabion rip rapping, according to the
dimensions and in the sites specified in the special specifications and contract documents.
5.8.3.2 Materials:
1.
Stone materials:
The stone materials to be used for rip rapping and protecting slopes shall be from
hard rocks which are resistant to water and weather. They shall be free from cracks, clay,
soluble, and fragile materials. They shall achieve, except otherwise indicate special
specifications, the qualitative requirements shown on table (5.8.1). The loose or grouted
rip rap shall fulfill the volumetric distribution requirements indicated in the special
specifications and contract documents or one of the distributions listed in table (5.8.2).
The smallest dimension of the stone shall not be less than 1/3 of its maximum dimension.
Materials shall be from angled stones to provide sufficient friction between stones.
Gabion works may use circular stones and the size of the used stones shall range
between 100-200 mm, their weight between 2-15 kg, and the percentage of stones with
more than 5 kg in weight shall not be less than 50%.
169
Table No. 5.8.1: Stone material requirements

Property
Apparent density, ton/m3, minimum.
Absorption, %, maximum.
Durability index for coarse materials, %, minimum.
Testing method
AASHTO T-85
AASHTO T-85
AASHTO T-210
Values
2.5
6
50
Table No. 5-8-2: Volumetric distribution of rip rap stone materials

Material rate of
Approx. cubic
Type
Weight, kg
indicated weight, %
dimensions, mm
20
10-15
150-200
30
5-10
125-150
First
40
0.5-5
50-125
10
Less than 0.5
Less than 50
20
25-50
200-250
30
10-25
150-200
Second
40
1-10
75-150
10
Less than 1
Less than 75
20
100-150
350-400
30
50-100
250-350
Third
40
5-50
125-250
10
Less than 5
Less than 125
Contractor, before commencing work by a period not less than 15 days, shall
choose stone material sources, conduct the necessary tests on them, and submit a technical
report including sources, available and estimated quantities to the engineer for approval.
Contractor shall obtain the acceptance for using those sources from their owners.
2.
Cement grout:
Cement grout used for grouted stone rip rap shall be from sand, cement, and water mix in
the ratio of 1 cement to 3 sand in the grout. It shall achieve requirements of specification
ASTM C270 and the used cement shall be sulphate resistant class 5 type or normal
Portland cement class (I) and compliant with requirements of the standard specification
ASTM C150, except otherwise allow special specifications for another type. Cement shall
be supplied from approved sources and with cement shipments shall be enclosed
certificates of source guarantee duly approved and authenticated.
Water used in mixing shall be in compliance with the requirements of item 5-5-3 of these
specifications. The used sand shall be in compliance with requirements of specification
AASHTO M 45.
3.
Gabions:
Except otherwise stipulate special specifications, wires used in making and
assembling gabions, including end, tie, and connection wires, shall be from wires
compatible with specification ASTM A641, and diameter of those wires shall not be less
than3 mm; and they shall be galvanized and zinc coated in the rate of not less than 0.24
kg/m2. When the engineer requires that, the coating shall be verified according to
AASHTO T-65 test. Materials can be accepted according to the source guarantee
certificate or ASTM E376 test, according to the engineer's instruction.
170
Gabions shall be fabricated such that the dimensions of their openings do not
exceed 100 mm, and they shall be supplied in the form of pieces which allow assemblage
of gabions in the sizes specified on the drawings or in the special specifications. When
length of gabions exceed by one and a half times their base width (1.5) or 1200 mm,
whichever is lesser, they shall be divided into cells of equal length and width by middle
elements which separate between adjacent cells. Assembled gabions and all the materials
used in assembling shall be capable of bearing the pressure arising from being filled with
stones.
5.8.3.3 Execution:
1.
Loose stones rip rap:

When special specifications or other contract documents for executing loose rip
rap, contractor shall before commencing executing them, prepare the surfaces and slopes
over which they are going to be executed and finish these surfaces such that they become
stable and smooth and compliant with the approved cross section. All areas of slumps and
heights shall be treated and all slopes shall be finished within tolerance that does not
exceed finishing limits indicated in the special specifications, other contract documents or
backfill work requirements indicated in section 5-4 of this division.
Before commencing stone rip rap works, contractor shall construct a trench at the
conjunction level of slope with natural ground level with the dimensions shown on
drawings or other contract documents. And except otherwise stipulate contract documents
for specific dimensions, the width of the trench shall not be less than thickness of the
protection layer to be constructed and its depth shall not be less than 60 cm.
Rip rapping materials shall be placed in such a way that does not damage slopes
being protected. Loose stones rip rap shall be laid with the required thickness such that
they stabilize according to the internal friction angle in one batch or in layers, all in
accordance with special specifications or other contract documents. Construction shall be
carried out whereas large size stones shall be in the lower part of the slope and the suitable
arrangements shall be taken for bedding such that separation between sizes shall be
avoided. Spaces between large stones shall be filled with stone materials of smaller sizes.
2.
Grouted rip rap:

Before he starts construction, contractor shall prepare surfaces according to the
method stated in item (1) above, and it is recommended that stones shall be selected such
that the rate of stones with at least one leveled face is about 50%. The rip rap stones shall
be bedded and arranged in such a way that makes the faces of the level faced stones are
the apparent ones and spaces between adjacent stones shall be in the range of 50-100 mm.
After completion of spreading the stones and cleaning them from all clay and deleterious
materials and moistening them properly, grout is then filled in the joints by the method
accepted from the engineer until it penetrates between stones to a depth ranging from
25-50% of stone with larger size used, providing that depth shall not be less than 100%.
The grout used shall be in compliance with material requirements stated in paragraph
5.8.2.2 and its spreading and filling shall be completed before the start of initial setting
time. Contractor shall carry out the moistening and curing works by water spraying and
soaking or by covering it with moistened jute bags and covering those bags with plastic
sheets. He shall repeat the moistening of jute bags
171
at least two times daily and re-cover them with plastic; or he may apply curing membranes
according to special specifications and engineer's instructions. Curing period shall not be
less than the period specified in the special specifications or for three days whichever is
lesser.
3.
Gabions:
When special specifications and other contract documents specify for executing
stone rip rap gabions, those works shall be executed at the locations specified in the
contract documents or in writing from the engineer.
Gabions shall be assembled such that the sides and base shall be assembled
completely but the cover is fixed only from one of its sides. Assembling shall be made by
using the materials and methods recommended by the manufacturer and all assembling
locations and materials shall achieve a resistance that is not less than that specified for the
gabion.
After assembling, inspecting and accepting the gabions from the engineer, those
gabions are placed empty at the sites shown on the drawings and other contract
documents. Binding between adjacent elements is done by tie wires with the same
specifications of gabion assembling wires. The gabion base is tied from the front and rear
sides with gabions of previously executed row, if any.
After placing and tying gabions with each other and straining them to take the
nearest position to the specified rout, the gabions are filled with stone materials compliant
with approved specifications. Materials shall be filled in layers which do not exceed 30
cm for gabions with heights more than 60 cm, but gabions with less height are filled in
two nearly equal layers. After completing filling materials of each layer, the front face of
the gabion is tied with the rear face by tie wires of the same specifications of tie wires
used in assembling. They are wrapped around two adjacent openings of the gabion to
represent the sufficient tying. After that filling of materials is recommenced till the gabion
is filled to the extend that allows for covering it with the cover and obtaining a semi
smooth upper surface. After completing the filling and closure of the gabions in each row,
backfilling shall be conducted behind them by materials in compliance with backfilling
material requirements stipulated in special specifications. Backfilling materials, except
otherwise special specifications stipulate for specific type, shall be from type A-1a, A-1b.
5.8.4 Concrete rip rap:
This item contain slope rip rap by normal or on site cast reinforced concrete or
premix concrete, according to the type and in the sites specified in special specifications
or other contract documents.
5.8.4.1 Materials:
1.
Concrete:
Except otherwise stipulate special specifications, cement concrete mixes shall be
produced by using sulphate resistant cement type 5 that is compliant with SASO 570 or
ASTM C 150 specifications. Also, except otherwise stated in the special specifications
and contract documents, the cement concrete shall fulfill requirements listed in Table
(5.8.3).
172

Table No. 5.8.3: Rip rap concrete requirements

Property
Cement quantity, kg/m3,
minimum.
Water cement ratio, %, maximum
Slump, mm, maximum.
Air voids, %, minimum.
Aggregate gradation.
Limits
350
0.5
125
4
As per AASHTO M 43 &
max. size shall not exceed 37.5 mm.
Compressive strength, at 28 days

age, MPa, minimum.
25
2.
Aggregate:
The aggregate used shall achieve qualitative requirements listed in Table No.
14-2-3 and gradation requirements indicated in Table (14.2.4), except otherwise stipulate
special specifications and contract documents.
3.
Water:
The water used in mixing and curing concrete shall be compliant with
requirements of item 14.2.3 of these general specifications.
4.
Reinforcement steel:
Reinforcement steel shall meet requirements of item 14.2.6 of these general
specifications.
5.
Curing materials:
Curing materials shall achieve requirements of item 14.2.5 of these general
specifications.
6.
Joints filling materials:

Joint filling materials shall fulfill requirements of item 14.2.7 of these general
specifications.
5.8.4.2 Cast insitu concrete rip rap:
If the special specifications and contract documents specify that execution of rip rap
works are to be carried from normal concrete or cast insitu reinforced concrete then the
contractor shall prepare surfaces on which those rip rap works shall be constructed such that
they become compliant with the approved dimensions, level, and cross sections. These
surfaces shall be leveled and when it is stipulated in the special specifications and contract
documents for using reinforced concrete, to install reinforcement steel or grid in accordance
with the types, diameters, and separating distances shown on the drawings and other contract
documents. Reinforcement steel shall be raised above the slope surface by the distance
required for providing the specified protection layer. This layer shall not, by any mean, be less
than 5 cm.
Before he commences concrete supplying, contractor shall submit to the engineer the
design job mix formula according to item 14.3.3 of division 14. Also, he shall submit a
technical report including construction and curing method, plus method of constructing and
filling joints. Contractor is not allowed to commence construction
173
before he obtains the engineer's acceptance for the design job mix formula, work plan, and
equipments and machines list.
Before commencing casting of concrete, the necessary metal or wooden forms
shall be fixed to control concrete thickness and locations of longitudinal and transverse
joints. Longitudinal joints shall be parallel to the intersection line of side slopes with road
lateral section but transverse joints are perpendicular with them. Joints shall be
constructed at the locations specified on the drawings and other contract documents and
according to requirements of sub item 4.4.1.7, except otherwise indicate special
specifications. Also, contractor shall take the required provisions to keep reinforcement
steel in position and prevent displacement due to casting works.
Concrete casting, joints construction, and concrete curing shall be conducted
according to requirements of section 14.4, of division 14 of these general specifications,
except otherwise stipulate special specifications. Just before casting, contractor shall
moisten the forms, steel, and surfaces on which work shall be executed. Concrete shall be
cast in such a way that it should prevent occurrence of grain segregation. Casting shall be
started from the lower part of the slope towards the top and after completion of casting
surfaces shall be finished by straight edge or scraper. Joints shall be formed at the
locations shown on the drawings and other contract documents, and they shall be filled
with approved filling materials.
Contractor shall cure concrete according to requirements of paragraph 14.4.1.5.
Curing shall continue and concrete shall be kept in a moist state for a period not less than7
days.
5.8.4.3 Premix concrete rip rap:
When special specifications call for rip rap from premix concrete elements, those
elements shall be supplied from approved plants. Contractor, before starting supply
should, submit specimens of those elements together with testing results showing
compliance of the elements with the approved qualitative requirements of concrete,
dimensions and shapes. Contractor shall construct an experimental section showing the
installation method and distribution of colors and shapes, when special specifications call
for some architectural requirements. Contractor shall obtain the acceptance of the
engineer for the results of the experimental section.
Prefabricated elements shall be installed, whether they were prefabricated slabs or
normal or overlapping tile elements, according to the instructions of the manufacturer or
according to special specifications as to surface preparation, materials and method of
constructing the bedding layer, tiles installation, and joint filling.
5.8.4.4 Rip rap with concrete in bags:
When special specifications stipulate for protecting or rip rapping slopes using
concrete in bags, the used bags shall be from textile or jute or any other material indicated
in the special specifications and contract documents. The concrete used shall be enough
for quality requirement as shown in Table No. 5.8.3, except otherwise state special
specifications and other contract documents.
The bags shall be capable of accommodating and bearing resulting pressures from the
moment they are filled with concrete up to concrete hardening and reaching
174
the required strength. Bags dimensions shall be adequate enough for forming rows of
bagged concrete with a thickness of about 30 cm per row. It is recommended that the
dimensions of the used bags 60x90 cm and each bag accommodate approx. 3% (0.03) m3
of concrete. Two rows of concrete bags at least shall be placed in the protection
foundation trench to form the required foundation, except otherwise stipulate special
specifications and contract documents. Then concrete bags are placed in rows, providing
that the number of bags placed in one row shall not exceed four vertically, before the start
of initial setting time of first row concrete. When each bag is placed it shall be pressed a
little to obtain, somehow, level surface between adjacent bags.
Bags shall be placed in such a way that no two knots or openings of two adjacent bags
shall be facing each other.
5.8.5 Culvert inlet and outlet lining:
Contractor shall execute lining to culvert inlets and outlets according to the type of
lining shown on drawings or special specifications and other contract documents. Lining
may be loose stone, or grouted or on site cast concrete or pre-cast concrete tiles rip rap.
Contractor shall carry out the lining works at the specified locations and according
to the dimensions and type indicated in the special specifications and contract documents.
Lining from loose stone or grouted or concrete rip rap shall be constructed
according to requirements of items 5.8.3, 5.8.4 of this section. Lining depth shall be
increased at its beginning and end by not less than double the required lining thickness or
60 cm whichever is greater, except otherwise special specifications and contract
documents mentioning for greater depth.
Contractor shall control the quality of slopes rip rap and protection works by all
the required procedures to ensure that the used materials, construction methods, executed
works, shall achieve quality requirements stated in standard specifications, special
specifications, or these general specifications and other contract documents.
The ministry shall ensure the quality of the product by verifying that contractor
has performed quality control procedures correctly, either through direct supervision on
quality control procedures or through performing quality assurance procedures neutrally
and independently on representative samples in sufficient numbers for judging on
execution standard, and decide about acceptance or rejection of the executed work, all
according to the detailed principles in division 17 of these general specifications, except
otherwise specify special specifications and contract documents.
1.
Quality control:
Contractor shall control the quality of materials, executed works, and shall
monitor, record, and draw quality data for critical properties. Also, he shall perform all the
tests, and measurements listed in Table (5.8.4).
Contractor shall provide the engineer with copies of source certificates and all testing
results promptly. Also, contractor shall apply all the points indicated in item 17.1.1 of
175
2.
Quality Assurance:
The ministry has the right at any time to the quality assure materials and executed
works by performing or by assigning under its supervision testing the materials of rip rap
and protection works and inspection of the executed work for each or some quality
control items specified in Table No. 5.8.4 of this paragraph. In addition the ministry has
the right to review contractor's quality control records and to compare these statistically
with the results it obtained though the method it decides for quality assurance, according
to division 17 of these general specifications. Also, it has the right to inspect contractor's
laboratory and his equipments, technical staff, inspection methods, testing methods,
production and execution sites and methods applied by the contractor to ensure the
efficiency of his technical staff, equipments, and compliance of his testing and execution
methods with approved methods.
5.8.7 Measurement:
Slopes rip rap and protection works are measured in m2 or m3 according to the
types and according to special specifications. Measurements are made only for executed
and technically accepted works within the limits and dimensions specified in special
specifications and other contract documents. No measurements shall be made for the
purpose of payment outside the approved boundaries.
5.8.8 Payment:
Payment shall be made for work quantities actually completed and technically
accepted within the approved limits and dimensions according to contract rates or
reduced prices as a result of quality assurance works, when the contract documents call
for that.
The amounts paid are considered full compensation for supplying materials,
carrying out leveling, compaction, installation, casting, jointing, execution of loose rip
rap, grouted rip rap, gabion rip rap works. Also, for execution of concrete works,
transportation, spreading, curing and compacting the materials plus work finishing
regardless of source. In addition to, provision and operation of equipments, machines,
labor, testing and measuring performance, and all requirements for executing the works in
accordance with drawings and special/general specifications. Payment shall not be made
for items charged on other items. Payment shall be done according to one or more of the
items, for example and not limited to, listed in Table (5.8.5), without contradiction with
contract documents.
176
Table No. 5-8-4: Quality control procedures for rip rap & protection works
Work
Raw
materials
Properties
Quality
requirements
and gradation
indicated in
Table 5.8.1,
5.8.2
Cement quality
requirements.
Testing method
All tests for
quality
requirements &
gradation
requirements.
Quality
requirements tests
indicated in
approved standard
specification.
Requirements of
gabions and
their elements
such as tie wires
Admixtures &
additive
compounds.
Cement
mixes
materials
Cement
concrete
mixes
Completed
works
All concrete
mixes properties
indicated in
Table 14.6.1
Cement concrete
requirements.
At source
Quality
requirement tests
indicated in
item14.2.5
All concrete mixes
tests indicated in
Table 14.6.1
All tests indicated
in Table 5.8.3
Loose &
grouted rip rap.
Visual inspection.
Gabion rip rap

properties.
Visual inspection.
Concrete rip
raps
Culvert
inlets and
outlets rip
rap.
All properties
required for
used type.
Sampling
site
Requirements
All tests at source

approval and at source
change or noticing
change in materials.
Table No.
5.8.1 &
Table 5.8.2
Source guarantee
certificate at starting
supply and whenever
source is changed.
Source guarantee
supply & whenever
source is changed
Source guarantee
supply & whenever
source is changed
Source guarantee
certificate and whenever
source is changed plus
aggregate tests as
indicated in Table 14.6.1
Sampling rates indicated
instable 14.6.1
At site
All tests indicated

in Table 14.6.1
All tests required
for slope rip
rapping according
to used type.
Re-sampling
At source
and site
Verifying execution
quality by visual
inspection.
Verifying execution
quality by visual
inspection.
Testing rates indicated
in Table 14.6.1
Same rates of testing &
inspection for ramp
slope rip raps according
to used type.
Sub item
5.8.3.2
Sub item
5.8.3.2
Item 14.2.5
Section 14.2
Table 5.8.3
Item 5.8.3
Item 5.8.3
Item 5.8.4
Item 5.8.5
Table No. 5.8.5: Rip rap & protection work items

Item No.
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
5.8.6
5.8.7
5.8.8
Type of work
Loose stones rip rap.
Grouted rip rap.
Gabion rip rap.
Cast on site concrete rip rap
On site cast reinforced concrete protection
Pre-cast concrete slabs protection.
Bag filled concrete protection.
Culverts inlets & outlets protection (classified according
to used type).
Unit
m3
m3
m3
m3
m3
m2
m3
m2
177
DIVISION 6
181
6.1
Description
6.2 Production And Storage Of A ggregate M aterials
6.2.1 Description
6.2.2 Material Sources
6.2.3 Aggregate Materials Production
6.2.3.1 Site Preparation
6.2.3.2 Machines And Equipments
6.2.3.3 Production Of Natural Aggregate
6.2.3.4 Production Of Crushed Aggregate 6.2.4
Aggregate Transportation
6.2.5 Aggregate Stockpiling
6.2.6 Surplus Waste Materials
6.2.7 Site Clearing
6.2.8 Acceptance
6.2.9 Measuring And Payment
Aggregate Subbase
6.3.1 Description
6.3.2 Materials
6.3.3 Design Job Mix Formula
6.3.4 Equipments
6.3.5 Experimental Section
6.3.6 Construction
6.3.7 Protection Of Constructed Layers
6.3.8 Finishing Requirements
6.3.9 Acceptance
6.3.10 Measurements
6.3.11 Payment
A ggregate Bases
6.4.1 Description
6.4.2 Materials
6.4.4 Equipments
6.4.5 Experimental Section
6.4.6 Construction
6.4.6.1 Surfaces Preparation
6.4.6.2 Mixing And Transportation
6.4.6.3 Spreading And Compaction
6.4.7 Maintaining The Constructed Layers
6.4.9 Acceptance
6.4.10 Measurements
6.4.11 Payment
6.5 Cement Treated Base
6.5.1 Description 6.5.2
Materials
6.5.2.1 Cement
6.5.2.2 Aggregate
181
181
181
181
181
181
181
181
183
183
183
184
184
184
185
185
185
185
186
187
188
188
190
190
190
191
191
195
195
195
196
196
196
196
196
197
197
199
199
199
200
200
202
202
202
202
202
6.6
6.5.2.3 Water
6.5.2.4 Admixtures
6.5.2.5 Asphalt Curing Membrane
6.5.4 Equipments
6.5.5 Construction
6.5.5.2 Weather Limitations
6.5.5.3 Mixing
6.5.5.4 Compaction And Finishing
6.5.5.5 Construction Of Joints
6.5.5.6 Curing
6.5.6 Traffic Control
6.5.8 Acceptance
6.5.9 Measurements
6.5.10 Payment
Em ulsified Asphalt Treated Base
6.6.1 Work Description
6.6.2 Materials
6.6.3 Emulsified Asphalt Treated Base Mix
6.6.3.1 Job Mix Formula
6.6.3.2 Job Mix Formula Acceptance Procedures
6.6.4 Equipments
6.6.5 Weather Limitations
6.6.6 Constructions
6.6.6.1 Emulsified Asphalt Material Preparation
6.6.6.2 Aggregate Preparation
6.6.6.3 Central Mixing
6.6.6.4 Road Mixing
6.6.6.6 Finishing
6.6.8 Work Acceptance
6.6.8.1 Quality Control
6.6.8.2 Quality Assurance
6.6.9 Measurements
6.6.10 Payment
202
202
202
202
204
205
205
205
206
209
210
210
211
211
211
213
213
214
214
214
215
215
215
216
216
216
216
217
217
217
217
218
219
219
219
219
219
221
General Specifications of Urban Roads Construction __________ Division 6- Subbase and Aggergate Base
DIVISION 6
6.1
Description:
This Division includes materials and execution methods required for the
construction of Subbases and aggregate Base courses, which includes:
- Production and storage of aggregate materials.
- Aggregate Subbase.
- un-treated aggregate base.
- Cement treated aggregate base. - Asphalt treated aggregate base.
6.2
Production and storage of aggregate materials:
6.2.1 Description:
This section includes production methods, transportation and stockpiling of
natural, crushed, or screened materials used in construction of roads and relevant
structures. Contractor shall provide the aggregate conform to the quality and gradation
requirements indicated in the special specifications, drawings, contract documents or
6.2.2 Material Sources:
Unless otherwise the material sources are shown on the drawings or in the special
specifications, the contractor should specify those sources whether they are new queries
or authorized existing crushers.
Contractor, in cases, prior starting production or supplying the aggregate materials
by a period not less than 30 days, shall submit to the Engineer a technical report, which
includes:
1. Source (s).
2. Types and approximate quantities of available rocks and materials.
3. The results of test on representative samples according to the type of work on
which these material proposed to be used, according to the requirement indicated
in the relevant divisions and sections of these general specifications or special
specifications.
4. Machines, equipments and methods of crushing, screening and transporting of
rocks.
5. Sites and methods of aggregate stockpiles.
6. The written agreement from the related agency and property owner for the new
suggested locations of material production and stockpiling.
Contractor is not allowed to start the production of aggregate materials before the
approval of the Engineer for the source. This approval is considered preliminary. The final
approval shall be made based on the test results for the materials actually supplied to the
project.
The contractor shall enable the Engineer to reach sites of the works, inspect
equipments, production and storing methods at any time during the construction. The
Contractor shall obtain a new approval for the source as mentioned above whenever the
181
source or production methods were changed or when the Engineer notices a significant
change in the supplied materials properties.
When contract documents contain information about the available sources and
specifications of materials, this information are considered as guides and does not release
the Contractor from the responsibility for providing materials conforming to the
specifications. The Contractor shall make his own studies to estimate the construction's
prices, regardless of the source and available materials. The Engineer has the right,
according to test results, to reject materials and to require from the Contractor to change
the source(s) if the materials were not technically acceptable the Contractor has no right
to claim any additional costs resulting from this.
6.2.3 Aggregate materials production:
This work shall consists of site preparation, provision of machines, equipments
and required arrangements for producing natural or crushed aggregate and screening of
the materials to the required sizes to obtain the required gradations, transportation, storage
of acceptable produced aggregate, disposal of extra materials and un-acceptable materials
at the approved sites. The produced aggregate shall achieve all the requirements indicated
for the specified works.
Contractor shall, at all work phases, follow the approved environmental standards
regarding to noise levels, air pollution and dust and he shall make all the required
arrangements to limit environmental pollution in all its forms.
6.2.3.1 Site Preparation:
Aggregate materials shall be produced at the approved sources according to item
(6.2.2) requirements of this section. Contractor, after the approval of the Engineer for the
source(s), shall remove overburden, waste and unsuitable materials covering the
aggregate or rock layers proposed to produce crushed aggregate, and transport all
removed and waste materials to sites approved by the Engineer. The removal and clearing
works are considered for charged only with other items and no payment for them shall be
made to the Contractor.
6.2.3.2 Machines and equipments:
Contractor shall provide all the machines and equipments required for the
production of crushed and natural aggregate according to the approved specifications and
it includes central or mobile crushers, suitable sieves sizes, belt conveyor, excavation,
loading, and transporting machines and all equipments needed for producing an aggregate
conform to specifications of the required work item.
6.2.3.3 Production of Natural Aggregate:
Contractor shall produce natural aggregate conforming to the specification's of the
specified works in the sources approved by the Engineer.
The production operation shall include removal of all unsuitable materials including the
sizes larger than the maximum size required, and disposal of soil materials and other
undesirable materials using suitable methods including screening and/or washing.
Contractor shall prepare a work plan for disposal of unsuitable materials from the
material's source, separate aggregate materials into sizes and transport each size separately
to the stockpiles.
182
6.2.3.4 Production of Crushed Aggregate:

Crushed aggregate production shall be made from the approved sources according
to the types and specifications of the available rock materials, using the crushing methods,
which achieve the requirements for number of crushed faces and shape of particle.
Contractor shall sieve the materials before crushing process through vibratory
sieves of suitable capacity to remove all the soil and rock materials of small sizes.
Contractor shall use the suitable crushers according to the rock types, select the
production capacity and calibrate the crusher to match the required gradations, screen all
the produced materials and apply a periodical inspection for blocked or wearied and
broken sieves.
The produced aggregate shall be separated into different sizes, which provide the
required gradation conform to the aggregate requirements according to the work type.
Contractor on his expense shall wash the aggregate if indicated in the special
specifications or when the clay materials and dust exceed the allowable limits.
The production process shall be stopped when the crushing and screening method
does not fulfill aggregate specifications requirements. The contractor has no right to
commence aggregate production before the Engineer approval for the required repair,
modification procedures taken and verification of the produced aggregate quality.
6.2.4 Aggregate Transportation:
Contractor shall load and transport aggregate from production centers or stockpile
by loaders and covered trucks using method which ensures no particle segregation occurs
or contamination of aggregate with soil or any deleterious materials. It is not allowed to
take aggregate from the 30 cm in contact with the ground from the aggregate stockpile
except when the storing floor is concrete. The aggregate shall be taken from the bottom
upwards to maintain the uniformity of aggregate gradation.
6.2.5 Aggregate Stockpiling:
Contractor shall transport and store the produced aggregate at the sites shown on
the drawings or other contract documents or sites approved by the Engineer. Contractor
shall obtain a written agreement from the site owners for its use before starting of
aggregate transportation to these sites, Contractor shall clear and level those sites to a
leveled surfaces and provide water drainage facility at those sites.
Contractor shall store aggregate materials in separated stockpiles according to
sizes in distance apart or using concrete walls to avoid mixing of different sizes, and he
shall transport, discharge and store each size of aggregate in layers in such a
way that prevents particle segregation. The height of the stockpile shall not exceed 8
meters.
It is not allowed to use bulldozers or any other chain machines lead to breaking or
fracturing of aggregate during stockpiling process.
183
Contractor is not allowed to use any areas within the urban for aggregate stockpiling
without a written approval from the concerned authorities.
Contractor shall follow the approved environmental standards at aggregate stockpiling
sites.
6.2.6 Surplus waste materials:
Contractor shall immediately dispose of all clearance and waste materials or any
other unsuitable materials and transport them outside the production site to disposal areas
approved by the Engineer.
The Contractor shall store all the produced technically accepted surplus materials at the
stockpile sites indicated on the drawings, contract documents or specified by the
Engineer.
When the aggregate production is permitted, for certain contract works, the
ownership of aggregate surplus materials from particularly works related to specified
contract, is belong to Ministry and Contractor has no right to claim any additional costs
for this.
6.2.7 Site clearing:
Contractor when finishing the works in production and/or stockpile sites, shall
level, arrange and clean these sites from all wastes, debris, temporary structures, and
transport products and wastes to the approved sites.
6.2.8 Acceptance:
Contractor shall apply quality control for aggregate production by carrying out all
the required arrangements to ensure that the produced materials, production methods
achieving the quality requirements, indicated in the general specifications, and other
contract documents.
The Ministry shall apply the quality assurance works by verifying that the
contractor has carried out quality control procedures properly either through direct
supervision of the quality control procedures or by undertaking quality assurance
procedures neutrally on representative samples and with adequate numbers to judge the
execution and to decide in accepting or rejecting the completed work according to the
principles detailed in Division 17 of this general specifications except otherwise specified
in special specification or other contract documents.
1.
Quality control:
Contractor shall apply quality control on materials and executed works and
monitor records and analyze results and draw quality charts for critical properties and
carry out all tests and measurements indicated in the relevant Divisions and Sections
according to type of works. Contractor shall submit to the Engineer copies from all tests
immediately and apply all the items indicated in sub-section 17.1.1 of these general
specifications
2.
Quality Assurance:
Ministry at any time has the right to assure the quality of materials and executed
works through carrying out or ordering others under its direct supervision to test materials
and inspect production sites, equipments and methods of production.
184
Ministry has the right to review contractors quality control records and compare
them statistically with quality assurance results to insure quality according to division 17
of these general specifications. And it has the right to inspect the contractors laboratory
and its equipments, its technical staff, methods of testing and construction to insure the
efficiency of the contractors technical staff and equipments and conformity of
investigation, testing and construction methods with the approved methods.
The Engineer has the right at anytime to stop the Contractor's production or
stockpiling process when he notices that suitable production or stockpiling conditions
according to specifications is not available, or when the contractor does not follow the
environmental protection standards, or when the produced materials do not achieve the
required specifications. The Engineer has the right to change the production source when
the available materials not conform to the specifications and the Contractor has no right to
claim any additional payments for this.
6.2.9 Measuring and Payment:
Measurement shall be made only for determining the produced and available
quantities but payment shall be done according to the work items in which aggregate
materials are used and the aggregate price shall be included in the prices of those items
unless otherwise indicated in the contract documents that payment shall be made for the
aggregate materials separately.
6.3
Aggregate Subbase:
6.3.1 Description:
This section includes material requirements and construction methods for the
aggregate Subbase includes supply, wetting, spreading, leveling and compaction of the
materials conformed to the approved technical specifications and finishing surfaces
according to the dimensions, levels and slopes shown on the drawings, special
specifications, contract documents and these general specifications.
6.3.2 Materials:
Contractor shall use, for the construction of Subbase layer, the aggregate that
conform to gradation and quality requirements indicated in the special specifications or in
this section.
The materials shall be capable of forming a durable and stable Subbase layer after
being wetted and compacted. The aggregate shall be solid water resistant materials from
natural sources or crushed rock, clean, free from impurities and friable materials such as
organic materials, clay lumps, soluble salts and metals and it is not allowed to use
materials susceptible to disintegration when subjected to wetting or drying.
Aggregate shall fulfill the quality requirements specified in Table (6.3.1) unless
otherwise indicated in the special specifications. The blended aggregate shall achieve one
of the graded shown in Table (6.3.2) or any other gradation stipulated in the special
specifications within the variation allowed in the approved
indicated in Table (6.3.3). design job mix formula
When construction is made in areas with high or
fluctuated water level or in salty environment, the aggregate material types shall be
suitable and water resistant having a soundness not exceeding 25 % according to
AASHTO T-104 test by using
185
sodium sulphate and their plasticity index shall not exceed 4 according to AASHTO T 90 test. When the special specifications require using of open gradation aggregate, the
gradation indicated in the special specifications shall be used otherwise the gradation No.
5 in Table (6.3.2) of this section shall be used.
Table 6.3.1: Quality requirements for Subbase layer aggregate
Property
Los Angles Abrasion test %
Soundness by Na SO4, 5 cycles
Liquid limit%
Plasticity index %
Test Designation
AASHTO T-96
AASHTO T-104
AASHTO T-89
AASHTO T-90
Value
50% (Maximum)
25% (Maximum)
25% (Maximum)
6 % (Maximum)
ASTM D-1883
50% (Minimum)
CBR %
Table 6.3.2: Gradation Requirements for gravel Subbase layers

Percent
Sieve size
(mm)
75 (3")
62.5 (2.5")
50 (2")
37.5 (1.5")
25 (1")
19 (3/4")
12.5 (1/2")
9.5 (3/8")
6.3 (1/4")
4.75 (No. 4)
2.36 (No. 8)
0.425 (No. 40)
0.3 (No. 50)
0.075 (No. 2000
(1)
(2 )
(3 )
Passing
Gradation
(4 )
100
100
97-100
100
97-100 70-100
100
90-100
65-79
50-85
45-59
28-42
40-60
30-60
(5)
(open graded)
100
70-100
50-85
15-55
-
35-70
0-20
0-10
9-17
4-8
0-12
0-10
0-15
0-8
0-5
Table 6.3.3: Allowable variation in Aggregate Subbase Gradation

Sieve size, mm
9.5 mm (3/8 inch) or larger
4.75 mm (No. 4)
0.075 mm (No. 200)
Tolerance limits
10 %
7%
4%
6.3.3 Design job mix formula:

1.
Job mix requirements

The materials used shall achieve the quality requirements specified in Table (6.3.1)
unless otherwise indicated in special specifications, and the total gradation shall conform
to the approved gradation in the special specifications or these general
186
specifications or those approved by the Engineer within the tolerance limits indicated in
Table (6.3.3).
2.
Job mix formula acceptance:

Contractor, prior starting of Subbase materials supply by a period not less than 30
days, shall submit to the Engineer a technical report of the design job mix formula
including:
1. Source(s) and gradation of the aggregate for each aggregate size or type and
blending percents of various sizes and the combined gradation.
2. Quality test results required in the special or general specifications for the
aggregate to be used in Subbase layer.
3. The method used for the production of each mix.
4. Date of starting aggregate production of Subbase material.
The Engineer shall review the proposed job mix formula and if it does not contain the
required information, it shall be returned within 7 days to the Contractor to complete the
information and data required, and then resubmitted to the Engineer for approval.
If the job mix formula includes all the required information it shall be reviewed within
14 days and accepted or rejected and returned to the Contractor to prepare and submit a
new job mix formula which fulfills the specified requirements and a new date for starting
production should be proposed.
When the test result and technical reports indicates that the proposed job mix
formula is conform to specification requirements, the Engineer shall issue a written
approval for it and the Contractor shall start the mix, production. It is not allowed to start
the aggregate production for Subbase mix before a written approval from the Engineer for
the job mix formula.
The Engineer approval for the design job mix formula does not release the
Contractor from responsibility for supplying materials conform to approved specifications
and construct Subbase according to drawings and contract documents or these general
specifications. The final approval shall be based on the test results of the actually used
materials.
The approved job mix formula is considered a basis for evaluating all materials
and constructed work in the subsequent phases of construction and the tolerance limits of
gradation shall be taken on the bases of same job mix formula.
Contractor has no right to make any modification in the approved job mix formula
unless a new job mix formula submitted and accepted according to requirements indicated
previously in this paragraph. The Contractor shall submit a new job mix formula
whenever the source of the materials actually supplied to the project or production
methods or materials properties and gradation is changed.
6.3.4 Equipments:
Contractor shall provide all the machines and equipments required for collecting,
mixing, screening, loading, transporting, spreading, leveling, wetting and compacting the
aggregate materials and finishing the Subbase according to the special specifications,
drawings, contract documents and these general specifications. The
187
machines and equipments shall be in good technical condition and in numbers and types
sufficient for constructing the work according to the work plan approved by the Engineer.
The contractor shall provide the required arrangements to lessen dust, noise and pollution
according to the environmental protection requirements.
The machines and equipments shall include, loading and hauling machines and
equipments such as loaders and trucks, spreading, grading, compaction and leveling
machines such as graders and rollers and tankers provided with water distributors, which
can be calibrated. It is not allowed to use chain machines, sheep foot rollers, and any
other machines, which leads to fracturing or breaking of aggregate particles.
6.3.5 Experimental Section:
when special specifications indicates or the Engineer requires that, Contractor
prior to starting of construction, shall, construct an experimental section not less than 200
meters long for the purpose of verifying the efficiency of the machines, equipments,
possibility of construction according to approved specifications, to determine the number
of the required compaction passes, the quantity of water to be applied to reach the
suitable moisture content, and the thickness of the layer before and after compaction.
Contractor shall modify the work plan or replace the machines and equipments if
the construction of Subbase layer not possible according to the Contractor's plan or
equipments. If the results of the experimental section are acceptable on the basis of the
test results then the construction method followed shall be approved, and Contractor has
not the right to make any modifications or replace machines or equipments without the
written approval from the Engineer.
6.3.6 Construction:
Prior to starting construction of Subbase, Contractor shall verify the completion,
finishing and handing over and approval of Subgrade layer by the Engineer and according
to the requirements of section 5.5. The Contractor shall verify that the Subgrade was not
damaged and when the period from Subgrade finishing and starting of Subbase
construction exceeds 15 days he shall verify the moisture content and compaction degree
and perform the required repair works when necessary. Contractor shall not be paid any
additional costs for this work.
Contractor shall remove all the loose materials, repair all the defects and adjust
levels of the parts not conforming with the final levels of Subgrade and achieve the
required cross slopes using method accepted by the Engineer for removing surplus
materials or adding new materials conforming to requirements of the Subbase while
adhering to construction requirements and compacting materials up to required degree of
compaction. Contractor has no right to claim any additional costs for repair works and no
right to start Subbase material supply and construction before obtaining the written
approval of the Engineer for the surfaces on which construction shall be made.
Contractor shall mix aggregate materials in central mixing plants and supply to the
site ready mix conforming to gradation requirements approved in the design job mix
formula. It is possible, if approved by the Engineer, to mix aggregate materials of
different sizes on special mixing pads or on site providing that the Contractor shall
188
verify the possibility of obtaining a gradation conforming to required gradation without

any deleterious aggregate materials.
The Engineer has the right, when the required gradation not achieved or
Contractor fail to prevent mixing Subbase material with other unsuitable materials or
when mixing on the road causes damage to the previously constructed layers, to stop the
work and require modifying and mixing method or providing of technically acceptable
materials from plants.
Materials shall be transported in wet or dry conditions by trucks having metal
boxes and discharged to the paver hopper or deposited on the surface considering that the
loading and unloading of the materials shall not cause segregation and the heaps shall be
distributed in distances that give a layer of required thickness before compaction. The
spreading of the heaps shall be made using graders, and it is not allowed to use
bulldozers. Spreading and leveling process shall continue until a layer with uniform
thickness and moisture content for the full depth is obtained with approved cross fall.
Unless otherwise indicated in the special specifications, construction shall be in
layers suitable for the used compaction machines and equipments and the individual layer
thickness shall not be more than 20 cm. When the thickness of the Subbase layer exceeds
the maximum indicated thickness these layer shall be constructed in approximately equal
layers providing that the thickness of each layer does not exceed 20 cm.
Contractor before starting compaction shall verify the layer surface is smooth with
no depressions or pockets of extra moisture content or particle segregation, when such
distresses were noticed the required arrangements should be made for repairing, using
method accepted by the Engineer.
Layer compaction shall begin from the outer edge towards the road center line
while achieving the required overlapping between adjacent compaction passes, using the
machines and equipments suitable for the materials and layer thickness, the compaction
shall continue until the degree of not less than 100% of the maximum dry density
specified by AASHTO T- 180 modified Proctor test at a uniform moisture content not
differ by more than 2% from the approved optimum moisture content.
Contractor shall provide the equipments capable of compacting areas which can't
be compacted by normal rollers including manual operation equipments or vibratory plate
and shall change the thickness of compacted layers in these areas to suit the used rollers
so that uniform compaction degrees may be obtained for the full constructed layer
thickness and width.
The field density for each layer shall be determined by sand cone method
according to (AASHTO T-191) test or the nuclear method according to AASHTO T
310-01 or any other approved non-destructive test. The test shall be carried for the full
depth of the layer. The minimum number of readings when using nuclear or
non-destructive method at each location shall be not less than three (3) taken at each area
in different direction, and the average of these three readings is considered as the field
189
For the purpose of determination of payment factor, the previous mentioned

required density values shall be reduces by 2% using statistical method.
Contractor shall level the final Subbase layer surface and spread materials so that
thickness before compaction shall be greater than the target thickness by approximately
20-25% of the target thickness. The contractor shall continue leveling and removal
process until achievements of the finishing requirements regarding thickness, slopes and
levels.
Each layer of the Subbase shall be measured at the beginning of construction and
during construction, the thickness measurements shall accepted when the final level of the
Subbase does not exceed tolerance limits of the levels indicated on the drawings and in
the contract documents, providing that the material requirements and compaction degrees
for the full depth of each layer is achieved.
The thickness used for determining payment factor shall be the specified thickness
minus 20 mm if the subsequent layer was aggregate and 10 mm if it was asphalt or 90 %
of the thickness shown on the drawings whichever is lesser.
6.3.7 Protection of Constructed layers:
Contractor shall maintain the constructed layers surface, free from any deleterious
or loose materials, and take the required arrangements to maintain moisture content,
compaction degree and water drainage until the subsequent layer is laid. When the
constructed layer is damaged for any reason, Contractor before subsequent layer
construction shall carry out the required repair works including re-pulverization,
spreading, wetting, compaction and finishing without any additional costs and the costs
shall be included on the other construction items.
The Subbase layer shall be constructed according to the dimensions, slopes, and
thickness indicated on the drawings and special specifications.
The final surface levels of the Subbase shall not vary from the level shown on the
drawings or approved by the Engineer by more than 10 mm if the subsequent layer is of
asphalt or concrete or by not more than 20 mm if the subsequent layer is aggregate.
The final surface of Subbase shall be verified by taken cross sectional levels at 25
meters intervals providing that the number of the sections is not less than 5 in each 2000
square meters of the constructed layer. Measurement shall be done at each cross section in
5 points at least.
The final surface smoothness shall be verified using straight edge 3 meters long
and the gap between the bottom surface of the straight edge and the surface between any
two contact points in any direction shall not exceed 10 mm when the subsequent layer is
aggregate or 6 mm when it is asphalt or concrete.
6.3.9 Acceptance:
Contractor shall control the quality of Subbase through performing all the required
measures to insure the used materials, methods of construction and the completed works
documents.
190
The Ministry has the right to ensure the quality by verifying Contractor's quality
control procedures either, through direct supervision of quality control activities or
performing quality assurance procedures neutrally, on a sufficient number of
representative samples to determine the level of construction and to accept or reject the
constructed work on detailed bases in division 17 of this specifications except otherwise
indicated in the special specifications and other contract documents.
1.
Quality control:
Contractor shall control the quality of materials and constructed works, monitor,
required tests and measurements in Table (6.3.4).
Contractor shall submit to the Engineer with copies of all the measurements, reports tests
results and he shall apply all the articles stated in item 17.1.1 of this specifications.
2.
Quality assurance:
The Ministry has the right to ensure the quality of materials and completed works
through carrying out or ordering others under its direct supervision to carry out the
necessary tests and measurements, and checking the completed work for each or some of
quality control items specified in Table (6.3.4).
compare these records statistically with the results obtained by quality assurance as
specified in division 17 of these specifications, and inspect contractors equipments,
technical staff, and measurement and construction methods, to determine the degree of
compliance of measurements and constructed methods with the approved requirements.
prices or might be rejected according to the quality levels by applying the statistical
method specified in division 17 of these specifications except otherwise specified by the
6.3.10 Measurements:
The Subbase layer shall be measured in cubic meters or as specified in the special
specifications, after being laid and compacted according to the specified thickness and
within the dimensions and levels shown on the drawings or according to the Engineer's
instructions.
6.3.11 Payment:
Payment shall be made for actually constructed and technically accepted works
within the approved limits, dimensions and prices indicated in the contract or reduced
prices results from applying of quality assurance procedure.
The paid amounts are considered full compensation for the extraction, supply,
mixing, transporting, spreading, wetting, compacting of materials and finishing the works,
provision and operation of machines and equipments, labor, tests, measurements benefits,
revenues, fees, third party payments and all other requirements to construct the works in
accordance with the drawings, special and general specifications. Payment shall be
according to the item indicated in Table (6.3.5) without contradiction with contract
documents:
191
Table 6.3.4: Quality Control Procedures for Subbase

Work
Raw
materials
Materials
during use
Constructed
works
Location
Properties Test method
of
Sampling frequency
Samples
AASHTO
gradation
T-(27)
samples from each source
All
and at source approval
Aggregate requirements
and at design job mix
quality
requirements indicated in At source
formula, or when source
Table 6.3.1
is changed, or when
Moisture constructed works
Density
AASHTO
properties is changed and
T 180
relationship
one test each month
Aggregate
AASHTO
3 tests at the starting of
gradation
T-27
material supply and one
Moisture/
AASHTO
test each 5000 cubic
Density
T-1 80
meters of supplied
relationship
materials or when
Aggregate Requirement
constructed work
quality
s indicated in
is
properties
changed.
requirements Table 6.3.1
AASHTO
One test every day or for
T-191/
T -310-01
every constructed 2000
Field density
or any nonsquare meters of each
destructive
layer
test method
At site
One measurement every
day or for each 2000
Field
Thickness measurements
square meters of the
constructed layer
Cross sectional levels at
25 m interval or 5 cross
Levels and
Survey
sections each 2000
dimensions measurement
square meters whichever
the greater.
Five (5) measurements
each 2000 square meters
Surface
Straight edge
or between cross sections
smoothness
indicated for levels
whichever greater.
Requirements
Items 6 3 2
6.3.3
Item 6.3.3
Item 6 3 2
Table 6.3.1
Item 6 3 6
Item 6.3.8
Item 6.3.8
Item 6.3.8
Table 6.3.5: Payment Items for subbase layer

Item No.
Work type
6.3.1
Subbase layer
Unit
m3
192
6.4
Aggregate Bases:
6.4.1 Description:
This section contains material requirements and constructed methods for the
construction of the un-treated aggregate Base according to the dimensions, levels,
thickness and slopes shown on the drawings and other contract documents.
6.4.2 Materials:
Contractor shall provide the aggregate materials conform to requirements of the
special specifications or these general specifications, these materials shall be crushed
coarse and fine aggregate or natural aggregate or furnace slag after being broken and
screened to achieve the required gradation and verify its density.
The materials used shall be clean, free from impurities, organic materials, friable
particles and clay lumps, and not more than 10% of thin and elongated particles. The
materials, after being spread, wetted and compacted, shall form a sound and stable base,
which complies with the special technical specifications or these general specifications.
The untreated aggregate Base shall achieve, unless otherwise indicated in the
special specifications, the quality and gradation requirements indicated in Table (6.4.1)
and Table (6.4.2) considering the following:
1. Category (A) aggregate, type (1) gradation shall be used for arterial roads,
highways, industrial areas and heavy vehicles parking areas,
2. Category (B) aggregate, gradation (2) shall be used for collective roads.
3. Category C aggregate, using gradation (3) shall be used for secondary roads at
residential areas.
When the specifications require using of open gradation aggregate it shall conform
to one of the gradations indicated in Table (6.4.3) and the quality of the materials shall be
from category (A) as shown in Table (6.4.1). Open gradation materials shall be treated,
when constructing main roads and streets, industrial area roads and heavy vehicles
parking areas, with cement or any other method stipulated in the special specifications or
the technical study.
Table 6.4.1: Quality Requirements for Aggregate Bases
Quality Requirements
Soundness in sodium sulfate, five
cycles , maximum, %
Los Angles Abrasion Test,
maximum, %
Sand equivalent , minimum, %
Liquid limit, maximum, %
Plasticity index ,maximum, %
California Baring Ratio,
minimum, %
Aggregate angularity two crushed
faces, minimum, %
Testing
Method
AASHTO
T-104
AASHTO
T-196
AASHTO
T-176
AASHTO
T - 89
AASHTO
T-90
AASHTO
T-193
ASTM
D-5821
Values according to
classificatio
Class A
Class B
Class C
12
18
24
40
45
50
45
35
25
25
25
25
100
80
65
80
70
50
193
Table 6.4.2: Gradation Requirements for Aggregate Bases

Percent passing by weight
(1)
(2)
(3)
50 mm, (2 inches)
100
37.5 mm, (1.5 inch)
97-100
100
25 mm, (1 inch)
97-100
100
19 mm, (3/4 inch)
67-81
97-100
9.5 mm, (3/8 inch)
56-70
67-79
4.75 mm (No. 4)
33-47
39-53
47-59
0.425 mm (No. 40)
10-19
12-21
12-21
0.075 mm (No. 200)
4-8
4-8
4-8
Percent of material passing No. 200 sieve size (0.075 mm) shall not exceed half of
percent passing sieve No. 40 (0.425 mm)
Sieve Size, mm, (inch)
Table 6.4.3: Open Graded Gradations

Sieve Size, mm, (sieve No.)
75 (3 inch)
50 (2 inch)
37.5 (1.5 inch)
25 (1 inch)
19 (3/4 inch)
9.5 (3/8 inch)
6.3 (1/4 inch)
4.75 (No. 4)
2.36 (No. 8)
0.300 (No. 16)
0.075 (No. 200)
Percent Passing by weight
100
75-100
30-65
5-30
0-10
0-8
0-5
100
75-100
35-65
5-35
0-15
0-10
0-8
0-5
100
70-100
50-85
15-55
0-20
0-10
0-8
0-5
6.4.3 Design Job Mix Formula:

1.
Job mix requirements:
Contractor shall select the aggregate material source(s) and perform the
preliminary tests to verify achievement of the specifications quality requirement, the
possibility of mixing to obtain the required gradations and the quantities available at each
source.
The Base materials, unless otherwise indicated in special specifications shall
achieve the quality requirements indicated in Table (6.4.1), and the combined gradation
shall conform to approved gradation in special specifications or these general
specifications or the gradation approved by the Engineer within the tolerance limits
indicated in Table (6.4.4).
2.
Job mix formula acceptance procedures:

Prior to starting supply of the untreated Base materials by a period not less than 30
days, Contractor shall submit to the Engineer a technical report including the job mix
formula for the aggregate materials conform to requirements indicated in the special
194
specifications, contract documents or these general specifications. It should contain at

least the following:
1. Source(s) of materials.
2. The aggregate gradations available at each source.
3. Gradations of different sizes in each stockpile.
4. Percent and methods of mixing different sizes and the produced gradation that
conform to the approved gradations in the specifications.
5. Results of quality tests
6. Expected date for starting mix production.
The Engineer shall study the report of design job mix formula proposed by
Contractor, if the report does not include all the required information the Engineer shall
return the report within 7 days and Contractor shall complete the information and
resubmit it to the Engineer. But if the information and data were complete, the Engineer
shall verify materials conformity to quality and gradation requirements and approve or
reject the job mix formula within 14 days.
If the proposed job formula does not fulfill the specifications, the Contractor
shall submit a new job mix formula. However, if it achieves the specifications the
Engineer shall issue written approval and Contractor has the right to start production of
the mix.
The Engineer's approval for design job mix formula is only preliminary and the
final acceptance for the materials is made based on test results of materials supplied to
the site. Contractor shall enable the Engineer to take samples and investigate production
sites throughout construction phases.
The design job formula approved by the Engineer is considered a basis for
comparing the supplied and used material properties. Moreover, Contractor shall follow
the job mix formula throughout the work period and the gradations of the materials
supplied to the site shall conform to the approved gradation in job mix formula within
the tolerance limits allowed as indicated in Table (6.4.4).
Contractor whenever the materials source, properties, or production method
changed or when the Engineer notices a significant change in supplied materials
specifications, shall submit a new or modified job mix formula reflects those changes
and he shall not continue material supply before obtaining the Engineer's approval for
the new job mix formula.
Table 6.4.4: Gradations Tolerance Limits
Sieve size (No), mm
Tolerance lim its
19 (3/4 inch) or more

9.5 (3/8 inch)
4.75 (No. 4)
0.425 (No. 40)
6 percent
6 percent
6 percent
4 percent
0.075 (NO. 200)
3 percent
195
6.4.4 Equipments:
Contractor shall provide all machines and equipments required for producing the
aggregate materials and construct untreated Base according to drawings, special
specifications or these general specifications.
These machines and equipments shall be in the numbers, types, good technical condition
and capable to construct the works according to the approved time schedule.
The equipments shall include mixing, transporting, spreading, leveling, wetting
and compacting machines such as aggregate mixers, loaders, trucks, graders, spreaders,
adjustable water distributors and rollers, It is not allowed to use chain machines and sheep
foot rollers or any machines or equipments cause damage to the materials and affect their
properties and gradation.
6.4.5 Experimental Section:
Contractor, when special specifications or the Engineer requires that, shall
construct experimental section not less than 200 meters long, to verify his capability for
constructing aggregate Base conform to drawings, special specifications or these general
specifications and to determine the water quantity required to be added, the required
compaction passes and thickness required before compaction, Using construction method
and available equipments.
When test results show that, the work plan and available machines and equipments
are capable to construct the required works, results are approved and Contractor shall
follow the approved construction method and has no right to make any changes in
machines or that method without a written approval from the Engineer.
However, if the results of the experimental section were not technically
acceptable, Contractor shall make the required modifications in the construction method
or machines to achieve the approved specifications.
6.4.6 Construction:
6.4.6.1 Surfaces preparation:
Prior Contractor start materials supply and construction of aggregate Base all
previous works shall be completed and handed over according to drawings, special
specifications and these general specifications. It is necessary to insure these layers have not
been subjected to any damages or loose or change in their compaction degree or moisture
content.
Contractor on his own expense shall remove all deleterious and loose materials
and repair all surfaces' defects and has no right to claim any additional costs for this work.
When the period between the previous layer construction and the beginning of
Base construction exceeds two weeks the compaction degree and moisture content of the
constructed layer shall be verified by field density test, if the test results obtained show a
change in compaction degree, Contractor on his expense shall rewet and compact that
layer up to required compaction degree.
The Contractor is not allowed to start materials supply and aggregate Base
construction before receiving a written approval of the Engineer.
196
The Subbase or Subgrade shall be wetted before placing the aggregate Base to ensure
layers bonding.
6.4.6.2 Mixing and Transportation:
Water and aggregate shall be fully mixed in calibrated plant mixer capable to
control feeding and mixing of different material sizes to provide mix conform to approved
gradation in the design job mix formula and it is not allowed to mix materials on site.
Water shall be applied to the aggregate during mixing using calibrated distributor
to obtain a mix of uniform moisture content closed to optimum moisture content
determined by Modified Proctor Test, considering the percent of evaporation during
transportation and spreading.
The mixed aggregate shall be loaded and transported by covered trucks. The loading and
discharging process shall be performed in a method that prevents particles segregation of
materials.
6.4.6.3 Spreading and Compaction:
The aggregate Base shall be constructed in layers with thickness that suits the
materials used and the available compaction equipments on the basis of the experimental
section results and the thickness of each layer shall not exceed 20 cm.
The materials shall be supplied to the site in wet condition with moisture content
closed to optimum moisture content. The Base materials shall be spread using mechanical
spreader or shall be placed in distributed heaps on surface to provide, after spreading a
uniform layer conform to the approved thickness before compaction. Consideration shall
be made to avoid particle segregation during transportation, loading and spreading. When
these materials have been exposed to segregation, Contractor shall remove all segregated
materials and replace them with other acceptable materials. Moreover, the additional
grading can be done using motor grader.
The spread materials shall achieve the thickness, slope and approved cross section,
and the layer shall be leveled without depressions or particle segregated materials or
pockets in which water may collect.
Compaction shall be executed using approved work plan rollers and according to
experimental section results, those rollers shall be capable of compacting the layers for
full thickness up to required compaction degrees without leading to particle fracturing or
grinding.
The layer thickness before compaction indicated in Table (6.4.5) can be used
according to rollers, however, the approved thickness shall be determined based on test
section's results of field density and Engineer's comments during construction.
When total thickness of constructed Base is greater than thickness approved for
compaction according to available equipment, the construction shall be performed in
layers providing that the thickness of each layer shall not exceed the suitable thickness for
compaction.
197
Table 6.4.5: Suitable Layer Thickness According to Roller Type

Roller type
Vibratory, more than 12 tons
Layer thickness after compaction, cm

20
Vibratory, (10-12) Ton
15
Normal rollers
10
Contractor shall start compaction of each layer longitudinally, from the outer side
in the cross section to inner side with adequate overlapping distance between adjacent
passes, which shall be less than 15 cm.. Compaction shall continue up to degree of not
less than 100 % of the maximum dry density, determined by Modified Proctor Test
AASHTO T-1 80 for the same materials, at uniform moisture content not differs by more
than 2 % from optimum moisture content.
During compaction, Contractor shall compensate for water evaporation using
suitable distributor allow regular and uniform spraying.
Contractor shall remove loose materials and carry the required remedies for
depressed and cavity areas existed in the Base layer surface, treat and re-compact these
sections as directed by the Engineer, to obtain stable layer capable to sustain the
subsequent layers. Contractor has no right to claim any additional cost for this work.
Prior starting construction of the subsequent layer the first layer shall be finished
and compacted to required degrees and handed over and sprayed with water to provide the
required bond between layers.
The compaction degree shall be determined using field density test as percent of
maximum dry density obtained from Proctor modified test for the used material and the
minimum compaction degree for determination of pay item using statistical procedure is the
above acceptable level minus 2 %. The field density test shall be done using sand cone
method according to AASHTO T- 191 or nuclear method according to AASHTO
T-310-01or any other non-destructive testing method. The field density test shall be
performed for the full thickness of the layer. When using nuclear method or any
non-destructive test a minimum of three readings shall be taken at each location the
average of three readings should be the density of that location.
Base layer thickness shall be measured before construction and during
construction and the final level of the Base accepted if it does not exceed the tolerance
limits of levels shown on the drawings and contract documents, providing that the
materials requirements and compaction degrees for the full depth of each layer has been
achieved. The thickness shown on the drawings minus 10 mm shall be taken to determine
the quality index and payment factor.
The final Base layer shall be finished according to the dimensions, thickness and
slopes shown on the drawings, special specifications or these general specifications.
Consideration shall be given to spreading and leveling of the final layer materials and the
final levels can be verified using stakes or any other guiding method accepted by the
Engineer. The materials shall be spread so that their thickness before compaction is
198
greater than the specified thickness by approximately 20-25%. Leveling shall continue
until the final layer surface conformed to approved level and cross section.
6.4.7 Maintaining the constructed layers:
Contractor shall maintain the constructed layers free from any deleterious and
loose materials and perform all required procedures to maintain moisture content,
compaction degree and drains until lying of the subsequent layer. When any damage is
occur in the constructed layer Contractor shall perform the required repair works
including re-plowing, spreading, wetting, compaction and finishing, before commences
construction of the next layers, and Contractor has no the right to claim any additional
cost for this work and the cost shall be included on other construction item.
The Base shall be finished according to the dimensions, slopes and thickness
shown on the drawings and special specifications.
The final surface levels of the Base shall not differ from the level shown on the drawings
or approved from the Engineer by more than 10 mm if the next layer was an asphalt or
concrete layer.
Verification of the levels shall be on basis of final measurements performed in at
least 5 points of each cross section taken in interval of 25 meters providing that the
number of the sections shall not be less than 5 for each 2000 square meter.
The surface of the final layer of Base shall be smooth and conform to slope and
level shown on the drawings or special specifications. The smoothness shall be inspected
using straight edge 3 meters long. The clearance between bottom of straight edge and the
surface of the layer in any direction between any two contact points shall not exceed 6
mm.
6.4.9 Acceptance:
Contractor shall control the quality of aggregate Base through performing all the
required measurements to insure used materials, methods and the completed works meet the
quality requirements specified in these specifications and other contract documents.
The Ministry has a right to ensure the quality by verifying contractor's quality
control procedures either, through direct supervision or carrying out quality assurance
procedures, neutrally on a sufficient number of representative samples to determine the
level of construction, and to accept or reject constructed work on basis detailed in division
17 of this specifications, except otherwise indicated in the special specifications and other
contract documents.
1.
Quality Control:
Contractor shall apply control the quality of materials and constructed works,
monitor record and analyze the results, draw the quality charts for critical properties and
perform all tests and measurements indicated in Table (6.4.6).
Contractor shall submit to the Engineer copies of all tests and apply
all requirements indicated in item 17.1.1 of these general specifications.
2.
Quality Assurance: The Ministry has the right to ensure the quality of materials
and completed works through carrying out or ordering others under its direct
supervision to carry out
199
the necessary tests and measurements, and checking the completed work for each or some
compare these records statistically with the results obtained by quality assurance as
method specified in division 17 of this specifications except otherwise specified by the
The Base quantities shall be measured in cubic meters, unless otherwise indicate
special specifications and contract documents.
The measurements for payment shall include the actually constructed works
indicated on the drawings or contract documents, measurement shall not be done for
payment purposes for works constructed outside approved areas in drawings or specified
by the Engineer, and the quantities of these work items shall be calculated and paid
according to contract documents.
6.4.11 Payment:
Payment shall be made for actually executed and technically accepted work
quantities within the approved limits and dimensions according to contract rates or
reduced prices as a result of quality assurance works when contract documents call for
this.
The paid amounts are considered as full compensation for extraction,
transportation, spreading, wetting and compaction of the materials regardless of their
source, according to these general specifications, special specifications and other contract
documents. Plus provision, operation of machines, equipments and labor, tests, measuring
and all requirements to execute the works in accordance with drawings, special and
general specifications, benefits, revenues, fees and third party payments.
Payment shall be according to the item indicated in Table (6.4.7), without
contradicting the contract documents.
200
Table 6.4.6: Quality Control for the Aggregate Base

Work
Raw
materials
Materials
during
using
Properties
Test method
gradation
AASHTO
T-(27)
Aggregate
quality
requirements
All tests
indicated in
Table 6.4.1
Moisture
/Density
relationship
AASHTO T180
Aggregate
gradation
AASHTO
T-27, T-1 1
Moisture
/Density
relationship
AASHTO
T-180
Aggregate
quality
requirements
All
requirements
indicated in
Table 6.3.1
Field density
AASHTO -191
AASHTO
T-3 10-01
or any other
non-destructive
test
thickness
Field
measurements
Dimensions and
levels
Survey
measurements
Location of
Samples
Sampling frequency
Requirements
At source
samples from each
source for source
approval and design job
mix formula approval
or when source is
changed, or material
properties, or
constructed works is
changed, and a test
each month.
Items
6.4.2, 6.4.3
3 tests at starting of
material supply, and
one test every 5000 m 3
of supplied materials or
when properties of
constructed works is
changed or one test
each week.
At site
One measurement each

day or for each 2000 m 2
of the executed layer.
One cross section each
25 meters or 5 cross
sections each 2000 m 2
whichever greater.
Works
Surface
Smoothness
One test each day or for

each 2000 m 2 of each
constructed layer.
5 measurements each
2000 m2 or
measurements between
approved cross sections
for level's measurement
whichever greater.
Straight edge
Items
6.4.3
Items
6.4.2
Items
6.4.3
Items
6.3.6
Items
6.4.6
Items
6.4.7
Items
6.4.7
Table 6.4.7 Payment Item for Aggregate base

Item No.
Payment item
Payment unit
6.4.1
Aggregate Base
m3
201
6.5
Cement Treated Base:
6.5.1 Description:
This section consists of materials requirements and construction methods for
execution of cement treated aggregate Base. The work includes material provision, mix
production, transportation, spreading on prepared surfaces, compaction and finishing
according to approved thickness, slope, levels and cross section indicated in drawings,
special specifications and these general specifications.
6.5.2 Materials:
6.5.2.1 Cement:
The cement used shall conform to types indicated in special specifications; it should
be suitable to local environment conditions and fulfill the requirements of the standard
specifications indicated hereafter:
1. Sulfate resistant Portland cement shall achieve requirements of (ASTM C 150).
2. Blended cement shall achieve requirements of (ASTM C 595) for Pozolana
cement type IP or (ASTM C 1157) for modified Pozolana cement type I (PM).
6.5.2.2 Aggregate:
Cement-treated materials shall achieve gradation requirements indicated in Table
(6.5.1) or any other gradation indicated in special specifications or approved by testing
that it can achieve design requirements. The aggregate shall achieve quality requirements
indicated in Table (6.5.2), unless otherwise indicated in the special specifications.
6.5.2.3 Water:
Water used in concrete mixing and curing shall be clear and free from harmful
materials, which caused hardening of cement mixture such as oils, alkaline, plant, organic
materials and salt. Water shall not contain of more than 1000 unit per million of chloride
(CL2 - -) or 3000 per million of sulphates (SO4 + +), when the specifications or the Engineer
require water shall be tested according to (AASHTO T-26) test.
6.5.2.4 Admixtures:
When the special specifications require using of some admixtures such as fly ash or
retarding admixtures these materials shall be applied, using method and percent specified
in special specifications and they shall be supplied from approved sources according to a
source certificate. The fly ash shall conform to AASHTO M 295 specifications, and the
setting retarding admixtures shall fulfill the requirements of specification AASHTO M
194.
6.5.2.5 Asphalt Curing Membrane:
When special specifications indicate construction of asphalt curing membrane the
used material shall be emulsified asphalt type (SS-1h or CSS-1h) and achieve the
requirements indicated in division 7 of these general specifications.
1.
Requirements of design job mix:
The mix shall achieve all quality requirements indicated in the specifications and other
contract documents.
202
Table 6.5.1: Aggregate Gradations

Sieve Size
(mm)
50 (2 inch)
37.5 (1.5 inch)
25 (1 inch)
19 (3/4 inch)
9.5 (3/8 inch)
4.75 (4)
2.36 (8)
1.18 (16)
0.425 (40)
0.300 (50)
0.150 (100)
0.075 (200)
Gradation 1
100
Percent passing by weight %

Gradation 2
Gradation 3
100
90-100
60-95
100
15-75
50-100
Gradation 4
100
80-100
50-100
35-70
35-55
15-35
10-35
15-60
5-20
5-15
0-5
5-30
0-10
0-8
0-5
Table 6.5.2: Aggregate quality requirements

Index
Los Angles Abrasion Test, 500 cycle
Sodium Sulphate Soundness, 5 cycles
Durability index of fine and coarse
aggregate
Aggregate angularity
Liquid limit
Plasticity index
Organic materials
Sulphates %
Test Designation
AASHTO T-96
AASHTO T-104
Limits
50 %maximum
12 % maximum
AASHTO T-210
35 minimum
ASTM D 5821
AASHTO T-89
AASHTO T-90
AASHTO T-21
AASHTO T-290
50 % minimum
25 % maximum
6 % maximum
2 % maximum
1 % maximum
Unless otherwise indicated in special specifications, the average of five soaked

samples unconfined compressive strength of the cement treated Base shall not be less than
50 kg/cm2 and no individual sample shall have unconfined compressive strength less than
40 kg/cm2 after 7 days. The approved cement content not less than 4% by total weight of
mix when tested according to AASHTO T-(134, 126, 22) tests.
2.
Job Mix Formula Acceptance:

Prior starting construction of cement treated Base by 30 days, Contractor shall
submit to the Engineer a full technical report prepared by a specialized and qualified
agency including the design job mix formula. The report shall based on results of
laboratory tests of aggregate, cement, water and admixtures proposed for use in producing
the cement treated Base and shall contain the following information:
1. Source(s) of each material used to produce cement treated mix.
2. Source and type of cement and additives proposed attached with an approved
source certificate.
3. Quality test results of aggregate properties.
4. Gradation of aggregate sizes at all stockpiles.
5. Combined aggregate gradation and proportional percents of different sizes of
aggregate in the mix.
203
6. Cement content in the mix, and water-cement ratio.

7. Mixture density at the proposed water-cement ratio on basis of (AASHTO T - 134)
test method.
8. Quality properties of the mixture such as unconfined compressive strength and any
other quality properties indicated in the special specifications.
9. Results of all tests show materials conformity and mixture to requirements of
special specifications or these general specifications.
10. Type and percent of admixtures and additives in mixture on the basis of cement
dry weight and method of application and mixing.
11. Method of production, construction and curing of cement- treated Base.
The Engineer shall review the report of design job mix formula proposed by
Contractor, if not all required information is complete the Engineer shall return the report
within 7 days and Contractor shall complete the information and resubmit it to the
Engineer. If the information and data were complete, the Engineer shall verify materials
conformity to quality and gradation requirements and approve or reject the job mix
formula within 14 days from the date of its submission.
Contractor shall provide the adequate quantities of aggregate and all the mix
components and verify the availability of suitable water in adequate quantities for
production and wetting before starting production. It is not allowed for the Contractor to
change the sources and specifications of the materials used in preparing design job mix
formula without submitting a new design job mix formula approved by the Engineers.
The approval of design job formula by the Engineer shall be considered only
preliminary. The mix production and construction shall be verified to achieve the
requirements indicated in these specifications or special specifications based on tests
results of constructed experimental section, production quality control, and tests results of
field samples taken from the site during the first working day and quality control
procedure. When the Engineer notice significant in material or mix properties or in
constructed works shall require from contractor to stop the work and to take the required
arrangements to remove unsuitable materials and works and reconstruct these works
according to these general specifications, special specifications and Engineer's
instructions. Contractor shall be responsible for all the costs results from this and has no
right to claim any additional costs.
6.5.4 Equipments:
Prior to start construction, Contractor shall submit a list of proposed equipments
for cement-treated Base construction. These equipments shall be in good technical
condition, and in numbers, types conform to work plan requirements and time schedule
submitted by the Contractor, accepted by the Engineer, and capable of constructing and
finishing cement treated Base according to the drawings, special specifications and these
Equipments shall include central plant or mobile mixers, trucks, pavers, graders,
rollers and cement distributors, water distributor, asphalt distributor and all requirements
for constructing the work according to the specifications. Types and numbers shall be
selected according to the approved work plan, mix method and time schedule.
204
6.5.5 Construction:
6.5.5.1 Surface preparation:
Before starting construction of cement treated Base, all previous works shall be
completed, tested and handed over. The surfaces on which cement treated aggregate Base
will be constructed shall be free from deleterious and loose materials, level, durable to
receive cement treated base and capable to sustain traffic movement of construction
equipments and machines without causing any deformations.
Contractor should carry out all required works and arrangements to repair all
defects and surfaces deformations for the layer that receive cement treated Base. The
surface repair shall include removing deleterious, loose and waste materials, and adjusting
layer's levels. The layer's level shall be adjusted by removing of waste materials, or
adding new materials having same quality of repaired layer, and spreading, leveling and
compacting them according to the requirements of that layer, or by, re-wetting and
compacting the layer providing that the final surface shall achieve the thickness,
compaction, leveling and slope requirements indicated on the drawings or the special
specifications or these general specifications and according to the Engineer's instructions.
Contractor has no right to claim any additional costs for this work.
Contractor not allowed to starts material supply or spread the cement treated Base
before the approval from the Engineer's for surface preparation works. Prior to start
spreading of the cement treated base, Contractor shall uniformly wetting the previous
layer's surface without excessive water causing log or week areas unable to sustain
movement of spreading and compaction equipments or lead to an increase of moisture
content to limits which do not allow a uniform mixing of materials with cement when use
on road mixing.
6.5.5.2 Weather Limitations:
Contractor shall not construct cement treated Base during bad weather conditions
which tend to increase water evaporation or change cement ratio in the mix or affect mix
properties or cement hardening and limiting the gained strength required.
Cement treated aggregate Base shall not be spread when temperature is less than 5
c, or expected to reach this degree in the next day of spreading and compaction, or when
temperature is higher than 35 c. It is possible according to a written approval from the
Engineer to ignore the above weather limitations limits if Contractor takes the required
precautions to maintain the mix and constructed works to decrease water evaporation and
cooling of the mix or its components without affecting the quality of the treated base or its
efficiency after construction. Contractor shall be responsible for any results caused from
this works, and he shall carry out on his expense all repair works when necessary including
re-construction of all sections conforming to specifications. It is not allowed to construct
cement treated Base during rainfall or dust storms or when wind speed exceeds 25 km/hr
or when wind speed may leads to cement scattering during road mixing. The Contractor
shall be responsible for maintaining the surface on which the treated layer shall be laid in a
technically acceptable condition during all weather conditions, and dispose all materials or
mix or works performed in unsuitable weather conditions without having the right to claim
any additional costs for this work.
205
6.5.5.3 Mixing:
Cement, water, and admixtures indicated in the special specifications and design
job mix formula shall be applied according to approved percent and mixed until a
consistent mix were achieved for whole areas and thickness of treated layers. Unless
otherwise indicated in special specifications, the cement treated Base mix shall be
produced in central mixing plants.
When constructing small size works or approved from Ministry mixing may be
performed on road using mobile mixers if the Contractor proves that the produced mix
conform to required specifications and approved work plan. When approved by the
Engineer, the cement treated Base material may be mixed on the road surface using motor
grader for limited quantities when necessary and for not more than 50 linear meters.
Contractor is fully responsible for producing a mix conforming to specifications
and design job mix formula regardless of the applied mixing method.
1.
Mixing in Central Plant:

The cement treated Base mixes shall be produced in Batch plants mixers or
continuous mixers.
The mixers used shall be capable of producing uniform mix conforming to
requirements indicated in technical specifications and approved design job mix formula.
Mixers shall be calibrated and provided with all required control devices for feeding
aggregate according to approved gradation and feeding cement within tolerance limits not
exceed 5% and feeding water within tolerance limits not exceed 2% of the accepted
percentages in the approved design job mix formula.
Contractor shall submit with the design job formula a list shows type and site of
the plant proposed to use. Contractor not allowed starting mix production before the
Engineer's approval for the plant used. The produced mix shall be verified whether
conforming to specifications based on the first day production. When the produced mix
does not achieve the specified requirements, the production shall be stopped and the
required precautions shall be taken to calibrate the mixer or modify the design job mix
formula.
Contractor shall set out a plan to transport the mix according to a time schedule for
production and transportation, in which the time period from applying water to
aggregate-cement mixture, spreading and starting of compaction shall be within the
allowed periods. The period from water application to starting of compaction shall not
exceed 30 minutes, unless otherwise allowed in the special specifications. The mix shall
be transported in specialized transportation equipments. The mix shall be discharged from
the plant to the trucks, transported and deposited in to spreader, without any particles
segregation, and all required arrangements shall be taken to lessen the loss in moisture
content.
The mix shall be spread using mechanical spreader or special spreading boxes
and if available space was not adequate for using one of above mentioned methods it is
possible, when necessary, to spread the mix using motor grader. Spreading, regardless
of the used method, shall be executed with required compacted thickness of the layer
206
within the allowed variation and in one pass of spreading machine. The produced surfaces
shall be uniform, level, free from particles segregation and conform to the slopes and
cross sections shown on the drawings or in the specifications within the allowed variation
limits.
When the mix allowed to be spread on more than one lane simultaneously, the
period between spreading the mix on the constructed lane and staring of spreading on the
adjacent lane shall not exceed 30 minutes, otherwise construction joints shall be
constructed.
2.
On site mixing:
Road mix construction method by mobile or traveling mixers can be used after a
written approval from the Ministry, while mixing and spreading by motor grader shall
only used after a written approval from the Engineer for construction of limited quantities
of cement treated Base and for a distance not more than 50 meters. When using any of the
on site mixing methods, Contractor shall, on basis of practical experimental results, prove
that the test results of mix are uniform, achieve all requirements and do not differ from
design strength of the mix by more than 20%.
-
Mixing by Mobile Mixers:

Mixing may be done on site by mobile mixers when the available areas were
enough for the operation of such mixers. These mixers shall be capable of producing a
mix conformed to approved specifications and shall be equipped with control systems for
cement and water application. The supplied aggregate materials shall conform to
approved gradation and quality requirements, when discharged in to the mixer, whereas
cement shall be applied in dry state, with the approved rate, and mixing it with aggregate
materials until a uniform mix is obtained, then water is applied with the specified percent
and the mixing shall continue until the final mix conformed to specifications. The mix
shall be transported to the construction site using approved means of transportation and
discharged in the spreader or spreading box then spread according to the specified
thickness, slope and cross section, compacted and finished.
-
Mixing by Traveling Mixers:

When mixing on road by traveling mixers these mixers shall be capable of picking
all spread materials to be treated over the road, without contamination with any other
surface materials or deleterious materials. These mixers shall be capable of applying
cement within tolerance limits, and not more than 5 % of the specified rate in the design
job mix formula, then mixing it uniformly with the treated material and applying water
within variation limits not more than 2 % of the specified percent in the design job mix
formula.
Cement treated Base materials shall be spread on the prepared and approved
surface and leveled to thickness conformed to the approved technical specifications.
Transportation and spreading of aggregate materials shall be performed without causing
particles segregation or aggregate fracturing, according to slopes, cross sections and
thickness shown on the drawings or specifications and approved work plan.
The spread materials shall be wetted before applying cement by one day, and the
period between wettings and applying cement shall not be less than 12 hours. The
spreading process shall not lead to formation of weak areas or areas with excessive
207
moisture content or formation of cement lumps some extend that may restrict the
uniformity of cement and aggregate mixing for full depth.
It is possible to apply cement in one batch or many batches, without formation of
cement lumps, and mixing continuously until a uniform mix in color and gradation were
obtained, at the specified cement rate before water application. Immediately after
completion of aggregate and cement mixing, water shall be applied in specified rate and
mixing shall continue until uniform moisture content is obtained for the whole mix.
-
On surface mixing:
When special specifications allow that or when constructed limited quantities of
works, it is possible to distribute the cement over spread materials surface using a
distributor machine capable of applying cement uniformly on the material surface within
tolerance limits, and not more than 5% of the specified rate. The distributor openings shall
be as near as possible to the treated surface and covered from all sides to prevent cement
scattering. Spreading of cement also, can be performed by distribution of bags on surface
in forms of rows at calculated intervals, then the bags shall be opened and the cement
distributed in the transverse directions. Finally, distribution process shall be completed
using equipments accepted by the Engineer, so that a uniform cement rate is obtained for
the whole area and thickness of the layer to be treated. The materials on which cement is
distributed shall be dry.
After cement is distributed, it shall be mixed in dry state with the aggregate
materials using plowing, pulverizing and mixing equipments, equipped with plowing and
pulverizing arms, teeth and rotating screw plows capable of pulverizing the materials all
over the layer and treated area and mixing the materials properly with cement until a
uniform mix is obtained in one pass. Then water shall be applied in specified rates and
plowing and pulverizing shall be repeated until a uniform mixture is obtained according to
the required cement rate and moisture content for the whole depth of constructed layer
materials shall be spread according to approved slopes, levels and smoothness.
When constructing limited quantities of works it is possible, with approval of the
Engineer, to use automatic steering grader capable of pulverizing, uniformly mixing and
spreading materials according to the slopes, thickness and smoothness shown on the
drawings or in the special specifications or these general specifications. Motor grader
mixing shall not lead to materials contamination with Subgrade or Subbase materials or
any deleterious materials during mixing and spreading. The produced mix shall conform to
approved design job mix formula. Cement shall be applied in a dry state pulverized and
consciously mixed with aggregate for the full depth of the constructed layer, until a
uniform color and gradation of the mix is obtained at the specified cement rate. Water
shall be applied, pulverized and mixed until a according to specified moisture content,
then the mixture is spread in one pass according to thickness, slopes and smoothness
shown on the drawings or special specifications.
Levels and thickness of spread layers shall be controlled using fixed stakes that
allows construction according to approved slopes and levels.
The period between cement and water application and starting of compaction shall not
exceed 30 minutes and all compaction and finishing processes shall be completed during a
period not more than 2.5 hours from cement and water applications.
208
6.5.5.4 Compaction and Finishing:

Compaction operations shall be started immediately after finishing of spreading
using smooth steel rollers of suitable weight ranged from 6-10 tons, or vibratory rollers
after disconnecting vibration system, these rollers shall be capable of compacting the
cement treated aggregate Base to compaction degree not less than 98% of the density
determined by AASHTO T-134 test for the full depth. Compaction shall not lead to
breaking aggregate particles. The period between spreading completions and starting of
compaction shall not exceed 30 minutes considering the prevailing air temperature, while
the period between water application to aggregate-cement mixture and completion of
compaction shall not exceed 2.5 hours.
Contractor shall take all the necessary measures for eliminating formation of
random cracks through controlling the cement rate used, such that it does not exceed the
approved minimum limit in the design job mix formula and water ratio control. Also,
carrying out the works at the suitable climatic conditions when temperatures are getting
lower as far as possible and taking the required arrangements for construction in hot
weather and care about mostening throughout the curing period. When some random
cracks appear, he should carry out the required repair works according to the engineer's
instructions and filling cracks with the suitable materials. Except otherwise stipulated in
the special specifications for a specific type, filler materials shall comply with ASTM D
(3405, 3406). Also, he shall remove all parts in which cracks of more than 3 mm wide
cracks appear when the cracked area exceeds 15% of any 30 m2 area and to replace it
with another area technically accepted. As an alternative to removal and replacement,
contractor, according to a technical report prepared by a specialized agency and with the
acceptance of the engineer, may construct an asphalt layer absorbing to stresses.
Contractor has no right to claim any additional cost for that.
Compaction degree shall be determined for each constructed layer by taking
random samples at time interval immediately after completing compaction using sand
cone method, AASHTO T- 191 test or the rubber balloon method according to AASHTO
T-205 test or nuclear method according to AASHTO T-3 10 or any other approved
nondestructive test method. When using nuclear method or any non-destructive test a
minimum of three readings shall be taken at each location and the average of three
readings should be the density of that location.
Compaction degree shall be calculated by dividing field density with maximum
dry density determined from AASHTO T-134 test.
The minimum limit of accepted compaction degree for determining the payment
factor using statistical method shall be the indicated degree in the beginning of this
paragraph minus 2%.
The unconfined compressive strength shall be determined by taking samples at
random time intervals from the mix, preparing, maintaining and testing them according to
AASHTO T-(134, 126, 22).The minimum allowed limit for calculating the payment factor is
80% of the value obtained in the design job mix or the minimum strength specified in the special specifications
The applied cement rate shall be verified on field samples using AASHTO T - 211 test this
rate shall not differ from the approved percentage by more than 10% of the
209
rate specified in the design job mix formula providing that the total difference should not
exceed, 0.5 % whichever is lesser.
Thickness of each constructed layer shall be measured after verification of
compaction by taking five random core samples and it is possible to use the field density
test hole for this purpose. The thickness accepted for determining payment factor shall not
be less than the approved thickness minus 2 cm or 10 % of the thickness shown on the
drawings whichever is lesser.
6.5.5.5 Construction of Joints:
Joints shall be executed between adjacent sections constructed in consecutive days
or when constructing adjacent sections finished more than 30 minutes ago. Joint
construction shall be done by cutting edge of constructed layer straight and perpendicular
to a distance that extends up to the area where the surface regular with constant slope and
the cut width shall be not less than 10 cm. These cut faces shall be wetted properly before
starting the spreading of the new materials. The prepared joints shall be protected at the
end of each working day by wooden boards or other materials accepted by the Engineer.
When the pavement surface is asphalt concrete, transverse contraction joints shall
be performed for the full width of layer, with at interval not more than 10 meters, and
filled with the required filler materials. No need for performing contraction joints when
using a cement concrete surface layer. The cutting of contraction joints shall be within the
first five days after finishing of compaction, and joints shall be cleaned from loose
materials, and filled with filler material, providing that the level of sealing materials shall
not exceed the level of layer surface. The selection of filler type and method of
construction shall be in accordance with the requirements of division 14 of these general
specifications.
6.5.5.6 Curing:
Cement treated base surface shall be kept in wet state by water spraying for a
period not less than 7 days providing that spraying shall start immediately after finishing
of compaction process and the layer curing can be done using soaking method after
making confining water perms on its surface or covering it with wetted sacks. These sacks
shall be rewetted using water for minimum two days and recovered with the plastic sheets
after each wetting process.
Moisture content of constructed layer surface can be maintained, by covering that
surface with emulsified asphalt curing membrane composed from equal percent of asphalt
and water conforming to requirements indicated in paragraph (6.5.2.5) of this section. The
asphalt curing membrane shall be sprayed in a rate of 0.9-1.13 Litre/m2 based on the
experimental section. Prior construction of asphalt curing membrane the constructed
surface shall be wetted with water for a minimum 24 hours period.
The asphalt curing membrane shall be executed according to construction
requirements of asphalt Base indicated in the division eight (8) of these general
specifications. Contractor shall be responsible for repairing any damage caused to asphalt
membrane or cement treated base.
210
6.5.6 Traffic Control:

Contractor shall take all necessary requirements for traffic control during
construction and curing periods, and prevent movements of any equipment over the
treated layer before, the end of curing period, except water distributors are allowed to
pass providing that it should not cause any damage in the treated layer. Contractor shall
be responsible for maintenance and repair until construction of the next layer is allowed.
6.5.7 Finishing Requirements:
Cement treated Base shall be constructed according to dimensions, slopes and
thickness indicated on drawings and special specifications, providing that the difference
between constructed layer thickness and required thickness shall not exceed 2 cm or 10 %
of the approved thickness whichever is lesser.
The final surface levels of constructed layer shall not differ from the specified
levels by more than 10 mm. The final levels shall verified on basis of 5 points cross
section measurements taken every 25 m interval, providing that the number of the
sections shall not be less than 5 for each 2000 square meters of constructed layer.
The surface smoothness shall be verified visually and by using straight edge, 3
meters long in five (5) locations, and the clearance between straight edge bottom and the
constructed surface between any two adjacent points shall not exceed 6 mm.
6.5.8 Acceptance:
Contractor shall control the quality of cement treated base through performing all
the required arrangements to insure that materials, methods and the completed works
documents.
The Ministry has the right to ensure quality of constructed works by verifying
contractor's quality control procedures either, through direct supervision of quality control
activities, or through performing quality assurance procedures, neutrally, on a sufficient
number of representative samples, to determine the level of construction and to accept or
reject the constructed work, on basis detailed in division 17 of this specifications except
otherwise indicated in the special specifications and other contract documents.
1.
Quality Control:
Contractor shall control the quality of materials and constructed works, and
monitor, record and analyze results, draw quality charts for critical properties and perform
all required tests and measurements indicated in Table (6.5.3).
Contractor shall submit to the Engineer with copies of all the measurements,
reports tests results and he shall apply all the requirements stated in item 17.1.1 of this
specifications.
211
Table 6.5.3: Quality control for cement treated Base

Work
Properties
Test method
Aggregate
gradation
AASHTO
T-27, T-1 1
Aggregate
quality
requirements
Raw
materials
Cement
Aggregate
gradation
Moisture
/Density
relationship
Aggregate
quality
requirements
Materials
and mix
during use
Cement
percent
At source
Source
guarantee
certificate
AASHTO
T-(27, 11)
All
requirements
indicated in
Table 6.5.2
Requirements

from each source and at
approval of design job mix
formula, or when the source
changed or properties of
constructed works is changed,
and five tests on different
samples taken in time interval
for each 5000 cubic meters from
each source during construction
Paragraph
6.5.2.2
At starting of material supply

and whenever source is changed
Paragraph
6.5.2.1
In the
plant
3 tests when starting of

production and one test for each
5000 cubic meters from
produced mix or when
properties of constructed work
is changed.
AASHTO
T-211
AASHTO
T-22
unconfined
compressive
strength
AASHTO
T-22
Cement
percent
AASHTO
T-21 1
Same other properties rate with

necessity for preparing samples
and maintaining them according
to AASHTO T-(134,126)
3 tests at starting of construction
and one test each 10000 square
meters of treated layer and
when properties are changed.
Samples of strength test shall be
prepared and maintained
according to AASHTO T(134,
126) test.
AASHTO
T-(191, 205)
Core samples
Dimensions
and levels
Survey
measurements
Surface
smoothness
Straight edge
Paragraph
6.5.3.2
Table
6.5.2
Paragraph
6.5.3.2.4
At site
thickness
Frequency of sampling
Paragraph
6.5.3.2
AASHTO
T- 134
unconfined
compressive
strength
Field density
Constructed
Works
All
requirements
indicated in
Table 6.5.2
Sam pling
locations
3 samples immediately after

compaction.
One measurement each day or
for each 2000 square meters of
constructed layer.
Cross sections each 25 meters
or 5 sections each 2000 square
meters whichever greater.
5
2000
square meters or measuring
between each approved two
cross sections whichever
greater.
Paragraph
6.5.3.2
Paragraph
6.5.5.4
Paragraph
6.5.5.4
Paragraph
6.5.5.4
Paragraph
6.5.5.4
Item
6.5.7
Item
6.5.7
212
2.
Quality Assurance:
The Ministry has the right to ensure the quality of the materials and completed
works through carrying out or ordering others under its direct supervision to carry out the
necessary tests and measurements, and checking the completed work for each or some
Ministry has the right to review contractors quality control records and to compare
these records statistically with the results obtained by quality assurance procedure as
method specified in division 17 of this specifications except otherwise specified by the
6.5.9 Measurements:
The cement treated base shall be measured in cubic meters or as specified in the
special specification after its laying and compaction according to the required thickness
and within the dimensions and levels indicated on the drawings or according to the
Engineer's instructions. When special specifications require separate cement measurement,
the actually used quantity of cement shall be measured in tons. No measurements shall be
performed for purpose of payments for materials laid outside the limits of works indicated
on the drawings or special specifications or specified by the Engineer.
6.5.10 Payment:
within the approved limits and dimensions and according to Contract prices or reduced
prices because of quality assurance implementation when indicated in contract documents.
The paid amounts are considered full compensation for production, supplying, mixing,
transporting, spreading and compacting of materials, finishing of works, benefits,
revenues, fees and third party payments, provisions and operation of machines and
equipments, labor, tests, measurements and all requirements for constructing the works in
accordance with drawings, special and general specifications. Payment shall be made
according to one or more of the items indicated in the Table (6.5.4) without contradiction
with contract documents.
Table 6.5.4: Payment Items for Cement Treated base course
Item No.
Work type
Unit
6.5.1
Cement treated Base
m3
6.5.2
Cement
Ton
213
6.6
Emulsified Asphalt Treated Base:
6.6.1 Work description:

This Section consists of furnishing and cold-mixing aggregate and emulsified
asphaltic material, hauling, spreading, compacting and finishing the emulsified asphalt
treated base to the lines, grades and thickness shown on the plans, all in accordance with
the these General Specifications, Special Specifications, and as directed by the Engineer.
There are three of emulsified asphalt treated base mixes, which are classified
according to aggregate gradation used in these mixes as shown in Table (7.3.5) in these
General Specifications. They are type-I (open graded), type-II (dense graded), and
type-III (sand graded).
Type-I emulsified asphalt treated base mix is produced at ambient temperature
(cold-mix) and only by central mixing. However, the emulsified asphalt treated base
mixes Type-II and type-III may be produced in the ambient temperature (cold-mix) by
one of the following three methods:
Central mixing in a continuous mixing pugmill.
Central mixing in a batch plant.
Mix on-road by using a mobile mixing unit.
6.6.2 Materials:
A s p halt m ate r ia l: the material shall be from emulsified asphalt categories MS-2 or
MS-2h or CMS-2 or CMS-2h or SS-1h or CSS-1 or CSS-1h so that it complies with the
quality requirements indicated in Tables (7.2.5) to (7.2.7) in these General Specifications.
The selected asphaltic materials shall provide the required coating requirements stated in
Item 6.6.3.
Aggregate: Aggregate gradations 1 (open-graded), 2 (dense-graded), and 3
(sand-graded) from Table 7.3.5 in these General Specifications, shall be used for
preparing the emulsified asphalt treated base mixes provided that they achieve the quality
requirements indicated in Table (7.3.1) (Types 4, 5, 6) in these General Specifications.
The combined aggregate shall achieve the approved gradation requirements within the
allowed variation limits indicated in Table (6.6.1).
W ate r: Water shall be free of matter deleterious to the quality of the emulsified asphalt
treated mixture.
C em en t: It shall be from Portland cement type (I) or (II) which is compliant with the
requirements indicated in Item 7.3.4 in these General Specifications
Table 6.6.1: Allowable tolerance limits for total aggregate
Sieve size
9.75 mm (3/8 inch)
4.75 mm (No. 4) and more
2.36 mm (No. 8) and 0.300mm (No. 50)
0.150 mm (No. 100)
0.075 mm (No. 200)
Asphalt content
Variation percent points

8
7
6
4
2
0.40
214
6.6.3 Emulsified Asphalt Treated Base Mix:

6.6.3.1 Job Mix Formula:
Contractor, before starting the execution of the Emulsified asphalt treated base by
thirty (30) days, shall submit to the Engineer a full technical report prepared by an
approved specialized agency including the mix design and job mix formula (JMF) which
should be prepared according to the basic asphalt emulsion guide (MS-19) published by
the American Asphalt Institute using and ASTM D-1559 unless otherwise stated in the
Special Specifications. The JMF shall conform to the requirements shown in Table
(6.6.2).
Table 6.6.2: Quality requirements for emulsified asphalt treated mixes (MS-19)
Property
Marshall stability. Kilogram ASTM D 1559
Stability loss, percent %
Air voids, percent
Absorbed moisture rate after 4 soaking days, %
Aggregate coating, percent ASTM D 244 %
Minimum limit
227
2
50
Maximum limit
50
8
4
-
The Contractor shall submit the JMF together with the following information:
1. Necessary data on aggregate source, gradation, and properties related to crushing,
gradation and other quality requirements stated in Item 6.6.2.
2. Type and grade of the emulsified asphalt materials to be used.
3. All test results of the trial experimental mixes and mix design.
4. Asphalt content based on the total dry weight of the mix.
5. Percentage of the Portland cement, as required, of the total dry weight of the mix.
6. Percentage of additional mixing water on the basis of the total dry weight of the
mix.
7. Total liquid percentage (asphalt material and water) at compaction based on the
dry total weight of the mix.
8. Maximum theoretical density according to ASTM D-2041.
9. Type and site of mixer intended for use in preparing each mix to be submitted.
10. Date of commencing production of the emulsified asphalt treated base mixes.
11. A list for all the equipment to be used.
The Engineer shall be provided access to the materials sampling and testing
operations at all times.
Contractor shall supply to the Engineer one hundred (100) kilogram samples of
each individual aggregate size, eight (8) liters of asphaltic material and, when used,
sufficient quantities of mineral filler and chemical admixture to check design JMF and all
representing materials which the Contractor proposes to furnish.
6.6.3.2 Job Mix Formula Acceptance Procedures:
After Contractor submits the proposed job formula with all its appendices as
indicated in the previous item, the Ministry shall review the job mix according to the
following steps:
215
1. Assure that the report contains all requirements. If it does not contain all required
information, it shall be returned within seven (7) days to the Contractor for further
action and resubmission by the Contractor.
2. If the proposed JMF contains all required information but fails to meet all of the
requirements specified, it should not be accepted by the Engineer and will be
returned to the Contractor within fourteen (14) days. The Contractor shall prepare
and submit to the Engineer a revised JMF conforming to the requirements
specified.
3. It is not allowed to commence production of the emulsified asphalt treated base
mix until the Engineer has already issued his acceptance of the JMF.
4. The first-day work shall be considered as a field control strip. It shall be assured
that mix is constructible in terms of spreading and compaction.
5. The Engineer's acceptance of the job mix formula does not release the Contractor
from his responsibility for producing the emulsified asphalt treated base mixes,
which are compliant with all the specified requirements.
6. The Contractor shall not alter the methods of manufacturing, screening, mixing,
stockpiling of aggregate, or production of asphalt mixtures since this alteration
will mandate re-evaluation of JMF as stated in previous Subitem.
6.6.4 Equipments:
The Contractor shall furnish and operate sufficient equipment to execute the
asphaltic concrete work within the Contract time in accordance with his program of work
as approved by the Engineer. This equipment shall conform to the following
requirements:
1. The mobile mixer shall not be used for producing open-graded base mixes.
2. Water added to the mix shall be applied through volumetric rate meter, registering
in liters per minute, which will accurately measure the flow of water. The flow of
water shall be interlocked with the flow of aggregate, asphaltic emulsion material
and additives, if required.
3. Portland cement shall be introduced into the mixture through a positive auger or
belt feeder.
4. Cold-feed proportioning controls shall be used.
6.6.5 Weather Limitations:
Emulsified asphaltic treated mixtures shall not be placed on any surface with
stagnant water or frozen surface, during dust or sand storms, or when the air temperature
is less than fifteen (15) degrees Celsius.
6.6.6 Constructions:
6.6.6.1 Emulsified Asphalt Material Preparation:
The emulsified asphalt material shall be stored in temperatures within the ranges shown
in Table (6.6.3). The emulsified asphalt materials shall be protected from freezing due
snow and shall be pulverized and rotated in regular intervals to ensure its uniformity and
regularity. Forced air shall not be used for agitation process.
Table 6.6.3: Storing temperature ranges for emulsified asphalt materials.
Emulsified asphalt Material
SS-1, SS-1h, CSS-1, CSS-1h
MS-2, CS-2h, CMS-2, CMS-2h
Storing temperature (Degrees Celsius)

Minimum
Maximum
10
60
50
85
216
6.6.6.2 Aggregate Preparation:

Aggregate shall be stockpiled and transported from stockpiles according to the
requirements of Item 7.3.6 in these General Specifications
6.6.6.3 Central Mixing:
Unless the Special Specifications allow, all emulsified asphalt treated base types
(I, II, and III) may be produced in a central mixing plant. Aggregate, the emulsified
asphalt material, added water, Portland cement, and other additive materials, when
required, may be proportioned by approved JMF. Mixing shall be executed according to
the following steps:
1. The aggregate shall be fed from storage to the mixing chamber using a belt feeder
equipped with devices by which the rate of aggregate feed can be determined
while the plant is in full operation. Aggregate feed and the asphaltic emulsion
material-metering pump shall be mechanically or electrically interlocked in a
manner that maintains a constant ratio of aggregate and asphaltic emulsion
material.
2. Portland cement, when required, shall be introduced into the dry aggregate on the
belt feeder and shall be mixed thoroughly before adding water or emulsified
asphalt.
3. Mixing water, when required, shall be introduced into the aggregate through a
spray bar mounted at such a point that the water is added as the aggregate enters
into the mixing chamber.
4. The asphaltic emulsion material shall be introduced into the mixing chamber
through a spray bar that can be adjusted to vary mixing times between five and
thirty (5-30) seconds.
5. The aggregate, water and Portland cement as required, and asphaltic emulsion
material shall be mixed until the aggregate has been coated and a uniform and
homogeneous mixture has been obtained.
6. Type (I) open-grade emulsified asphalt treated base mix shall be discharged
directly into hauling equipment or stored in bins or silos. Type (I) open-graded
emulsified asphalt treated base mix shall not be stored on the ground.
7. Type (II) and Type (III) emulsified asphalt treated base mixes may be discharged
directly into hauling equipment or stored. Type (II) and Type (III) base mixes
shall not be stored for periods longer than forty-eight (48) hours without prior
written approval from the Engineer.
6.6.6.4 Road Mixing:
When the Special Specifications allow, types (II) and (II) of the emulsified asphalt
treated base mixes may be mixed using a propelled mobile mixing plant. The travel plant
shall be capable of producing a uniform, properly coated, emulsified asphalt
material-aggregate mixture conforming to the requirements of the JMF. Emulsified asphalt
material and aggregate proportioning devices shall be keyed to the rate of forward travel of
the mixer, or interlocked to ensure a constant asphaltic emulsion material-aggregate blend.
Multiple passes of the travel plant may be required for higher emulsified asphalt material
contents to achieve required uniformity of mix.
The surface to receive emulsified asphalt treated base shall conform to the compaction and
other requirements for the material involve. When the surface does not
217
conform to compaction and other requirements for the material involved, the Contractor,
at his own expense, shall correct all deviations.
When the surface to receive emulsified asphalt treated base is a soil subgrade,
aggregate subbase or aggregate base, and the total thickness of the asphaltic emulsion
treated base and surface course is less than ten (10) centimeters, the surface shall receive a
prime coat in accordance with the requirements specified in Section 8.3 in these General
Specifications. The prime coat shall be allowed to cure for at least forty-eight (48) hours
before placement of emulsified asphalt treated base.
Type (I) open-graded emulsified asphalt treated base shall be spread using a
self-propelled paving machine. The maximum thickness of one lift shall not exceed ten
(10) centimeters. Immediately after spreading, each lift shall be compacted with (1) one
coverage of a steel-drum tandem roller weighing not less than ten thousand (10,000)
kilograms. After the initial coverage, choke stone shall be uniformly spread across the
surface of the open-grade base at a rate between seven and thirteen (3-5) kilograms per
square meter using a self-propelled spreading device. Immediately after spreading choke
stone, the open-graded base shall receive three (3) additional coverages with a steel-drum
tandem roller weighing not less than ten thousand (10,000) kilograms. After completion
of compaction, surplus choke stone shall be removed by sweeping. Each lift of
open-graded base shall be allowed to cure for a period not less than seventy-two (72)
hours before spreading successive lifts.
Type (II) and Type (III) emulsified asphalt treated base may be spread using a
self-propelled paving machine, aggregate base spreader, or other device which results in a
base that is smooth, has a uniform texture, conforms to planned and specified thickness,
and is within the lines and grade shown on the plans. The maximum thickness of one lift
shall not exceed ten (10) centimeters unless otherwise approved by the Engineer provided
sufficient Portland cement is added to the mixture to accelerate curing and the Contractor
demonstrates that curing is effective.
Each lift shall be compacted using a steel-drum tandem roller weighing not less
than ten thousand (10,000) kilograms until the relative compaction is at least ninety-one
(91) percent of the theoretical maximum density determined from test method ASTM
D-2041.
Each lift of Type (II) and Type (III) emulsified asphalt base shall be allowed to
cure for the period specified in the Special Specifications, or for three to five (5) days, or,
when Portland cement is added to the mixture, for such shorter period as approved by the
Engineer. In all cases, the next layer shall not be placed and the traffic shall not be
allowed before the emulsified asphalt treated base is cured.
6.6.6.6 Finishing:
When it is shown on the drawings or specified in the specifications, the emulsified
asphalt treated base layers of all types shall be covered with a layer of asphalt slurry seal
type (3) sand compliant with the requirements of item 10-3 of these General
Specifications.
When the surface is tested by a four (4) meter straight edge, the deviations shall
not be more than five (5) millimeters in the longitudinal direction or ten (8) millimeters in
the transverse direction are allowed.
218
6.6.7 Traffic control:

The Contractor shall take effective action to control all traffic in accordance with
the Manual of Traffic Control through Work Zones issued by the Ministry of
Municipalities and Rural Affairs in 1421H (2001).
6.6.8 Work Acceptance:
The Contractor shall apply quality control procedures for emulsified asphalt
treated base works to ensure that the materials used and the executed work conform to
these General Specifications and other Contracts Documents.
The Ministry shall assure the quality of production by checking that the Contractor
is performing the quality control procedures in correct manners. The Ministry may have a
direct supervision on the quality control system or by applying quality assurance
procedures in an independent unbiased way, on adequate number of samples to judge the
execution level and decide whether to accept or reject the work. Division 17 in these
General Specifications shall be used for this purpose, unless stated otherwise in the
Special Specifications or Contracts Documents.
6.6.8.1 Quality Control:
The Contractor shall perform all required tests and measurements, and shall
collect, document, and draw the critical property diagrams to ensure that the raw materials
at source, materials while work execution, emulsified asphalt treated base produced, and
the executed work are within acceptable limits. The tests may be performed at The
Contractors laboratory or at an independent laboratory, approved by the Ministry. The
Contractor shall submit copies of all test results to the Engineer. Table (6.6.4) shows the
tests that the Contractor shall perform on raw materials and mixes, the frequency of these
tests, and the allowance limits. The Contractor shall submit copies of all tests to the
Engineers and shall apply all requirements detailed in Item 17.1.1 in these General
Specifications.
6.6.8.2 Quality Assurance:
The Ministry reserves the right, at any time, to assure the quality of materials and
executed work by performing or ordering the Contractor to perform, under its direct
supervision, some or all quality control tests that are shown previous Sub item. The
Ministry has also the right to inspect all Contractors' quality control test records and
compare them with its quality assurance test done according to Division 17 in these
General Specifications. Ministry may inspect Contractor's laboratory, devices, technical
staff, and testing methods to assure the full adequacy and capability of the Contractor to
execute the work according to standard approved methods.
6.6.9 Measurements:
Each type of the emulsified asphalt treated base shall be measured in cubic meters
according to its position and its compaction according to the specified thickness and within
the lines and levels shown on the drawings and according to the Engineer's instructions. It
is not allowed to perform any measurements for the materials laid outside the allowed
limits for payment purposes.
Mineral fillers, chemical admixtures and asphalt modifiers used by the Contractor
to meet the Job Mix Formula (JMF) requirements will be considered subsidiary to the
construction of the emulsified asphalt treated base and shall not be
219
measured separately unless specifically stated in the Special Specifications and listed in
the Bill of Quantities. When they are listed separately they shall be measured in liters,
kilograms, or tons.
Table 6.6.4: Quality control procedures for the emulsified asphalt treated base
Work
Properties
Test
Method
Asphalt
emulsion
Quality
requirement
s tests
Cement
Quality
requirement
s tests
Raw
materials
Sampling frequency
Compliance certificate at
supply starting and
whenever source is changed
Requirements
Tables
7.2.5 to 7.2.7
Quality
requirements
in item 7.3.4
Aggregate
Quality and
Gradation
Requiremen
ts tests
Three (3) tests on different

samples from each source at
source approval or JMF,
change source. Minimum
of five (5) tests on samples
taken at different times
every five-thousand (5000)
cubic meter for each source
at production
Tables 7.3.1
and 7.3.5
Aggregate
Gradation (dry
mix)
AASHTO
T-27
Three tests for mix design

and test each week and
Table 7.3.5
Three tests to use the

asphalt materials and the
aggregates and for mix
design and test whenever
source is changed
Table 6.6.2
Source
Materials
in use
Aggregate
coating in the
mix
Aggregate
Gradation and
Asphalt content
in mix
Marshall
stability and
Loss
Compaction
Thickness
Executed
work
Sample
location
Surface layer
smoothness
Measuring
dimensions,
levels, slopes
and
smoothness
ASTM D244
AASHTO T1 64/T-27
ASTM D1559
AASHTO
T-3 10
ASTM D3549
Sub item
6.6.6.6
Geometric
measureme
nts
Stocked
Materials
Mixing
plant or
behind
the paver
Project
site
One (1) test for each five

hundred (500) cubic meters
of each layer or a day-work,
whichever minimum
Table 7.3.5,
Table 6.6.1,
and JMF
Requirement
Table 6.6.2
Test for each one thousand

(1,000) square meters
Test for each one thousand
(1,000) square meters
Straight edge measuring
method for every day work
Sub item
6.6.6.5
Contract
documents
Sub item
6.6.6.6
Transverse segments every

twenty-five (25) meters or
five segments every one
thousand (1000) meters,
whichever the maximum
Contract
documents
220
The surface treatment shall be measured by square meters as indicated in Division

10 of these General Specifications.
Choke stone will be considered subsidiary to the construction of asphaltic
emulsion treated base and will not be measured.
6.6.10 Payment:
Payment shall be made at the contract unit price, or adjusted contract unit price,
per cubic meter measured as described in the pervious Item for each type emulsified
asphalt treated base and all related items listed in the Bill of Quantities.
The above prices and payment shall cover and be full compensation for furnishing
labor, materials, equipment, tools, and incidentals necessary for completing all work
involved in construction and acceptance of emulsified asphalt treated base.
Table 6.6.5: Emulsified asphalt treated base mix pay items

No.
6.6.1
Pay Item
Emulsified asphalt treated base type
Pay units
Cubic meter
221
DIVISION 7
7.1 Scope
7.2 A sphalt M aterials
7.2.1 Asphalt Cement
7.2.1.1 Uses
7.2.1.2 Requirements
7.2.2 Liquid Asphalt (Asphalt Cutback)
7.2.2.1 Uses
7.2.3 Emulsified Asphalt
7.2.3.1 Uses
7.2.4 Modified Asphalt
7.2.4.1 Uses
7.2.5 Asphalt Materials Production
7.2.6 Asphalt Materials Acceptance Procedures
7.2.6.1 Supplied Container
7.2.6.2 Delivery Ticket
7.2.6.3 Certificate Of Compliance
7.2.6.4 Acceptance Sampling Procedures
7.2.7 Measurement
7.2.8 Payment
7.3 A ggregates
7.3.1 General Requirements
7.3.2 Coarse Aggregate
7.3.2.1 Description
7.3.2.2 Quality Requirements
7.3.2.3 Gradation Requirements 7.3.3
Fine Aggregate
7.3.3.1 Description
7.3.3.3 Gradation Requirements 7.3.4
Mineral Filler
7.3.4.1 Description
7.3.4.3 Gradation Requirements
7.3.5 Combined Aggregate In Asphalt Mixes
7.3.5.2 Gradation Requirements For Asphalt Mixes
7.3.6 Aggregate Stockpiling
7.3.7 Aggregate Acceptance
7.3.8 Measurements
7.3.9 Payment
225
225
225
225
225
225
227
227
227
227
227
227
227
227
227
235
235
235
235
236
236
237
237
237
237
238
238
238
238
238
238
238
238
238
238
240
240
240
240
240
241
241
241
243
Division 7- Materials of Asphaltic Mixes
DIVISION 7
7.1
Scope:
This Division comprises of the specifications of asphalt mixes materials, which
include asphalt binders, asphalt modifiers, coarse and fine aggregates, and mineral filler. It
also includes acceptance procedures, measurement method, and payment methods.
7.2
Asphalt Materials:
The asphaltic materials used in asphaltic mixes shall be produced as by-products
of crude petroleum refining or manufactured from their derivatives. They shall include the
following types:
1. Asphalt Cement: produced from petroleum refineries and/or special factories by
mixing different grades of asphalt or by oxidation or by both methods.
2. Cutback Asphalt: produced by diluting the asphalt cement by naphtha, kerosene,
or diesel.
3. Emulsified Asphalt: produced by emulsifying the asphalt cement by special
millers using water and emulsifying agents.
4. Modified Asphalt: produced by treating the asphalt cement by special chemical
modifiers in specialized plants.
All asphalt types shall have homogenous properties and conform to the following
requirements.
7.2.1 Asphalt Cement:
7.2.1.1 Uses:
The asphalt cement is used in hot asphalt concrete mixes and some surface treatments.
7.2.1.2 Requirements:
Unless specified in the Special Specifications, the asphalt cement shall conform to
the requirement of the Standard Saudi Specification Number 1776, which classifies
asphalt based on viscosity; or shall conform to the requirements of AASHTO M-20,
which classifies asphalt based on penetration grades. The asphalt cement shall be of 60/70
or 40/50 penetration grades or any grade specified in the Special Specifications. The
grades of asphalt materials shall conform to the requirements set forth in Table (7.2.1).
When the Special Specifications specifies the use of asphalt cement graded as
Performance Grade (PG) according to Strategic Highway Research Program (SHRP), the
specification detailed in Division 12, in these General Specifications, shall be applied.
225
T
able 7.2.1: Quality requirement of penetration grade asphalt binder
Property
AASHTO
Test
40-50
Penetration Grade
85-100
60-70
120-150
200-300
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
T-49
40
50
60
70
85
100
120
150
200
300
25
25
25
25
25
Viscosity, at 60 o C, Poise,
min. (2)
T-202
6000
2600
Viscosity at 135 o C,
Kinematic min.
T-201
240
200
170
T-48
232
232
232
218
177
T-51
100
100
100
100
T-44
99
99
99
99
99
0.8
1.3
1.5
Penetration at 25 Degrees C,
100g, 5sec.
Penetration Ratio, percent
min. (1)
Flash point, Cleveland

Open, o C, min.
Ductility at 25 o C, 5cm per
min, cm, min
Solubility in
trichloroethylene, percent,
m in.
Thin film oven test, 3.2 mm, 163 degree Celsius, 5 hour
Loss on bearing, percent of
0.8
original, max.
Penetration, of residue,
percent of original
Ductility of residue at 25 o C,
5 cm per, cm, min.
Solubility in
trichloroethylene, %, min.
T-49
58
54
50
46
40
T-51
50
75
100
100
T-44
99
99
99
99
99
Spot Test, when and as specified (3), with:

Negative for all grades
Standard naphtha solvent

Naphtha-xylene solvent
Heptane-xylene solvent
T-102

Note 1: Penetration Ratio = (Penetration at 4 degree Celsius, 200 grams, and 60 seconds) x (100) /
(Penetration at 25 degree Celsius, 100 grams, and 5 second).
Note 2: Penetration Viscosity requirement was added to these General Specifications based on local study.
Note 3: The use of the spot test is optional. When it is specified, the Engineer shall indicate whether the
standard naphtha solvent, the naphtha-xylene solvent, or the heptane-xylene solvent will be used
in determining compliance with the requirement, and also, in the case of the xylene solvents, the
percentage of xylene to be used shall be specified.
226
7.2.2 Liquid Asphalt (Asphalt Cutback):

7.2.2.1 Uses:
The liquid diluted asphalt is used as prime coat, tack coat, in cold-mix, single and
multiple surface treatments, sand seal, and soil and dust stabilizer.
The liquid asphalt shall conform to the requirements of AASHTO M-8 1 and M 82. It shall be medium curing (MC) or rapid curing (RC) or as specified in the Special
Specifications for a particular work. They shall conform to the requirements shown in
Tables (7.2.2) (A and B) and Tables (7.2.3) (A and B).
7.2.3 Emulsified Asphalt:
7.2.3.1 Uses:
The emulsified asphalt is used in slurry seal, prime coat, and tack coat, in cold
mixes, single and multiple surface treatments, sand seal, fog seal, and soil and dust
stabilizer.
The emulsified asphalt shall conform to the requirements of AASHTO M-140 for
anionic (negative charge) as shown in Tables (7.2.4) to (7.2.6). and AASHTO M-208 for
cationic (positive charge) as shown in Table (7.2.7).
There are two groups of emulsified asphalt: anionic (negative charge) and cationic
(positive charge) and each group is divided into three grades: rapid setting, medium
setting, and slow setting. These grades are further divided into types according to
emulsified asphalt viscosity and hardness of the asphalt cement used in the emulsified
asphalt.
The emulsified asphalt shall be selected based on the charge group according to
the type and condition of the aggregates and soils to be treated or stabilized. The anionic
emulsified asphalt shall be used with basic aggregates such as limestone, where as the
cationic emulsified asphalt shall be used with the acidic aggregate such as basalt or quartz.
7.2.4 Modified Asphalt:
7.2.4.1 Uses:
The modified asphalt is used when the use of normal asphalt or the asphalt mix
produced by normal binder is not suitable for the performance requirements imposed by
materials properties, environmental conditions, or operating traffic. The asphalt is mixed
with specific materials such anti-stripping agents, rubber, polymers, plastic or other
modifiers during the asphalt mix production.
When specified in the Special Specification, only the tested and tried asphalt
modifiers shall be used to modify the asphalt properties without affecting the general
performance. The asphalt modifiers shall posses to following basic requirements:
227
T
able 7.2.2.A: Quality requirement of medium curing (MC) liquid asphalt
MC-30
AASHTO
Property
Test
Kinematic Viscosity at 60 o C, cSt

(1)
T-201
Flash Point, Tag, open-cup, o C
T-79
Water Percent
T-55
MC-70
MC-250
MC-800
MC-3000
Min
Max
Min
Max
Min
Max
Min
Max
Min
Max
30
60
70
140
250
500
800
1600
3000
6000
38
66
66
..
66
0.2
0.2
0.2
0.2
0.2
38
-
Distillation Test: Distillate percentage by volume of total distillate to 360 de gr e e Ce l si us

To 225 o C
T-78
To 260 o C
T-78
T-78
To 315oC
25
20
10
40
70
20
60
15
55
35
15
75
93
65
90
60
87
45
80
15
75
50
55
67
75
80
T-202
300
1200
300
1200
300
1200
300
1200
300
1200
T-51
100
100
100
100
100
T-44
99.0
99.0
99.0
99.0
99.0
Residue from distillation to 360

C volume percentage of sample
by difference, min.
Tests on residue from distillation:

Absolute viscosity at 60o C,
Poise,
Ductility. (2) 5 cm/minute, cm,
min.
Solubility in Trichloroethylene,
percent, min.
Spot test with (3):
Standard naphtha
T-102

N ote 1: As an alternate, Saybolt Furol viscosities may be specified as follows:

Grade MC-30 -- Furol viscosity at 25 degree Celsius - 75 to 150 sec.
Grade MC-800 -- Furol viscosity at 82.2 degree Celsius - 100 to 200 sec.
Grade MC-3000 -- Furol viscosity at 82.2 degree Celsius - 300 to 600 sec.
Note 2: If the ductility at 25 degree Celsius is less than 100, the material will be acceptable if its ductility at
15.5 degree Celsius is more than 100.
N ote 3: The use of the spot test is optional. When it is specified, the Engineer shall indicate whether the
standard naphtha solvent, the naphtha-xylene solvent, or the heptane-xylene solvent will be used in
determining compliance with the requirement, and also, in the case of the xylene solvents, the
228
Table 7.2.2.B: Quality requirement of medium curing (MC) liquid asphalt
Property
AASHTO
Test
MC-0
MC-1
MC-2
MC-3
MC-4
MC-5
MinMax.
MinMax.
MinMax.
MinMax.
MinMax
MinMax.
Flash Point, Tag, open-cup, oC,

T-79
100
100
150
150
150
min.
75-150
Furol viscosity at 25o C
75-150
Furol viscosity at 50oC
T-72
100-200
250-500
125-250
Furol viscosity at 82.2o C
Distillation Test: Distillate percentage by volume of total distillate to 360 degree Celsius
To 190 oC
0-25
0-20
0-10
0-5
0
To 225 oC
40-70
25-65
15-55
5-40
0-30
T-78
75-93
70-90
60-87
55-85
40-80
To 3 15oC
Residue from distillation to
50
60
67
73
87
360o C volume percentage of
sample by difference, min.
Tests on Residue from Distillation
Penetration, 25 oC, 100 grams,
T-49
120-300 120-300 120-300
120-300 120-300
5seconds
(1)
T-51
100
100
100
100
100
Ductility 5 cm/min., cm, min.
Solubility in
T-44
99.50
99.50
99.50
99.50
99.50
Trichloroethylene, percent,
min.
Temperature for Application
25-65
50-80
65-105
80-120
90-135
-by Spraying, in oC
All shall be free of water
General Requirement
150
300-600
0
0-20
20-75
82
120-300
100
99.50
105-150
Note 1: If penetration of residue is more than two hundred (200) and its ductility at 25 degrees Celsius is less
than one hundred (100), the material will be acceptable if its ductility at 15.6 degrees Celsius is more
than one hundred (100).
229
Table 7.2.3.A: Quality requirement of rapid curing (RC) liquid asphalt
Property
Kinematic Viscosity at 60
o C, cSt (1 )
Flash Point, Tag, open-cup,
o C, min.
Water Percent, max.
AASHTO
Test
RC-70
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
T201
70
140
250
500
800
1600
3000
6000
T-79
T-55
0.2
Distillation Test: Distillate percentage by

volume
To 190 o C
To 225 o C
T-78
To 260 o C
To 315 o C
Residue from distillation to
360o C volume percentage
of sample by difference
Tests on residue from distillation:
Absolute viscosity at 60o C,
T-202
Poise,
Ductility 5 cm/minute, cm.
T-51
(2)
Solubility in
Trichloroethylene, percent,
m in.
Spot test (3) with:
Standard naphtha
T-44
10
50
70
85
RC-250
27
-
RC-800
27
27
0.2
0.2
25
70
of total distillate to 360 degree Celsius

35
15
60
45
80
75
55
RC-3000
0.2
65
75
85
300
1200
300
1200
300
1200
300
1200
100
100
100
100
99.0
99.0
99.0
99.0

T-102

N ote 1 As an alternate, Saybolt Furol viscosities may be specified as follows:

Grade RC-70 -- Furol viscosity at 50 degree Celsius - 60 to 120 sec.
Grade RC-250 -- Furol viscosity at 60 degree Celsius - 125 to 250 sec.
Grade RC-800 -- Furol viscosity at 82.2 degree Celsius - 100 to 200 sec.
Grade RC-3000 -- Furol viscosity at 82.2 degree Celsius - 300 to 600 sec.
Note 2: If the ductility at 25 degree Celsius is less than 100, the material will be acceptable if its ductility at
15.5 degree Celsius is more than 100.
Note 3: The use of the spot test is optional. When it is specified, the Engineer shall indicate whether the
standard naphtha solvent, the naphtha-xylene solvent, or the heptane-xylene solvent will be used in
determining compliance with the requirement, and also, in the case of the xylene solvents, the
230
Table 7.2.3.B: Quality requirement of rapid curing (RC) liquid asphalt

Property
A A SHTO
Test
RC-0
RC-1
RC-2
RC-3
RC-4
RC-5
MinMax.
MinMax.
MinMax.
MinMax.
MinMax
MinMax.
80
80
Flash Point, Tag, open-cup, o C,

T-79
80
80
m in.
75-150
75-150
Furol viscosity at 50oC
T-72
100-200
250-500
Furol viscosity at 82.2o C
Distillation Test: Distillate percentage by volume of total distillate to 360 degree Celsius, min.
To 190 o C
15
10
To 225 o C
T-78
55
50
40
25
75
70
65
55
To 315oC
Residue from distillation to 360
50
60
67
73
o C volume percentage of sample
by difference, Min.
Tests on Residue from Distillation
Penetration, 25 o C, 100 grams,
T-49
80-120
80-120
80-120
80-120
5seconds(1)
T-51
100
100
100
100
Ductility 5 cm/minute, cm, min.
Solubility in Trichloroethylene,
T-44
99.50
99.50
99.50
99.50
percent, min.
Temperature for Application by
25-50
50-80
65-95
80-105
-Spraying, in degrees C
All shall be free of water
General Requirement
125-250
300-600
8
40
25
87
82
80-120
80-120
100
99.50
100
99.50
95-120
105-135
Note 1: If penetration of residue is more than two hundred (200) and its ductility at 25 degree Celsius is less
than one hundred (100), the material will be acceptable if its ductility at 15.6 degree Celsius is more
than one hundred (100).
Table 7.2.4: Quality requirements of anionic rapid setting (RS) emulsified asphalt
Property
AASHTO
Tes t
RS-1
Min.
Max.
Min.
100
-
T-72
20
-
T-59
T-59
60
T-59
T-59
55
0.1
-
Penetration, 25 o C, 100 g, 5s
T-49
100
100
Ductility, 25 o C, 5 cm/min, cm, min.
T-51
40
200
-
Solubility in Trichloroethylene, %, min.
T-44
97.5
97.5
Viscosity, Saybolt Furol, 25 o C, second
T-72
Viscosity, Saybolt Furol, 50 o C, second

Storage stability test, 24-h, %
Demulsibility (1), 35 ml, 0.02 N CaCl2 , %,
min.
Sieve test, %, max
Residue by distillation, %, min.
75
RS-2
Max.
400
1
60
63
0.1
-
Tests on residue from distillation test:
Typical Applications (2)
surface treatment,
penetration macadam,
sand seal coat, tack coat,
mulch
40
200
-
surface treatment,
penetration macadam,
coa
t
t
l
1. The demulsibility test shall be made within 30 days from date of shipment.
2. These typical applications are for use only as a guide for selecting and using the emulsion for
pavement construction and maintenance.
231
Table 7.2.5:
Quality requirements of anionic medium setting (MS) emulsified asphalt
Property
Viscosity, Saybolt Furol, 25 o C, seconds
Storage stability test, 24-h, %
MS-1
MS-2
AASHTO
Test
T-72
Min
Max
Min
20
100
T-59
Good
MS-2h
Max
Min
100
Good
Good
Fair
Fair
Fair
Fair
Fair
HFMS-1
Max
Min
Max
100
20
100
Good
Good
Good
Good
Good
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Coating ability and water resistance:

- Coating, dry aggregate
- Coating, after spraying
- Coating, wet aggregate
T-59

Sieve test, %
T-59
0.1
0.1
0.1
0.1
Residue by distillation, %
T-59
55
65
65
65
Penetration, 25 o C, 100 g, 5second
T-49
100
200
200
100
200
40
90
100
T-51
40
40
40
40
T-44
97.5
97.5
97.5
Float test, 60 o C s
Test on residue from distillation text:
cold plant mix,

coarse aggregate
seal coat (single
and multiple),
crack treatment,
road mix, tack
coat, sand seal coat
cold plant mix,

road mix, sand
seal coat, crack
treatment,
tack coat
cold plant mix,

hot mix, coarse
aggregate seal
coat (single and
multiple crack
treatment, road
mix track coat
97.5
1200
cold plant mix,

road mix, sand
seal coat, crack
treatment, tack
coat
Table 7.2.5 (cont.): Quality requirements of anionic medium setting (MS) emulsified asphalt
Property
Storage stability test, 24-h, %, max.
AASHTO
Test
T-72
T-59
HFMS-2
HFMS-2h
HFMS-2s
Min
Max
Min
Max
Min
Max
100
-
100
-
50
-

Good

T-59
Good
Good
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Sieve test, % , max.
T-59
0.1
Residue by distillation, % , min.
T-59
65
Penetration, 25 o C, 100 g, 5second
T-49
200
T-51
40
T-44
Fair
0.1
0.1
65
65
100
200
40
90
200
40
40
97.5
97.5
97.5
1200
Float test, 60 o C s
cold plant mix, coarse

aggregate seal coat
(single and multiple),
crack treatment road
mix, tack coat, and seal
1200
cold plant mix, hot plant
mix, coarse aggregate
seal coat (single and
multiple), crack
treatment road mix, tack
coat
1200
dense-graded cold
plant mix and
road mix
stockpile mix,
crack treatment,
patching mix
232
Table 7.2.6: Quality requirements of anionic slow setting (SS) emulsified asphalt
Test
Storage stability test, 24-h, % , max.
Cement mixing test, %, max.
Sieve test, %, max
Residue by distillation, %, min.
Tests on residue from distillation test
Penetration, 25 o C, 100 g, 5seconds.
Solubility in Trichloroethylene, % , min.
1.
2.
SS-1h (1)
SS1
AASHTO
Test
Min.
Max.
Min.
Max.
T-72
20
20
100
T-59
100
T-59
T-59
0.1
0.1
T-59
57
57
T-49
100
200
40
90
T-51
40
40
T-44
97.5
97.5
T-59
cold plant mix, road mix, slurry seal coat, tack

coat, fog seal, dust layer, mulch
Quick setting emulsified asphalt (CQS-1H) requirements are same as slow setting (SS-1h)
emulsified asphalt except for storage stability and cement mixing tests, which are not required.
These typical applications are for use only as a guide for selecting and using the emulsion for
233
T
able 7.2.7: Quality requirements of cationic emulsified asphalt
Rapid Setting
Test
Viscosity, Saybolt Furol, 25 o C,
seconds
Viscosity, Saybolt Furol, 50 o C, s
Storage stability test, 24-h, %, max.
Demulsibility (2), 35ml, 0.8%
sodium diocytl suffosucinate, %,
m in.
Classification test
CRS-1
Medium Setting
CRS-2
Min
Max
20
100
100
400
40
40
Passes
Min
Max
Passes
CMS-2
Min
Max
Slow Setting
CMS-2h
Min
CSS-1
CSS-1h (1)
Max
Min
Max
Min
Max
20
100
20
100
450
50
450
Good
50

Good
Fair
Fair
Fair
Fair
Fair
Fair
Particle charge test
Positive
Positive
Positive
Positive
Positive
Sieve test, % , max.
0.1
0.1
0.1
0.1
0.1
0.1
Cement mixing test, % Distillation:

Oil distillate, by volume of
emulsion, % , max.
Residue, % , min.
12
60
65
Penetration, 25 o C, 100 g, 5s
100
250
100
250

Solubility in Trichloroethylene, %,
m in.
40
40
97.5
97.5
Positive
12
65
65
57
57
250
40
90
100
250
40
90
40
40
40
40
97.5
97.5
97.5
97.5
surface
treatment,
penetration
macadam,
sand seal
coat, tack
mulch
surface
treatment,
penetration
macadam,
coarse
aggregate
seal coat
(single and
multiple)
100
cold plant
mix, coarse
aggregate
seal coat
(single and
multiple),
crack
treatment,
road mix,
track coat,
sand seal
coat
cold plant
mix, hot
plant mix,
coarse
aggregate
seal coat
(single and
multiple),
crack
treatment,
road mix,
tack coat
1. Quick setting emulsified asphalt (CQS-1H) requirements are same as

emulsified asphalt except for cement mixing test, which is not required.
2. The demulsibility test shall be made within 30 days from date of shipment.
3. These typical applications are for use only as a guide for selecting and
cold plant mix, road mix,

slurry seal coat, tack coat,
fog seal, dust layer, mulch
slow setting (CSS-1h)

using the emulsion for
234
1.
2.
3.
4.
5.
Easy to mix with the base asphalt materials.

Short mixing time.
Economically feasible.
Compatible with the asphalt materials.
Stable under the production and construction conditions.
Asphalt modifiers shall produce modified asphalt that conforms to the required
purpose for modification according to AASHTO guide for the laboratory evaluation of
modified asphalt (AASHTO PP-5) and the AASHTO guide for grading and verifying the
performance grade of an asphalt binder (AASHTO PP-6).
The manufactures instructions shall be followed when using the asphalt in terms
of mixing temperature, mixing time, suitable base asphalt type, suitable aggregate, etc.
In all cases, modified asphalt shall be checked that they dont negatively affect the
standard quality requirements of the asphalt binder by performing standard tests such as
aging, mass loss, flash point, spot test, ductility, and viscosity.
When using the liquid or solid anti-stripping agents, the final mix shall be checked
by coating and stripping test (AASHTO T- 182) for loose mix or Marshall Stability loss
for asphalt concrete compacted mix.
7.2.5 Asphalt Materials Production:
All asphaltic materials and modifiers shall be produced by locally approved
factories or by foreign manufactures. These factories shall have quality control programs
accredited by the foreign authorities at the place of origin. Technical properties, user
guide, and standard tests shall be accompanied with the product certificate of asphalt
materials.
Asphalt materials shall not be heated during the process of its manufacture or
during construction so as to cause damage to the materials as evidenced by the formation
of carbonized particles
7.2.6 Asphalt Materials Acceptance Procedures:
All asphalt materials shall be accepted according to Product Certificate and the
Engineer shall check the product by proper tests in these General Specifications subject to
the following:
7.2.6.1 Supplied Container:
Before loading, the manufacturer shall examine the supplied container and remove
all leftover materials of previous supplies that may contaminate the material to be loaded
or change its properties.
7.2.6.2 Delivery Ticket:

The manufacturer shall furnish with each shipment two (2) copies delivery ticket
containing the following:
Consignees
Project number
Grade
235
Net liters
Net weight
Type and amount of anti-stripping agent or other modifiers (if any)
Identification number (truck, tank, etc.)
Destination
Date
Loading temperature
Specific gravity at 15.6 degrees centigrade.
7.2.6.3 C ertificate of Compliance:

The manufacturer shall deliver a signed Certificate of Compliance to cover the
quality and quantity of material and the condition of container for each supply. Test
results shall be provided either with the supply or within one week after supply.
Asphalt materials may be used, with Engineers approval, prior to sampling and
testing when a Certificate of Compliance is furnished by the manufacturer stating that the
asphalt material, at the time of loading, conformed to all specified requirements and that
the supplied container was clean and contained no contaminating residue.
This Certificate of Compliance shall reference the lot and identify the test
numbers representing the lot. If the test results showed non-compliance, the work shall be
rejected or accepted at reduced payment, if the results are technically accepted, according
to Division 17 of this General Specification.
Asphalt materials furnished without a Certificate of Compliance should not used.
7.2.6.4 Acceptance Sampling Procedures:
The Contractor shall obtain acceptance samples of asphalt materials according to
AASHTO T-40 at the applicable point of acceptance as follows:
1. Asphalt material used in direct application on the road: Samples shall be taken
from each shipping container at the time of discharge into distributors or other
conveyances on the project.
2. Asphalt material initially discharged into storage tanks on the project: Samples
shall be taken from the line between the storage tank and the distributor or the
mixing plant after each delivery. Samples shall be taken after a sufficient period
of circulation has taken place to ensure samples are representative of the material
in the storage tank.
3. The manufacturer of asphalt materials shall test all materials produced and the test
results retained for reference. The Contractor, under the supervision of the
Engineer, shall sample each shipment of asphalt material delivered to an asphalt
concrete mixing plant, asphalt treatment production project, or other project
requiring the incorporation of asphalt materials. The samples shall be numbered
consecutively and identified by project, type and grade of asphalt material, date of
delivery, and use. All samples shall be tested for conformance with the General
and Special Specifications.
4. Work in which asphalt materials failed to conform to the specifications shall be
rejected. Rejected asphalt materials shall be immediately removed from the work,
including all portions of the work in which said rejected asphalt materials were
placed, and the Contractor shall replace rejected materials with specification
materials at his own expense. The Ministry has the right to accept
236
the executed works at a reduced payment according to Division 17 of this General

Specification, if those works are acceptable.
7.2.7 Measurement:
Unless specified in the Special Specifications and listed in the Bill of Quantities
asphalt materials shall be considered subsidiary and no measurements shall be made.
Otherwise, asphalt materials should be measured by liters, kilograms.
7.2.8 Payment:
When specified in the Special Specifications and listed in the Bill of Quantities,
payment will be made at the contract unit price per each item listed in the Bill of
Quantities.
Such prices and payments shall cover and be full compensation for equipment,
labor, tools and incidentals necessary for furnishing asphalt materials.
7.3
Aggregates:
Aggregate is a mix of granular particles with different sizes and shapes produced
by mechanical crushing of natural or industrial stones.
The aggregates are the main component of composes the skeleton of the asphalt
mixes with about ninety-five (95) percent by weight or eighty-five (85) percent by
volumes of the total mix. The type, shape, microtexture, and chemical properties of
aggregate particles determine the durability and the adhesion level of asphalt binder, and
thus the strength of asphaltic concrete mixes. Aggregate is divided into three types:
coarse, fine, and mineral filler.
7.3.1 General Requirements:
Aggregate shall conform to the following general requirements:
1. All aggregate shall be hard durable particles and free from decomposed materials,
organic materials, and other deleterious substances. The aggregate shall not
contain more than one (1.0) percent by weight of particles having a specific
gravity below 1.95 (in natural aggregate).
2. When the Special Specifications indicate using crushed aggregate, the soil and
gravel particles with size less than the maximum size shall be separated and stored
away from the crushed aggregates with proper marking. The crushed and
uncrushed aggregate shall not be mixed together.
3. Crushing plant shall conform to the environmental requirements stated in Section
4.5 in these General Specifications and other requirements of local environmental
authorities.
4. Crushing plants shall be capable to produce cubical or semi-cubical aggregate
particles with adequate quantities of crushed sand and mineral. The crushed
aggregate produced shall be free from flat and elongated particles.
5. The aggregate shall be stockpiled and stored in separate sizes. It is desired to have
the maximum size in each layer of the stockpile twice the second layer in that
stockpile, with the maximum size not less than fine (5) millimeters.
6. The aggregate shall be washed to remove any deleterious substances or dust that
may reduce the adhesion of asphalt binder to aggregates particles or may spoil the
asphalt mix.
237
7. Whenever possible, aggregate susceptible to polishing shall not be used in asphalt

surface course to provide adequate skid resistance according to ASTM D-3319.
8. Carbonate aggregate with percentage of insoluble residue of less that twenty five
(25) percent should not be used in asphaltic concrete mixes when tested according
to ASTM D-3042.
9. Aggregate shall be dry when used in road-mixing method with cutback asphalt,
while the aggregate shall be wetted when mixing with emulsified asphalt.
7.3.2 Coarse Aggregate:
Coarse aggregate is the solid stones that have size greater than 4.75 millimeter
(retained on sieve No. 4). It shall be, unless Special Specifications indicate, crushed stone,
crushed slag, crushed gravel, or natural aggregate and shall conform to the general
requirements stated previous Item 7.3.1.
7.3.2.2 Quality Requirements:
Coarse aggregate shall conform to AASHTO M-283 unless contradict with the
limit shown in Table (7.3.1) or the Contract Documents.
7.3.2.3 Gradation Requirements:
Unless contradicting with the total gradation of the asphaltic mix, coarse aggregate
shall conform to one of the gradations specified in AASHTO M-43, which match with the
maximum nominal aggregate size of asphalt mixes.
7.3.3 Fine Aggregate:
Fine aggregate is material passing the 4.75-millimeter (No. 4) sieve and shall be
produced from crushed stone, crushed slag, crushed gravel, or manufactured sand. When
the Special Specifications allow, the crushed aggregate shall not be less than seventy-five
(75) percent. Natural sand may not be used without the prior written approval of the
Engineer. Crushing shall be in accordance with the general requirements stated previous
Item 7.3.1.
Fine aggregate shall conform to AASHTO M-29 unless contradicts with the limit
shown in Table (7.3.1) or the Contract Documents.
7.3.3.3 Gradation Requirements
Unless contradicts with the combined gradation of the asphaltic mix, fine
aggregate shall conform to one of the gradations specified in AASHTO M-29.
7.3.4 Mineral Filler:
Mineral filler is that portion of the fine aggregate that has size less than 600
micrometer (passing sieve No. 30). When the Special Specification state, the work
conditions require, or the mineral filler used is not suitable, crushed stone powder or
238
Table 7.3.1: Aggregate quality requirements for asphaltic mixes
Test
Test used
Loss Angeles abrasion,

percent, max.
Sand equivalent,
particles passing sieve
No. 4, %, min.
Density (for coarse
steel slag aggregate),
m in.
Flat and elongated
particles, Ration of
max. dimension to the
min. is 5: 1, %, max.
Plasticity index for
aggregate passing sieve
No. 40, min.
Soundness %, max.,
-- Sodium Sulfate:
-- Magnesium Sulfate:
Percent fracture (two
faces), for aggregate
passing sieve No. 8,
m in.
Limits
Type Type
(5)
(6)
Type
(1)
Type
(2)
Type
(3)
Type
(4)
Type
(7)
Type
(8)
Type
(9)
Type
(10)
AASHTO
T-96
40
40
40
40
40
35
30
30
30
AASHTO
T-176
45
45
45
40
45
45
60
AASHTO
T-1 9
1120
1040
960
ASTM
D-4791
10
10
10
AASHTO
T-90
NP
10
10
10
10
10
15
10
10
15
12
12
12
20
ASTM
D-5821
90
65
25
75
75
90
75
90
Clay content, %, max.
AASHTO
T-112
0.25
0.25
0.25
Coating and stripping,

%, min.
AASHTO
T-182
95
95
95
95
Polishing resistance,
%, min.
ASTM
D-3319
35
40
Absorption, % , max.
AASHTO
T-85
Angularity, %, min.
AASHTO
T-33
45
Durability, %, min.
AASHTO
T-210
35
40
AASHTO
T-104
Aggregate uses index

Type.
Use
Type.
Use
Asphaltic concrete base/wearing
Emulsified asphalt treated base
1
6
courses (Type A)
(Sand-Graded)
2
7
Slurry seal
courses (Type B)
3
8
Surface treatments
courses (Type C)
4
9
course
Asphaltic friction
(Open-Graded)
5
10
Stone mastic asphalt (SMA)
(Dense-Graded)
239
dust, steel slag powder or dust, Portland cement, lime, or any mineral powder shall be
used as mineral filler provided it conform to the quality requirements.
Mineral filler shall conform to AASHTO M-17. The plastic limit, except for lime
and cement, shall not be more than 4%.
The mineral filler shall be stored in a special tank linked to the mixing plant.
When furnished as supplemental fine aggregate, mineral filler, at the time of use, shall be
dry, free flowing, and without lumps or agglomerations.
Mineral fillers either Portland cement, blended hydraulic cement, or lime, shall conform
to the requirements shown in Table (7.3.2).
Table 7.3.2: Mineral filler requirements
Material
Requirement
AASHTO M-85
Portland Cement, Type I or II
AASHTO M-240
Blended Hydraulic Cement, Type IP
ASTM C-207
Lime, Type N or S
7.3.4.3 Gradation Requirements:
Mineral filler, when tested separately, shall provide uniform gradation conforms to
AASHTO M-17 shown in Table (7.3.3).
Table 7.3.3: Mineral filler gradation requirements
Sieve Size
Percent passing
100
0.600 mm (No. 30)
95 - 100
0.300 mm (No. 50)
70 - 100
0.075 mm (No. 200)
7.3.5 Combined Aggregate in Asphalt Mixes:
Combined aggregate shall conform to the quality requirements of each separate
type of aggregate. These requirements include percent fracture, abrasion resistance,
soundness, plasticity index, flat and elongated particles, coating and stripping, adherent
materials, and others as shown in Table (7.3.1).
7.3.5.2 Gradation Requirements for Asphalt Mixes:
Asphalt mix proportioning shall be made based on the average test results of
adequate number of representative samples taken from cold bins of coarse and fine
aggregate as well as mineral filler. When using mixing plants with hot bins, adequate
number of samples shall also be taken from each bin for proportioning.
).
Tables (7.3.4) to (7.3.9) show the aggregate gradations used in different types of
asphalt mixes. The maximum aggregate size is preferred provided it is not exceeding one-half
(1/2) the pavement thickness, except for surface treatments.
240
7.3.6 Aggregate Stockpiling:

The site for constructing stockpiles shall be approved by the Ministry and
located in a manner that the stockpiled materials will not be contaminated with other
aggregates or altered by dust, dune sand, or other natural or processed material.
Following requirement shall be observed when stockpiling aggregates:
1.
2.
3.
Before placing aggregates on the stockpile site, the site shall be cleared from
vegetation, rocks, and debris; the ground leveled to a smooth, firm, and uniform
surface, and allows adequate drainage.
The stockpiles shall be not more than eight (8) meters in height
Stockpiles in excess of two hundred (200) cubic meters shall be built up in layers
not more than one and one-half (1.5) meters in depth using approved methods and
equipment. Pushing aggregate into a stockpile using dozers shall not be permitted.
Each layer shall be completed over the entire area of the pile before depositing
aggregate in the succeeding layer. Any method of placing aggregate in a
stockpile, which results in segregation, breaks, degrades, or otherwise damages
the aggregate will not be permitted.
4.
Stockpiles of different kinds or sizes of aggregate shall be separated by space or

suitable walls or partitions to prevent mixing. Aggregate shall not be stockpiled
where vehicles will run over or through the piles and cause foreign material to
become mixed with the stockpiled aggregate. Each aggregate type and size shall be
marked by unique number.
5.
Aggregate shall be removed from the stockpiles using equipment and methods
approved by the Engineer and in a manner that prevents segregation of particle
sizes or adulteration with underlying or adjacent soil or foreign material.
The environmental requirements, stated in Division 4 in these General
Specifications, shall be observed while stockpiling aggregates.
6.
7.3.7 Aggregate Acceptance:

Aggregate in different asphalt mixes are accepted using the procedures outlined
in the respective sections in these General Specifications.
7.3.8 Measurements:
Unless specified in the Special Specifications and listed in the Bill of Quantities
aggregate shall be considered subsidiary and no measurements shall be made.
Otherwise, aggregate shall be measured by cubic meter.
Table 7.3.4: Aggregate gradation requirements for asphaltic concrete mixes
Sieve size
Sieve size
37.5 mm (1.5 in)
25 mm (1 in)
19 mm (4/3 in)
12.5 mm (2/1 in)
9.5 mm (8/3 in)
4.75 mm (No 4)
2 mm (No 10)
0.425 mm (No 40)
0.180 mm (No 80)
0.075 mm (No 200)
Percent passing
Asphaltic concrete base course
Gradation
(A)
100
75-90
65-80
55-70
45-60
31-46
18-33
5-18
3-13
2-9
Gradation
(B)
100
75-90
65-80
55-65
35-60
20-35
7-20
5-25
3-7
Gradation
(C)
100
90-100
78-93
57-72
43-58
28-43
13-28
3-7
Asphaltic concrete wearing course

Gradation
(A)
100
75-90
64-79
41-56
23-37
7-20
5-13
3-8
Gradation
(B)
100
90-100
78-83
46-60
30-42
14-25
8-16
3-7
Gradation
(C)
100
90-100
54-68
32-46
14-25
8-16
3-7
241
Tabl
e 7.3.5: Aggregate gradation requirements for emulsified asphalt treated base
Percent passing
Sieve size
Open-Graded
Dense-Graded
Sand-Graded
100
95-100
25-60
0-10
0-5
100
90-100
60-80
25-60
15-45
5-18
1-7
100
75-100
5-30
5-12
37.5 mm (1.5 in)

25 mm (1 in)
12.5 mm (2/1 in)
4.75 mm (No 4)
2.36 mm (No 8)
0.300 mm (No 50)
0.075 mm (No 200)
0-2
Table 7.3.6: Aggregate gradation requirements for slurry seal mixes

Percent passing
Sieve size
Gradation (1)
-
9.5 mm (8/3 in)

4.75 mm (No 4)
2.36 mm (No 8)
1.18 mm (No 16)
0.600 mm (No 30)
0.300 mm (No 50)
0.150 mm (No 100)
0.075 mm (No 200)
Gradation (2)
Gradation (3)
100
90-100
65-90
45-70
30-50
18-30
10-30
5-15
100
70-90
45-70
28-50
19-34
12-25
7-18
5-15
100
90-100
65-90
40-65
25-42
15-30
10-20
Table 7.3.7: Aggregate gradation requirements for surface treatment mixes

Sieve size
25 mm (1 in)
19 mm (4/3 in)
12.5 mm (2/1 in)
9.5 mm (8/3 in)
4.75 mm (No 4)
2.36 mm (No 8)
2 mm (No 10)
Percent passing
Gradation Gradation
(3)
(4)
-
Gradation
(1)
100
Gradation
(2)
100
55-85
0-15
0-2
0-3
0-3
90-100
20-55
0-10
0-3
0-5
100
90-100
30-60
0-10
0-10
0.300 mm (No 50)
Gradation
(5)
-
Gradation
(6)
-
100
90-100
10-30
0-10
-
100
85-100
10-30
0-40
-
100
85-100
-
0-5
Table 7.3.8: Aggregate gradation requirements for friction course mix

Sieve size
12.5 mm (2/1 in)
9.5 mm (3/8 in)
4.75 mm (No 4)
2.36 mm (No 8)
0.075 mm (No 200)
Percent passing
100
95-100
30-50
5-15
0-5
242
Table 7.3.9: Aggregate gradation requirements for stone mastic asphalt (SMA) mixes
Percent passing
Sieve size
Gradation (2)
19 mm (4/3 in)
Gradation (1)
-
16 mm (5/8 in)
100
12.5 mm (2/1 in)

9.5 mm (3/8 in)
90-99
82-88
70-85
75 max
4.75 mm (No 4)
30-50
20-30
22-30
14-20
8-11
9-11
2.36 mm (No 8)
0.075 mm (No 200)
100
7.3.9 Payment:
When specified in the Special Specifications and listed in the Bill of Quantities,
payment will be made at the contract unit price per each item listed in the Bill of
Quantities.
Such prices and payments shall cover and be full compensation for equipment,
labor, tools and incidentals necessary for furnishing aggregate. Payment will be made
according to Table (7.3.10).
Table 7.3.10: Materials of asphaltic mixes pay items
No.
7.2.1
7.2.2
7.2.3
7.2.4
7.3.1
7.3.2
Pay Item
Asphalt cement grade
(if measured separately)
Liquid asphalt grade
Emulsified asphalt grade
Chemical admixtures and asphalt modifiers (if measured
separately)
Aggregate gradation
Mineral fillers (if measured separately)
Pay units
Kilogram
Kilogram
Kilogram
Kilogram
Cubic meter
Kilogram
243
DIVISION 8
ASHPH ALTIC CONCRETE W ORK S
8.1 Scope
8.2 Asphalt Mixes In Urban Areas
8.2.1 Characteristics Of Urban Roads And Streets
8.2.2 Urban Areas Asphalt Work Requirements
8.3 Prime Coat

8.3.1 Description
8.3.2 Materials
8.3.3 Application Rates
8.3.4 Equipment
8.3.5 Construction
8.3.5.2 Preparation Of Asphalt Material
8.3.5.3 Test Sections And Selection Of Application Rates
8.3.5.4 Application Of Asphalt Material
8.3.5.5 Maintenance Of Prime Coat
8.3.8 Measurement
8.3.9 Payment
8.4 Tack Coat
8.5
247
247
247
247
247
248
248
249
249
249
249
249
250
250
250
251
251
251
251
252
252
8.4.1 Description
8.4.2 Materials
8.4.4 Equipment
8.4.5 Construction
8.4.5.3 Test Sections And Selection Of Application Rates
8.4.5.4 Application Of Asphalt Material
8.4.8 Measurement
8.4.9 Payment
252
252
252
252
252
252
253
253
253
253
253
253
253
Asphltic Concrete
253
253
254
254
254
255
255
255
255
257
257
258
258
259
8.5.1 Description
8.5.2 Materials
8.5.3 Asphaltic Concrete Mixes
8.5.3.2 Acceptance Of Job Mix Formula
8.5.3.3 Job Mix Formula Requirements
8.5.4 Equipment
8.5.4.1 Mixing Plants
8.5.4.2 Asphalt Paving Machine
8.5.4.3 Rollers
8.5.4.4 Power Broom
8.5.4.5 Hand Tools
8.5.6 Construction
8.5.6.1 Preparation Of Asphaltic Materials
8.5.6.2 Preparation Aggregates
8.5.6.3 Preparation Of Asphaltic Concrete Mixture
8.5.6.5 Hauling Asphaltic Concrete Mixtures
8.5.6.6 Placement Of Asphaltic Concrete Pavement
8.5.6.7 Joints
8.5.6.8 Compaction Of Asphaltic Concrete Pavement
8.5.6.9 Pavement Thickness Measurement
8.5.6.10 Wearing Course Smoothness
8.5.6.11 Wearing Course Skid Resistance
8.5.9 Measurements
8.5.10 Payment
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259
259
260
262
262
262
264
264
265
265
266
266
267
267
267
267
269
Division 8- Asphaltic Concrete Works
DIVISION 8
ASHPHALTIC CONCRETE WORKS
8.1
Scope:
This Division comprises of the requirements for asphalt work in urban area using hot
asphaltic concrete mixes. It details the specifications related to these mix designs and construction
of including surface preparation, prime and tack coating, spreading and compacting the mixture on
a prepared surface, specifying the proper equipment for construction, controlling the traffic, and
quality control, quality assurance, acceptance, measurement, and payment requirements.
8.2
Asphalt Mixes in Urban Areas:
8.2.1 Characteristics of Urban Roads and Streets :

Roads in urban areas differ from rural areas roads in several aspects, which in turn affect
performance, design, and construction of these roads. Following are the major differences:
1. Road network is operationally divided into freeways, arterials, collectors, local streets,
and industrial roads.
2. Existence of parking for small vehicles and trucks.
3. Existence of areas of intersections, acceleration, deceleration, stopping, and u - turns.
4. Affected by surface and sub-surface water.
5. Existence of buried utility lines.
6. Houses and other structures are on roads and streets shoulders.
8.2.2 Urban Areas Asphalt Work Requirements:

The relationship between road class and asphalt work requirements is shown in Tables
(8.2.1) and (8.2.2), with the following considerations:
1. Asphaltic concrete of type (A) shall be used in following roads, which require asphalt
concrete with high rutting resistance and with maximum possible nominal size aggregates
for this type:
Freeways that are passing cities or in their peripheral with high speeds and high traffic
loads.
Arterial roads with high traffic volumes, which are characterized by frequent
signalized and un-signalized intersections, frequent acceleration, deceleration,
stopping, and turning areas.
Roads in industrial areas and truck traffic parking areas, which are
characterized by high axle loads, low speeds, and frequent turnings.
Collector roads, which are characterized by frequent acceleration
deceleration, and turning areas, with high traffic loads.
247
Table 8.2.1: Selection of asphalt works according to areas and road class
Road class
Urban roads and Parking
areas
Low volume roads (less than
100 vehicles per day) at
remote areas and rural
com plexes
Base course
Wearing course
Asphaltic Concrete
(Table 8.2.2)
Asphaltic Concrete
(Table 8.2.2)
Cold-mix asphalt
(Division 13)
Slurry seal or surface

treatments (Division 10)
Table 8.2.2: Selection of asphalt concrete mixes according to road class

Road Class
Type of mix (Table 8.5.2)

Base course
Wearing Course
Freeway
Arterial road
Collector road (*)
A/B
A/B
A/B
A
A
A/B
Local road (Residential)
Industrial area road

Truck parking area
Small vehicle parking area
A
A
C
A
A
C
(*) Type (B) is used if the traffic volume is less than fifteen hundreds (1,500) vehicles per day, and truck traffic is
less than five (5) percent.
2.
Asphaltic concrete of type (B) shall be used in collector roads with low traffic loads.
3.
Asphaltic concrete of type (C) that has relatively fine gradation, shall be used in local roads and
parking areas with high traffic volume and low traffic loads.
Quality requirement for parking areas for cars and trucks presented in Division 4 shall be
implemented to provide pavement resistance to oil and fuel spillage. All other quality requirements,
presented in Division 4, shall be implemented.
When the asphaltic concrete of type (A) is used in acceleration, deceleration, and turning areas, the
following additional requirements shall be implemented:
8.3
Site specific conditions such, as temperature, traffic volumes, and aggregate

and asphalt types, shall be considered in preparing special mix design.
Use of coarse open-graded aggregate gradation.
Use of asphalt modifiers to provide high durable wearing and base course layers.
Prime Coat:
This Section comprises of the execution of prime coat with the used materials, spraying rates, and
maintenance.
8.3.1 Description:
A prime coat consists of applying a coat of cutback or emulsified asphalt material to the surface of an
untreated soil or aggregate or other surfaces as shown on
248
the plans and specified in the Special Specifications. Blotter sand is used to correct areas with excess
prime coat materials.
8.3.2 Materials :
A sphalt Materials: Unless a different grade is specified in Special Specifications,
asphalt materials shall be MC-1/MC-70 or MC-2/MC-250 conforming to the requirements in Table
(7.2.2.A,B) for cutback asphalts or SS-1h or CSS-1h and shall conform to Tables (7.2.6) or (7.2.7) for
emulsified asphalt, in these General Specifications. Emulsified asphalt may be diluted by similar
amount of water to increase the spaying rate and keeping a constant asphalt residue on the surface.
Blotter Sand: It shall be natural sand, manufactured sand, or combinations of both that
are free from organic matter or clay, having a grading consisting of one hundred (100) percent passing
the 4.75 millimeter (No. 4) sieve and not more than five (5) percent passing the 0.150 millimeter (No.
100) sieve.
8.3.3 Application Rates:
Application rates for prime coat shall be within limits shown in Table (8.3.1). Blotter sand shall
be used, as needed, to correct the excess prime coat materials that are more than the specified amount in
the test sections.
Table 8.3.1: Application rates for prime coat materials

Material
MC1/MC-70- MC-2/MC-250
SS-1h/CSS-1h
Application rate (liters per square meter)

0.50 - 1.75
0.20 - 0.50
8.3.4 Equipment:
The Contractor shall furnish and operate sufficient equipment to complete the work within the
Contract time in accordance with his program of work as approved by the Engineer. These equipments
shall include rotary type power brooms, aggregate spreaders, rollers, asphalt material distributors, and
equipment for heating asphalt material.
ng a truck-mounted distributor capable of uniformly spraying asphalt material full lane widths.
Distributor shall be equipped with controls for application rates and asphalt temperature.
8.3.5 Construction:
8.3.5.1 Surface Preparation:
Immediately prior to application of the prime coat, the surface to receive a prime coat, shall
conform to the specified compaction and elevation tolerance and be free of organic and other deleterious
material and accepted by the Engineer. When deemed necessary by the Engineer, the soil and aggregate
surface shall receive a light application of water to reduce the surface tension and improve penetration of
the prime into the surface.
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8.3.5.2 Preparation of Asphalt Material:

The asphalt material shall be uniform throughout the distributor tank and be heated to the
application temperatures required. Recommended heating temperatures are shown in Table (8.3.2).
Table 8.3.2: Recommended heating temperature for prime coat materials

Material type
Temperature (Degrees Celsius)
MC-70/MC-1
MC-250/MC-2
SS-1h/ CSS-1h
50 - 80
75 - 100
20 - 70
8.3.5.3 Test Sections and Selection of Application Rates:

The Contractor shall construct two (2) or more test sections for each grade of asphalt material
specified for use or used and for every type of material. A test section shall be at least three (3) meters wide
by one hundred (100) meters long. Contactor shall establish application rates for prime coat material based
on the results from test sections.
On the date scheduled or any day prior to beginning prime coating, the Contractor shall apply two
(2) or more rates of asphalt material to consecutive test sections. When the test sections are completed, the
prime coat operation shall be stopped for a minimum of four (4) hours to allow the Engineer to assess the
suitability of the rates applied. Test sections receiving insufficient prime coat shall receive an additional
application of prime coat; test sections receiving excess prime coat shall be blotted with sand, as required by
the Engineer.
8.3.5.4 Application of Asphalt Material:

The following requirements shall be considered at application of asphalt materials and blotter sand:
1.
The asphalt material coverage shall be uniform without streaking or uncoated spots. When
streaking occurs, as determined by the Engineer, the application of asphalt material shall cease
until adjustments are made to the distributor and application procedures, which will result in
elimination of streaking. Uncoated spots shall be coated with asphalt using the hand held nozzle.
2.
Asphaltic materials shall be reheated, i f necessary, to temperatures within those stated in

paragraph 8.3.5.2. During all reheating operations the asphalt shall be agitated to prevent localized
overheating.
3.
The sprayed area shall more than thirty (30) centimeters wider than the layer to be prime-coated or
within the curbstone of sidewalks or shoulders.
4.
Blotter sand, when required, shall be spread from a truck-mounted hopper equipped with controls
to deliver the sand in a uniform application at specified rates to the surface treated with a prime
coat. Sand may be spread manually on isolated bleeding spots.
5.
Traffic should not be permitted on surfaces, which have been primed until approved by the
Engineer. Remaining spots of excess asphalt shall be lightly covered with blotter sand before
constructing asphalt layers.
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8.3.5.5 Maintenance of Prime Coat :

The Contractor shall maintain the prime coat and coated surface until covered with a subsequent
course of material. Additional prime coat material and blotting sand shall be applied as required by the
Engineer. Except for small areas, the blotter sand shall be sprayed from a truck-mounted hopper equipped
with controls to deliver the sand in a uniform application at specified rates. The prime coat shall be
allowed to cure for twenty-four (24) hours to penetrate the primed layer.

All traffic control work shall be done in accordance with the Manual of Traffic Control through
Work Zones issued by the Ministry of Municipality and Rural Affairs in 1421H (2001). Additionally,
the Contractor shall implement the following:
1.
2.
Assure the safety and convenience of public traffic and protect the residents and
property owners adjacent to the project during prime coat operations.
Erect and maintain signs, barricades and other traffic control devices and shall
take effective action to exclude all traffic from the roadway surface for as long
as may be required in the judgment of the Engineer.
3.
When traffic is restricted to a one-way basis, provide such flagmen and pilot cars as
deemed necessary for the protection of traffic and the treated surface.
4.
While the construction of an asphaltic prime coat is in progress, the treated surface of the
roadway shall not be used by the Contractor or others until the Engineer approves that the treated
surface is in a good condition and will not be damaged by traffic.
5.
Detoured traffic around the construction in conformance with detailed detour plans including
layout, signing, and marking and other traffic control devices shall be approved by the Engineer.
Detours shall be properly constructed and maintained throughout the period traffic uses the
detour.
6.
When it is necessary to provide for traffic crossing the prime coat before the asphaltic material
has been applied for forty-eighty (48) hours, the crossing shall be blotted with sand to the extent
approved by the Engineer before the crossing is opened to traffic.
7.
When traffic is permitted on a blotted prime coated surface, the Contractor shall effectively
limit vehicle speeds to thirty (30) kilometers per hour for the first two (2) hours of use.
8.
Necessary crossings of a prime coated surface before the asphaltic material has been applied for
forty-eighty (48) hours, shall be re-primed just prior to the construction of the subsequent layer
to the satisfaction and approval of the Engineer.
9.
The excess blotter sand shall be removed from the prime coated surface, and any damage
shall be repaired before constructing asphalt layers.

Asphaltic material for prime coat shall not be applied to any surface when the air and surface
temperature is less than fifteen (15) degrees Celsius or during rain, dust or sand storms.
8.3.8 Measurement:
Asphaltic material for prime coat shall be measured in square meters for the areas sprayed within
the limits shown on the plans, specified in the Special Specifications or ordered by the Engineer. Prime
coat material placed outside
251
authorized limits shall not be measured. The blotter sand shall be considered subsidiary and no
measurements shall be made for payment purposes.
8.3.9 Payment:
Payment will be made for the executed and accepted work according to the measured made. Payment
will be made at the contract unit price per each item listed in the Bill of Quantities.
Such prices and payments shall cover and be full compensation for furnishing all materials,
equipment, labor, tools, human resources and incidentals necessary for completing prime coat.
8.4
Tack Coat:
This Section comprises of the execution of tack coat with the used materials and equipment,
spraying rates, and maintenance.
8.4.1 Description:
A tack coat consists of applying a coat of cutback or emulsified asphalt material to a prepared
surface, to an existing asphaltic or Portland cement concrete pavement to be overlaid, to the surface
between layers of asphaltic pavement, to bridge decks, and to vertical edges of pavement, curbs and gutters,
support side walls, bridge abutments and other surfaces in contact with asphaltic pavement.
8.4.2 Materials :
Asphalt Materials: asphalt materials shall be RC-1/RC-70 conform to the
requirements in Table (7.2.2) for cutback asphalts or SS-1h or CSS-1h conform to Tables (7.2.6)
or (7.2.7) for emulsified asphalt types, in these General Specifications. Emulsified asphalt may be
diluted by similar amount of water to increase the spaying rate and keeping a constant asphalt
residue on the surface.

Application rates for tack coat shall be within the limits shown in Table (8.4.1).
Table 8.4.1: Application rates for tack coat materials

Material
Application rate (liter per square meter)
0.10 - 0.30
RC1/RC-70
0.20 - 0.50
SS-1h/CSS-1h
8.4.4 Equipment:
The Contractor shall furnish and operate sufficient equipment to complete the work within the
Contract time in accordance with his Program of Work as approved by the Engineer. This equipment shall
include those stated in Item 8.3.4 in the previous Section.
8.4.5 Construction:
Immediately prior to application of the tack coat, the surface to receive a tack coat, shall conform to specified
requirements and be free of organic and other
252
deleterious material and accepted by the Engineer. Where tack coat is applied to bridge decks, joints shall be
cleaned and filled as specified in the Special Specifications.

The asphalt material shall be uniform throughout the distributor tank and be heated to the
application temperatures required. Recommended heating temperatures are shown in Table (8.4.2).
Table 8.4.2: Recommended heating temperatures for tack coat materials

Material type
RC1/RC-70
SS-1h/ CSS-1h
Temperature (degrees Celsius)

50 - 80
20 - 70
8.4.5.3 Test Sections and Selection of Application Rates:

The Contractor shall implement the requirements stated in paragraph 8.3.5.3 in the previous
Section for tack coat.
8.4.5.4 Application of Asphalt Material:

The Contractor shall implement the requirements stated in paragraph 8.3.5.4 in the previous
Section for tack coat.

All traffic control works shall be done in accordance with the Manual of Traffic Control through
Work Zones issued by the Ministry of Municipalities and Rural Affairs in 1421H (2001). Additionally, the
Contractor shall not allow any traffic operation over the tack coat.

Asphaltic material for tack coat shall not be applied to any surface when the air and surface
temperature is less than fifteen (15) degrees Celsius or during rain, dust or sand storms.
8.4.8 Measurement:
Asphaltic material for tack coat shall be measured in square meters for the areas sprayed within the
limits shown on the plans, specified in the Special Specifications or ordered by the Engineer for
documentation purposes not for payment purposes.
Tack coat material placed outside authorized limits shall not be measured. The blotter sand shall be
considered subsidiary and no measurements shall be made for payment purposes.
8.4.9 Payment:
Unless otherwise stated in the Special Specifications and listed in the Bill of Quantities, payment
will not be made for the tack coat work since it is considered subsidiary to the surface preparation work.
8.5
Asphltic Concrete: 8.5.1 Description:

This Section consists of furnishing and mixing aggregate and asphalt materials in a central mixing plant,
hauling, spreading, and compacting the mixture on a prepared
253
surface, in one or more bases, leveling or wearing courses, all as shown on the plans, specified in these
General Specifications, the Special Specifications, and other Contract Documents.
8.5.2 Materials :
Asphalt Materials: unless stated in the Special Specifications or Contact Documents,
asphalt materials shall be 40/50 or 60/70 penetration grade conforming to Tables (7.2.1), in these General
Specifications.
Aggregates: unless stated in the Special Specifications or Contact Documents, the

aggregate gradation shall be determined as shown in Table (7.3.4) and shall conform to the quality
requirement stated in Table (7.3.1) (types 1, 2 and 3) in these General Specifications.
M in era l Filler: mineral filler shall conform to the requirement stated in Table (7.3.4) in these General
Specifications.
C hem ica l Ad mixtures and Asphalt M o d ifie rs: The types and amounts of chemical
admixtures/asphalt modifiers used shall be limited to those listed in the Special Specifications or proposed
by the Contractor and approved by the Ministry. They shall conform to the requirements contained in Item
(7.2.4) in these General Specifications.
8.5.3 Asphaltic Concrete Mixes:
Unless stated in the Special Specifications or Contract Documents, the asphaltic concrete type shall
be as outlined in Table (8.2.2). The Contractor shall submit, in writing, a technical report including the Job
Mix Formula (JMF) at least thirty (30) days before the expected date of producing asphaltic concrete
mixtures. The report shall include the following:
1.
The source or sources, gradations, and properties of the aggregate for each mix to be furnished.
2.
The source or sources and properties of the asphalt materials to be used for each mix to be furnished.
3.
The source or sources and properties of the asphalt modifiers for each mix to be furnished.
4.
Original test data and a written certification signed and stamped by the Contractor, that the aggregates
to be furnished conforms to all of the quality requirements.
5.
Original test data of the type and properties of the asphalt cement (virgin and modified asphalt), with a
written certification signed and stamped by the Contractor and the authorized laboratory.
6.
7.
Proportions of all components in the asphalt mix.

Original test data and a written certification signed and stamped by the Contractor
that asphaltic concrete mix conforms to the specified requirements.
8.
9.
The type and location of plant to be used for mixing each mix t
The proposed beginning date for producing asphaltic mixtures.
The Contractor shall do the following:
254
1.
Supply the adequate amounts of aggregates, asphalt materials, and modifies to prepare and the mix
design checks.
2.
Provide full access to the Ministry's Representatives to the materials stockpiling, sampling, testing,
production, and construction operations, at all times.
8.5.3.2 Acceptance of Job Mix Formula:

The Ministry or its Representative shall review the JMF and all related matters submitted by the
Contractor according to the following steps:
1.
Assure that the report contains all requirements. I f it does not contain all required information, it shall
be returned within seven (7) days to the Contractor for further action and resubmission by the
Contractor.
2.
I f the proposed JMF contains all required information but fails to meet all of the requirements
specified, it shall not be accepted by the Engineer and will be returned to the Contractor within
fourteen (14) days. The Contractor shall prepare and submit to the Engineer a revised JMF conforming
to the requirements specified
3.
When the revised JMF is accepted, the Engineer shall inform the Contractor about preliminary
acceptance of JMF.
4.
The first-day work shall be considered as a field test control strip. It shall be assured that mix is
constructable in terms of spreading, compaction, and smoothness level.
5.
The Contractor shall not alter the methods of manufacturing, screening, mixing, stockpiling of
aggregate, or production of asphalt mixtures since this alteration will mandate evaluation of JMF.
6.
Changing JMF shall not be permitted without retesting and resubmission of a revised JMF in
accordance with all the steps in paragraph 8.5.3.1 and this paragraph.
8.5.3.3 Job Mix Formula Requirements:

Unless the Special Specifications or Contract Documents state otherwise, Table (8.2.2) shall be
used as a guide to select the suitable asphaltic concrete mixes according to the road class and parking area
type. The combined aggregate gradation shall conform to the gradation and quality requirements in JMF
within the tolerances shown in Table (8.5.1) as well as to conform to the quality requirements shown in
Table (8.5.2).
8.5.4 Equipment:
The Contractor shall furnish and operate sufficient equipment to execute the asphaltic concrete
work within the Contract time in accordance with his Program of Work as approved by the Engineer. This
equipment shall be, but not limited to, the following:
8.5.4.1 Mixing Plants:

Asphaltic concrete mixtures shall be produced in either batch plant, continuous pug mill, or
dryer-drum mixing plant. Proportioning of aggregates may be by hot or cold feed control for the first and
second types, and cold feed for the drum type, at the
option of the Contractor and the approval of the Engineer.
Feeding shall be controlled and the screening sieves shall be arranged in a way
suitable to the plant capacity and without changing aggregate gradation at production
time.
255
The dryer drum mixing plant shall be equipped with temperature meters for the produced
materials. The meter shall be precise plus or minus five (5) degrees Celsius. All mixing plant shall
conform to environmental protection requirements of the region in terms of dust collection and disposal.
Table 8.5.1: Allowable tolerance limits for asphaltic concrete mixes

Sieve size
19.0 mm (3/4 in.)
12.5 mm (1/2 in.)
9.5 mm (3/8 in.)
4.75 mm (No. 4)
2.00 mm (No. 10)
0.425 mm (No. 40)
0.180 mm (No. 80)
0.075 mm (No. 200)
Asphalt cement
I.
II.
Allowable tolerances in JMF (percent)

Base Course
Wearing Course
I
II
I
II
6
8
5
6
5
6
6
8
6
7
5
6
5
6
4
5
3
4
3
4
2
3
1.5
2
1.5
2
0.40
0.40
0.40
0.40
Allowable tolerance limits for JMF and daily testing using one-sample method for evaluation.
Allowable tolerance limits for quality assurance procedures testing using statistical method of evaluation.
Table 8.5.2: Asphaltic concrete mix quality requirements (Marshall Method)

Base
Property
Number of compaction blows
Marshall Stability @ 60C (kg)
minimum (*)
Flow (mm) at 60 Degree Celsius
Voids Filled With Mineral
Aggregate (%) minimum
Voids in mix (%)
Asphalt Cement content by
weight of mix (%) (**)
Retained Strength Percent,
(Minimum)
(*)
Weari
Type
(A)
Type
(B)
Type
(C)
Type
(A)
Type
(B)
Type
(C)
75
75
50
75
75
50
1000*
750*
500*
1000*
750*
500*
2-4
2-4
2-4
2-4
2-4
2-4
See Table (8.5.3)

3-5
3-5
3-5
3-5
3-5
3-5
3-6
3-6
3-6
4-6
4-6
4-6
70
70
70
75
75
75
The stability deviation at construction phase shall not be more than 20 percent from the values adopted in the JMF.
(**) Actual values shall be determined in the JMF.
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Table 8.5.3: Voids filled with mineral aggregate ( V M A ) for asphaltic concrete mixes
Maximum nominal size in the mix
Minimum voids filled with mineral

aggregate ( % ) *
63 mm (2.5 in.)
50 mm (2 in.)
37.5 mm (1.5 in.)
25 mm (1 in.)
19.0 mm (3/4 in.)
12.5 mm (1/2 in.)
9.5 mm (3/8 in.)
4.75 mm (No. 4)
2.36 mm (No. 8)
1.18 mm (No. 16)
11
11.5
12
13
14
15
16
18
21
23.5
(*)
VMA shall be calculated based on the effective specific gravity (Gse).
When the use of natural sand or dune sand is allowed, they must be fed to the dryer through a
separate funnel, and within the allowable amount in the JMF.
8.5.4.2 Asphalt Paving Machine:

All operators of the asphalt concrete paving machine shall be well acquainted to the basic
operation of the paver to produce a smooth surface free of distresses. The paving machine shall conform
to the following requirements:
1.
2.
It shall be self-propelled capable to spread asphaltic concrete mixtures in a uniform manner

with the required thickness.
The thickness control unit shall be adjustable from fifteen (15) to one hundred and fifty
(150) millimeter.
3.
It shall contain a screed unit to control the pavement boundaries and its thickness. It shall
include a vibratory unit, leveling plate, heating device, and automatic sensors to control
feeding and horizontal and transverse slopes.
4.
It shall include an infra-red heating device for leveling and sealing joints while spreading.
8.5.4.3 Rollers:
The Contractor shall furnish sufficient rollers to execute the asphaltic concrete compaction,
which shall include the following:
1-Pneumatic-Tired Roller: It shall conform to the following requirements:

1.
2.
It shall be self-propelled.
It shall have two (2) to seven (7) front-tires and four (4) to eight (8) rear-tires. The tires
shall be free to provide vertical vibrations. The front and rear tires shall be staggered to
provide complete coverage of the entire area over which the roller travels with minimum
overlapping of ten (10) millimeters.
3.
The overall weight of the roller shall be between two and seven-tenth to three (2.7-3) tons
while empty, and between thirty-two and thirty-five (32-35) tons when filled with
aggregate and wet sand.
4.
It shall include a scraper to clean the tires from any adherent materials, and a wetting
arrangement for wetting the rolls to prevent adherence of the placed material.
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2-Steel-Tired Roller: It shall conform to the following requirements:

1.
It shall have two (2) or Three (3) self-propelled steel tires with one (1) or two (2) steering
tires. The tire diameter shall be between one hundred fifty to one hundred eighty (150-180)
centimeters, and the width shall be between fifty to sixty (50-60) centimeters. The total
weight of the roller shall be adjustable within seven and sixteen (7-16) tons using additional
masses.
2.
It shall include a power mechanism capable of propelling the roller smoothly and without
jerking when starting, stopping, or reversing directions.
3.
It shall be in a good operational condition and free from any defect in its steering
mechanism or its tires and their axles.
4.
The steering mechanism shall operate readily and permit the roller to be
directed on the alignment desired, without damaging the surface.
5.
It shall include a scraper to clean the tires from any adherent materials, and a
wetting arrangement for wetting the rolls to prevent adherence of the placed
material.
3-Steel Vibratory Roller: It shall conform to the following requirements:

1.
2.
It shall be self-propelled.
It shall have adjustable vibration capacity suitable to the required thickness and rollers speed
to provide the required compaction with a leveled undamaged surface shall operate it.
3.
It shall have a minimum dead weight of two thousand (2000) kilograms.
4-Hand-Operated Steel Wheel Roller: It shall conform to the following requirements:

1.
It shall be mounted on a small platform unit and shall be a smooth surfaced steel wheel with
thirty to sixty (30-60) centimeters in diameter and fifty to seventy (50-70) centimeters in width.
It shall have a combination of static weight and dynamic force, with frequency and amplitude
of the force being adjustable.
2.
It shall have a compaction capability for patches and pavement side to the same level of the
pavement body.
5-Vibratory Plate Compactor: It shall have an adequate weight to compact the

pavement sides and isolated patches with the same compaction level of the pavement body.
8.5.4.4 Power Broom:
Power broom shall be capable to remove the dust and other materials from the pavement surface
before spraying asphalt, and to remove the loose aggregate after the compaction process is completed.
Power broom shall be in good operational condition before starting the work, and shall be
mechanically checked
The broom bristles must be long enough to clear the surface thoroughly for the width of the brush.
8.5.4.5 Hand Tools:

The Contractor shall furnish all hand tools required for cleaning and heating purposes provided they are
thoroughly checked before starting the pavement process.
258
These tools include: rakes, shovels, hand compactors, leveling and smoothing tools, pavement saw
machines, heaters, cleaning tools, hand brooms, small vibratory compactors, liquid asphalt painting, and all
other tools that may be needed by the Contractor to complete the work.

Asphaltic concrete pavement shall not be placed on any wet or frozen surface, during dust or sand
storms, when wind or other weather conditions prevent the proper handling of the Asphaltic mixtures or
when the average surface temperatures are less than specified in Table (8.5.4).
Table 8.5.4: Surface temperature limits for asphaltic concrete paving

Compacted layer
thickness (cm)
Less than 3
3 to 6
6.1 to 10
M ore than 10
Minimum average surface temperature (degree Celsius)

Wearing course or Base
Leveling course
course
25
20
Not applicable
Not applicable
20
15
10
5
8.5.6 Construction:
Construction requirements for the work under this section shall conform to the requirements in the
following paragraph:
8.5.6.1 Preparation of Asphaltic Materials:

The mixing and compaction temperatures shall be determined based on asphalt viscosity. The
required mixing temperature shall be the one at which the asphalt viscosity is 170 20 centistokes, while
the compaction temperature shall be the one at which the asphalt viscosity is 280 30 centistokes.
Asphaltic materials, of penetration grade 60/70, to be used as binder for asphaltic concrete shall be
at a temperature between one hundred and forty-five to one hundred and eighty (145-180) degrees Celsius
when introduced into the mixing plant or as necessary to obtain the required viscosity without burning the
asphalt or hardening it. Different grades of asphaltic materials shall be stored in separate tanks, transported
in separate vehicles, and shall not be mixed without the approval of the Engineer.
When asphalt modifiers are used, their use shall comply with the manufacturer's recommendations as to
their preparation, blending, and placement.
8.5.6.2 Preparation Aggregates:

Aggregate shall be stored in separate stockpiles a minimum of ten (10) meters apart or separated by
walls so that various sizes are not mixed together. Any aggregate, which has been mixed together, shall be
removed and replaced with aggregate of specified grading and quality requirements.
259
Supplemental fine aggregate and mineral and chemical admixtures shall also be stored separately
in special tanks, which prevent their mixing or change in their properties or be affected by environmental
conditions.
Dust collected in skimmers, expansion chambers, and centrifugal collectors may be returned to the
aggregate without being stored separately, provided the dust is returned uniformly at a point in advance of
the sampling device in batch-mix and continuous pugmill mixing plants or between the sampling device and
the dryer-drum mixer in dryer-drum mixing plants. The combined aggregate gradation at the time asphaltic
material is added shall conforms to the requirements specified in Item 8.5.2.
Before being fed to the dryer, aggregate shall be separated into sizes and stored in compliance with
requirements of the preparation of asphaltic concrete mixture in the following paragraph 8.5.6.3.
The various sizes of aggregate shall be fed from storage in their proper proportions, directly to a
dryer or dryer-drum mixer, using mechanical feeders and at a rate to permit correct and uniform temperature
control and mixing with asphaltic material. Except for mixtures produced in a dryer-drum mixer, drying
shall continue for a sufficient period of time at a sufficiently high temperature so that, at the time of
spreading, the moisture content of the mixture shall not exceed one (1) percent. At the time of spreading,
mixtures produced in a dryer-drum mixer shall not contain more than three (3) percent moisture.
8.5.6.3 Preparation of Asphaltic Concrete Mixture:

Aggregates and asphaltic material for asphaltic concrete shall be proportioned in accordance with
the requirements of the approved JMF and mixed using equipment that will produce a mixture conforming
to these General Specifications and the Special Specifications.
When a plant equipped with hot-feed controls is used, aggregate after drying shall be separated into
sizes as follows:
1.
2.
Three (3) or more sizes for aggregates used in asphaltic base course or wearing
course of gradation (1) or (2), and each size stored in a separate funnel.
Two (2) or more sizes for aggregates used in asphaltic wearing course of
gradation (3), and each size stored in a separate funnel.
Supplemental fine aggregate and mineral admixtures shall each be stored in a separate funnel.
Chemical admixtures shall be added to the asphaltic material, at a uniform rate, in the specified amount,
through the asphaltic material supply line using an on-line blender. Each size aggregate, supplemental fine
aggregate and mineral admixture shall be delivered from storage bins, in their proper proportion, by weight
or by volume.
The combined aggregate, including supplemental fine aggregate and mineral admixtures and
asphaltic material content shall conform to the approved JMF grading within the tolerances shown in Table
(8.5.1).
The Contractor shall consider the following requirements during production of asphaltic mixtures:
260
1.
When discharged from the mixing plant, the temperature of the asphaltic concrete shall not exceed
one hundred and sixty-five (165) degrees Celsius as an approximate temperature.
2.
Each material storage bin shall be equipped with a suitable, safe sampling device which will
provide a sample of the material discharged from the storage funnel, when the Contractor elects to
use batch-mixing plant.
3.
Unless specified in the Special Specifications, aggregate and asphaltic material may be manually
or automatically proportioned by weight or by volume in a manner that produces a mixture
conforming to the requirements specified in JMF.
4.
An automatic plant shall not be operated manually unless the automatic circuits are malfunction to
the extent that they cannot be activated by the operation of a switch, circuit breaker, or other
routine procedure.
5.
When automatic batch mixing is required by the Special Specifications, or when the Contractor
selects to use an automatic batching system, the proportioning devices shall be automatic to the
extent that the only manual operation involved in proportioning all materials for one batch shall be
a single operation of a switch or starter.
6.
Asphaltic material shall be introduced into the mixer through a meter capable of varying the rate
of delivery of asphaltic material when continuous pugmill mixing or dryer-drum mixing is used.
7.
The correct proportions of each aggregate size, supplemental fine aggregate and mineral
admixture shall be drawn from storage bins by a continuous mechanical or electrical feeder, which
will supply the exact amount of aggregate in proportion to the asphaltic material and be arranged
so that each aggregate size can be adjusted separately. Aggregate feeders and the asphaltic
material pump shall be interlocked.
8.
When cold feed proportioning is used with continuous pugmill or dryer-drum mixing, the
asphaltic material feeder, each of the aggregate feeders, the supplemental fine aggregate feeder,
the mineral admixture feeder, and the combined aggregate feeder shall be equipped with devices
by which the rate of aggregate feed can be determined while the plant is in full operation. The
combined aggregate shall be weighed using a belt scale.
9.
A method of sampling shall be used that will provide a representative sample for each size of
aggregate or the combination of aggregates immediately prior to introduction of asphaltic binder.
The plant shall be equipped with devices to permit sampling of aggregates while the plant is in full
operation and be such that the plant production rate may be determined.
10. Aggregate, supplemental fine aggregate and mineral admixtures, when used, shall be mixed
uniformly and completely and coated, when tested in accordance with the requirements of
AASHTO T-195, shall not be less than ninety-five (95) percent.
11. When asphaltic concrete material is stored, it shall be stored in a manner that prevents segregation
of the completed mix. Asphaltic mixtures with hardened lumps shall not be used. Any storage
method that results in a mixture with hardened lumps in it shall not be used.
12. All asphaltic concrete material placed in storage shall be used before darkness on the day of
mixing.
261

The following steps shall be followed to properly prepare the surface for the placements of asphaltic
concrete layers:
1.
Before placing the asphaltic concrete mixtures, the subgrade, subbase, or aggregate base layer shall
be prepared according to Divisions 5 and 6 in these General Specifications and sprayed by prime
coat.
2.
When the asphaltic concrete wearing course is to be placed on an asphaltic base course, all loose
materials shall be removed from the surface and the surface shall be cleaned by means of approved
mechanical sweepers or blowers and/or hand brooms, until it is as free from dirt as is deemed
practicable and then sprayed by tack coat. No traffic shall be permitted on the surface after it has
been prepared to receive the asphaltic material.
3.
The existing pavement, base, or subgrade shall be removed through broken, shattered, or unstable
areas as shown on the plans or designated by the Engineer. The areas shall be excavated to a depth
directed by the Engineer, and refilled with asphaltic mixture described in these specifications.
When the Contract does not provide a patching item, the unit price for the "asphaltic concrete
wearing course" mixture, as specified in the Bill of Quantities, shall be used for such Work. The
excavation required will not be paid for directly but will be considered subsidiary to the pay items
of "asphaltic concrete wearing course" as specified in the Bill of Quantities.
4.
When the asphaltic mixture is placed on a prepared Subgrade, aggregate base layer, or previous
asphaltic layers, the surfaces of these layers shall receive a prime coat or a tack coat as specified in
Sections 8.3 and 8.4.
5.
When the asphaltic surface is to be constructed on a previously newly primed base, and where
deemed advisable by the Engineer, the above specified tack coat may be eliminated. No mixture
will be laid on a tack coat prior to the approval of the Engineer.
8.5.6.5 Hauling Asphaltic Concrete Mixtures:

The asphaltic concrete mixtures shall be transported to project site by strong clean trucks with
smooth steel surfaces.
The surfaces shall always be clean and free from any oil or dilutes or any materials, which may affect the
properties of, asphalt mixtures.
When necessary, the surfaces may be sprayed with a thin layer of lubricant to prevent sticking the mixtures
with the surfaces.
The transported asphaltic concrete materials shall be covered at cold times or when the mixing plant is far
away from the project site to minimize the heat loss of the mix.
8.5.6.6 Placement of Asphaltic Concrete Pavement:

Asphaltic materials shall be placed as a base course, leveling course, or surface course according to
the thickness, dimension, and slopes of the individual courses shown on the plans. Base course is defined as
a layer or layers of asphaltic materials placed on a paved or unpaved surface in preparation for placing a
wearing course.
A leveling course is defined as a layer of asphaltic material used to reshape a roadway

cross-section and eliminate sags and irregularities in the longitudinal grade line. Wearing course is defined
as a layer to serve as a traffic surface. The maximum and minimum thickness of any layer shall be
constructed in accordance with limits
262
showen in Table (8.5.5). I f higher thicknesses are needed, they shall be constructed in equal layers. The
maximum limit is determined by multiplying the nominal maximum aggregate size by three (3); the
minimum limit is determined by multiplying the nominal maximum aggregate size by two (2).
Table 8.5.5: Maximum and minimum thickness limits for asphaltic concrete layers
Asphaltic layer
Asphaltic base course, Gradation (1)
Asphaltic wearing course, Gradation (1)
Minimum
thickness, cm
7
5
4
3.5
3
2.5
Maximum
thickness, cm
10
7
6
5
4
3
The asphaltic materials shall be dumped from the hauling equipment directly into the
self-propelled paving machine or any other specified device. The materials may be dumped in front of the
paving machine provided that the paving machine is designed to pickup the dumped materials.
When the asphaltic materials are dumped from hauling equipment directly into the paving
machine, care shall be taken to avoid jarring the paving machine or moving it out of alignment. No vertical
load shall be exerted on the paving machine by hauling equipment. Hauling equipment, while dumping into
the paving machine, shall be attached firmly to the paving machine.
When asphaltic materials are dumped on the surface to receive the mixture and loaded to the
paving machine, the loading equipment shall be self-supporting and not exert any vertical load on the
paving machine. Substantially all of the asphaltic materials shall be picked up and loaded into the paving
machine.
Sufficient quantities of asphaltic materials shall be delivered in a continuous manner, using a

self-propelled paving machine conforming to these General Specifications, in a manner that the finished
surface is smooth with uniform texture, no segregation is evident, planned and specified thickness is
complied with and joints are tight and thoroughly sealed. The paving machine shall be operated at a
uniform forward speed consistent with plant production. During paving operation, stopping and starting the
paving machine and folding sidewalls of the paver hopper shall be avoided. The condition of the
self-propelled paving machine becomes not good, then Engineer, may approve equipment other than
self-propelled paving machines for placing base and leveling courses when such other equipment produce
the results specified.
All self-propelled paving machines used to spread asphaltic material, shall be equipped with
automatically actuated screed controls and sensors mounted on both sides of the paver. The sensor shall be
constructed to operate from a reference line or a multi-footed ski-type arrangement. The automatic screed
control system shall operate at all times during spreading of asphaltic materials except under conditions, or at
certain
263
locations where the Engineer deems the automatic controls impractical. Failure of the automatic controls to
function properly shall be a cause for suspension of placement of asphaltic materials. The Contractor shall
establish all reference lines as may be necessary for the operation of automatic screed controls.
Spreading and compacting asphaltic concrete wearing courses will not be permitted at night except
when specified in the Special Specifications or approved by the Engineer.
8.5.6.7 Joints:
Whenever it is possible, longitudinal and transverse joints shall be held to the minimum
practical number.
However, when these joints are used, following requirements shall be fulfilled:
1.
Longitudinal joints for each course shall be offset thirty (30) centimeters from the joint in the
immediate underlying course. Transverse joints shall be offset a minimum of sixty (60)
centimeters from the joint of the immediate underlying course.
2.
Longitudinal joints shall be located within fifteen (15) centimeters of the centerline of the
roadway or within fifteen (15) centimeters of the centerline of a lane.
3.
The new asphaltic concrete layer shall overlap with the adjacent layers by the maximum of five
(5) centimeters or one-half (1/2) the layer thickness.
4.
Transverse joints shall be formed by cutting back the first layer placed to the full depth of the
layer, removing and wasting the material, spreading new asphaltic material in sufficient quantity
to create a compacted thickness equal to the thickness of the first layer. The joint shall be
cross-rolled with one coverage and the joint checked with a straight-edge not less than four (4)
meters in length. High points shall be removed and sags filled with additional asphaltic material
and the joint rolled a second time. The joint shall again be checked with a straight edge, humps
and sags adjusted i f necessary, and rolled until the joint is complete and compacted as specified.
5.
Contact surfaces, where asphaltic concrete mixtures are placed against concrete or curb stone
and gutter, bridge abutments, retaining walls, drainage facilities, a cold pavement joint or metal
surface, shall be tack coated properly as specified in Section 8.4 in these General Specifications.
8.5.6.8 Compaction of Asphaltic Concrete Pavement:

All courses of asphaltic concrete pavement shall be spread and the initial coverage or breakdown
compaction shall be performed when the temperature of the mixture is not less than one hundred forty
(140) degrees Celsius, unless the Engineer orders lower temperatures. All rolling shall be completed before
the temperature of the mixture drops below ninety (90) degrees Celsius.
Longitudinal joints shall be rolled first, and then rolling shall begin at the lower edge and proceed
towards the highest portion, except when compacting layers that are thicker than nine (9) centimeters.
Compaction of layers more than nine (9) centimeters in thickness, shall begin in the middle and proceed
alternately towards each edge. When the roller is within sixty (60) centimeters of either edge, it shall
proceed by
264
lapping the uncompacted mixture by not more than thirty (30) centimeters per coverage. Coverage consists
of one pass of the roller over any portion of the layer being placed.
Sufficient compaction equipment shall be provided and compaction shall continue until each lot of
asphaltic concrete pavement is compacted to an in-place density within ninety one to ninety-five (91-95)
percent of the theoretical maximum density determined from AASHTO T-209 for all layers calculated
based on three to five (3-5) percent air voids, and the compaction level of ninety-six (96) percent of
Marshall density. At calculation the quality index required for statistical evaluation, this range shall be
widened by one (1) percent in both sides.
The actual density shall be determined from cores, random nuclear gauge readings, or any other
non-destructive testing method. When using the nuclear gauge, the average of three (3) random readings
shall be compared with the theoretical maximum density. The compaction level shall be evaluated based on
one-sample method for small area works, and using the statistical evaluation method for large projects
detailed in Section 17.3 in these General Specifications.
8.5.6.9 Pavement Thickness Measurement:

The thickness of each course of asphaltic concrete pavement, complete as placed and compacted,
shall be measured from cores obtained from random locations. The layer thickness shall not deviate from
the specified thickness in the plans, Special Specifications, or Contract documents by more than three (3)
millimeters. The thickness of each core shall be determined, using a set of calipers, in accordance with
ASTM D-3549.
8.5.6.10 Wearing Course Smoothness:

Smoothness: The completed asphaltic wearing course shall be compacted as specified, smooth and free
from ruts, humps, depressions, or irregularities. Any ridges, indentations, roller checking, or other
objectionable marks left in the surface, as determined by the Engineer, shall be eliminated by whatever
means are necessary and approved by the Engineer. The use of any equipment that leaves ridges,
indentations or other objectionable marks shall be discontinued. In main roads and freeways, or between
intersections that allow the test speed, the surface roughness shall be measured by devices or methods
approved by the Ministry. In short paved sections in local streets, the straight edge shall be used for
smoothness checking
Straight-Edge Method Roughness: a straight edge of four (4) meters in length is laid
on the finished surface of the asphaltic wearing course parallel with or transverse to the centerline, in such a
manner that both ends are in contact with the surface, the surface shall have no depressions which vary
more than three (4) millimeters from the lower edge of the straight edge.
Equipment Method Roughness Measurement: surface smoothness is measured on

each lane under the wheel track using the roughness measuring device specified in the Special Specifications. The
measurement shall be made at the suitable speed to the
used device. The measurement shall be done for every one hundred (100) linear meters. ____________________
When the one-sample evaluation method is used, the average roughness value shall not exceed one hundred and
sixty (160) centimeters/kilometer according to the International
265
Roughness Index (IRI), unless otherwise stated in the Special Specifications. When the statistical method
for evaluation is used, the maximum acceptable limit of roughness shall be two hundreds (200) measured
by any approved device by the Ministry according to IRI. The one hundred (100) meter of the intersection
approaches and turning lanes shall be excluded from the roughness measurements. Bridges and culverts
with construction joints shall be also excluded.
8.5.6.11 Wearing Course Skid Resistance:

In high-speed roads (higher than 60 kilometer per hour), the asphaltic wearing course shall
conform to the minimum requirement of skid resistance when tested by the special equipment. Unless
otherwise stated in the Special Specifications, the minimum acceptable limit of skid resistance according
to the International Friction Index ( IFI) of the surface layer shall be thirty five (35) measured by any
equipment approved by the Ministry and calculated using the ASTM E-1960. The skid measurements
shall be made for each lane at the specified speed of the measuring device. When the surface does not
provide the minimum limit, it shall be corrected by applying a friction course layer according to Section
11.2 in these General Specifications. The Contractor will not be paid any compensation for this corrective
work.

The Contractor shall take effective action to prevent all traffic from using the asphaltic concrete
pavement until such time as the Engineer has given approval for traffic to use the pavement.
All traffic control work shall be done in accordance with the Manual of Traffic Control through
Work Zones issued by the Ministry of Municipalities and Rural Affairs in 1421H (2001). When the
roadway being paved is open to traffic, the following additional requirements shall apply:
1.
The Contractor shall keep road intersections and ramps open at all times except when a ramp is
being paved or the paving operations cross the road intersection or ramp. During such time, the
road intersection or ramp shall be closed for the minimum possible time period. In hot weather,
the Engineer may require the Contractor to apply water to the compacted pavement to accelerate
lowering the pavement temperature and opening to traffic.
2.
Before closing a ramp or access to the roadway, warning signs shall be placed and the detour or
alternate route signs displayed.
3.
During paving operations, temporary lane stripes shall be maintained throughout the length of
project open to traffic. Temporary striping shall consist of ten (10) centimeters by thirty (30)
centimeters strips of pressure sensitive tape applied to the roadway surface at eight (8) meter
intervals. The temporary stripes shall be placed at the end of each day's paving operation,
maintained and replaced until permanent lane marking is completed.
4.
When necessary to maintain one-way traffic, the Contractor shall furnish and operate a pilot car,
deploy flagmen and position all signs, markings, barricades and other traffic control devices as
needed to protect traffic during construction operations.
266

The Contractor shall apply quality control procedures for all asphaltic concrete works to ensure that
the materials used and the executed work conform to these General Specifications and other Contracts
Documents.
The Ministry shall assure the quality of production by checking that the Contractor is performing
the quality control procedures in correct manners as per specifications. The Ministry may have a direct
supervision on the quality control system or by applying quality assurance procedures in an independent
unbiased way, on adequate number of samples to judge the execution level and decide whether to accept or
reject the work. Division 17 in these General Specifications shall be used for this purpose, unless stated
otherwise in the Special Specifications or Contracts Documents.

The Contractor shall perform all required tests and measurements, and shall collect, document, and
draw the critical diagrams to ensure that the raw materials at source, materials while work execution,
asphaltic concrete produced, and the executed work are within acceptable limits. The test may be performed
at The Contractors laboratory or at an independent laboratory, approved by the Ministry. The Contractor
shall submit copies of all test results to the Engineer. Table (8.5.6) shows the tests that the Contractor shall
perform on raw materials and mixes, the frequency of these tests, and the allowance limits. The Contractor
shall apply all requirements detailed in Item 17.1.1 in these General Specifications.
8.5.8.2 Quality Assurance :

The Ministry reserves the right, at any time, to assure the quality of materials and executed work
by performing or ordering the Contractor to perform, under its direct supervision, some or all quality
control tests that are shown previous Subitem. The Ministry has also the right to inspect all Contractors'
quality control test records and compare them with its quality assurance test done according to Division 17
in these General Specifications.
Ministry may inspect Contractor's laboratory, devices, technical staff, and testing methods to
assure the full adequacy and capability of the Contractor to execute the work according to standard
approved methods.
8.5.9 Measurements:
The quantity of each lot and course of asphaltic concrete pavement shall be measured by the cubic
meter, as placed and compacted to the required density, within the lines and grades, and thickness shown on
the plans or directed by the Engineer. No measurement will be made for extra thickness or areas of
pavement placed outside authorized limits.
Prime coat, when placed, shall be measured as specified in Section 8.3 in this Division.
Asphalt cement and modified asphalt cement shall be considered subsidiary to the construction of each lot
of asphaltic concrete pavement unless specifically stated in the Special Specifications and listed in the Bill of
Quantities. When they are listed separately they shall be measured in liters.
267
Tack coat shall not be measured for payment purposes. Mineral fillers, chemical admixtures and
asphalt modifiers used by the Contractor to meet the Job Mix Formula (JMF) requirements will be
considered subsidiary to the construction of the asphaltic concrete layers and will not be measured
separately unless specifically stated in the Special Specifications and listed in the Bill of Quantities. When
they are listed separately they shall be measured in liters, kilograms, or tons as specified in the Special
Specifications and as listed in the Bill of Quantities.
Table 8.5.6: Quality control requirements for asphaltic concrete mixes

Work
Properties
Asphaltic
material
Quality
requirements
(Table 7.2.1)
Aggregates
Quality
requirements
(Tables 7.3.1
and 7.3.4)
Aggregate
gradation (dry
mix)
Raw
materials
Material at
use
Road
Finishing
Sample
location
Sampling frequency
Requirements
Certification of compliance at start of

supply or source change
Table 7.2.1
Three (3) tests on different samples from

each source at source approval or JMF,
change source. Minimum of five (5) tests
on samples taken at different times every
five-thousand (5000) cubic meter for each
source at production
Table 7.3.1
and Table
7.3.4
AASHTO T-27
One (1) sample every week or when the

source or mix properties change
Table 7.3.4
Specific
gravity, kg/m3,
(Gsb)
AASHTO T-19

mix properties change
Table 7.3.1
Los Angeles
Abrasion
AASHTO T-96
One (1) sample every month or when the

Table 7.3.1

Table 7.3.1
Source
Source
of
project
site
Sand equivalent
for passing
Sieve No. 4
AASHTO T-176
Soundness,
Sodium or
Magnesium
Sulfate
AASHTO T-104

mix properties changed
Table 7.3.1
Fracture faces
for retained on
Sieve No. 8
(two faces)
ASTM D-5821

source is changed
Table 7.3.1
Aggregate
gradation
AASHTO T-27
One (1) sample every five hundred (500)

cubic meter or a day work, whichever is
minimum for each layer
Table 8.5.1
One (1) sample every five hundred (500)

cubic meter or a working day, whichever is
minimum for each layer
Table 8.5.1
One (1) test every working day for each

asphaltic concrete mixing plant
Table 8.5.2
Asphalt
Mix
Test Method
Asphalt content
AASHTO T 164/T-308
Marshall Test
AASHTO T209/245/269
Project
site or
mixing
plant
Compaction
ASTM D-2726
Minimum one (1) test every one thousand

(1000) square meters from each layer
paragraph
8.5.6.8
Thickness
ASTM D-3549
Minimum one (1) test every one thousand

(1000) square meters from each layer
paragraph
8.5.6.9
Skid resistance test for each working day
paragraph
8.5.6.11
Straight edge or a device for each working

day
paragraph
8.5.6.10
Transverse segments every twenty-five

(25) meters or five segments every one
thousand (1000) meters, whichever the
maximum
Contract
documents
Skid resistance
for wearing
course
Approved
device
Surface
smoothness
Approved
device
Level,
dimensions,
slopes, and
smoothness
Contract
documents
Project
site
Project
site
268
8.5.10 Payment:
Payment shall be made at the contract unit price, or adjusted contract unit price, per cubic meter
measured as described above for each grading and class of asphaltic concrete base, leveling and wearing
courses listed in the Bill of Quantities.
The above prices and payment shall cover and be full compensation for furnishing labor, materials,
equipment, tools and incidentals necessary for completing all work involved in construction of asphaltic
concrete pavement. Payment will be made according to Table (8.5.7).
Table 8.5.7: Asphaltic concrete pay items

No.
8.3.1
8.4.1
8.5.1
8.5.2
8.5.3
Pay Item
Prime coat
Tack coat (if measured separately)
Asphaltic concrete base course type
Asphaltic concrete wearing course type
gradation
Asphalt cement (if measured separately)
Pay units
gradation
Square meter
Square meter
Cubic meter
Cubic meter
Kilogram
8.3.4
Chemical admixtures and asphalt modifiers (if measured

separately)
Kilogram
8.5.5
Mineral fillers ( if measured separately)
Kilogram
269
DIVISION 9
RECYCLING
9.1 Scope
9.2 Hot-M ix Recycling
9.2.1 Description
9.2.2 Materials
9.2.3 Recycled Asphaltic Concrete Mixes
9.2.4 Equipment
9.2.4.1 Cold Milling Machine
9.2.4.2 Heater And Scarifier
9.2.4.3 Crushers
9.2.4.4 Mixing Plants
9.2.4.5 Spreaders
9.2.4.6 Rollers
9.2.6 Construction
9.2.6.1 Central Plant Mixing
9.2.6.2 In-Site Mixing
9.2.6.3 Surface Smoothness
9.2.6.4 Determining Aggregate Gradation And Asphalt Content In
Recycled Mixes
9.2.8.1 Quality Control Procedures
9.2.8.2 Quality Assurance Procedures
9.2.9 Measurements
9.2.10 Payment
9.3 Cold -M ix Recycling

9.3.1 Description
9.3.2 Materials
9.3.3 Job Mix Formula
9.3.3.1 Proposing Job Mix Formula
9.3.4 Equipment
9.3.6 Construction
9.3.6.1 Pulverization
9.3.6.2 Mixing
9.3.6.3 Placing And Compaction
9.3.6.4 Surface Leveling
9.3.7 Traffic Control 9.3.8
Work Acceptance 9.3.8.1
Quality Control
9.3.9 Measurements
9.3.10 Payment
273
273
273
273
273
274
274
275
276
276
276
276
276
277
277
277
277
277
278
278
278
279
279
279
280
280
280
282
282
282
282
282
283
283
283
283
283
283
284
284
284
284
285
285
285
285
285
285
285
Division 9 - Recycling
DIVISIO N 9
RECYCLING
9.1 Scope:
The asphalt pavement recycling means producing new asphaltic mixes that comprise aggregate
obtained from an old asphalt pavement and from new added aggregate, the asphalt binder from an old
asphalt pavement and fresh asphalt, and recycling agent for the old asphalt i f needed. This technology is
used to preserve the natural resources and pavement construction and maintenance funds saving. It helps
also in environment protection. Asphalt pavement recycling has several advantages such as: upgrading the
structural capacity of the existing pavement by adding small thickness, correcting some pavement
distresses such as rutting, shoving, and cracking, treatment of some asphalt mixes, and providing
economical solution for reconstruction.
Asphalt recycled mixes are divided into two types: hot-mix recycling (asphaltic concrete) and
cold-mix recycling. Based on production, they are divided into central plant mixing and on-road mixing
using mobile mixing plant; and based on depth; they are divided into surface recycling up to fifty (50)
millimeters and deep recycling for more than fifty (50) millimeters.
9.2
Hot-Mix
Recycling: 9.2.1
Description:
This Section consist of furnishing and mixing new aggregate, pulverized asphaltic concrete
pavement, asphaltic material and asphaltic recycling agent, heating and mixing these components, hauling,
spreading, and compacting the mixture on a prepared surface, all as shown on the plans, specified in these
General Specifications or the Special Specifications.
This Section is applied only when the reclaimed asphalt pavement (RAP) exceeds twenty (20)
percent of the total aggregate weight. The recycled asphaltic concrete containing RAP shall conform to the
gradation and quality requirements specified in Section 8.5 in these General Specifications wherever it is
used in pavement layers. The recycled asphalt concrete mixes shall be produced in suitable mixing plants
which raises the RAP's temperature without damaging it or affecting the environment and controlling the
basic prosperities of the final product.
9.2.2 Materials:
Added A sphalt Materials: It shall be asphalt cement material conforming to the quality
requirements specified in Tables (7.2.1) in these General Specifications.
New Aggregate: It shall conform to the quality requirements specified in Table (7.3.1) (types 1, 2,
and 3) in these General Specifications.
M ineral Filler: Mineral filler shall conform to the requirements specified in Tables (7.3.2) and (7.3.3)
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R A P: RAP for hot-mix recycled Asphaltic Concrete shall consist of asphaltic concrete pavement,
which has been pulverized or crushed (without being ground), and reduced, in size to the
requirements shown in table (9.2.1).
Table 9.2.1: Gradation requirement of aggregate in RAP

Sieve Size
37.5 mm (1.5 inch)
25 mm (1 inch)
Percent Passing
100
90-100
A s ph alt- R e cycling Agent: Hot-mix recycling agent shall be from asphaltic origin and shall
conform to the requirements listed in Table (9.2.2) or as specified in the Special Specifications.
C hem ic a l A d m ix tu r e s and A s ph alt M o d if ie r s: The types and amounts of chemical
admixtures/asphalt modifiers used shall be limited to those listed in the Special Specifications or
proposed by the Contractor and approved by the Ministry. They shall conform to the requirements
specified in Item 7.2.4 in these General Specifications.
Table 9.2.2: Recycling agent requirements according to ASTM D 4522
Property
Test
Requirements
Low
High
Grade
Grade
(RA5)
(RA25)
AASHTO T-202
200-800
1000-4000
Viscosity @ 60 C, (cSt)
AASHTO T-48
219
219
Flash Point, C.O.C., (C) minimum
30 Max.
30 Max.
Saturates by weight (%), Maximum ASTM D 2007
Tests on Residue From Rolling Thin Film Oven ( R T F O ) @ 60C according to
A A S H T O T-240, OR
(TFO) Oven @ 163 C according to
Tests on Residue from Thin Film Oven
T-179
AASHTO
4.0
3.0
Weight change, (% ), Maximum
3.0
3.0
Viscosity Ratio, Maximum (See Note)
No te: Viscosity Ratio = RTFO Residue Viscosity @ 60 C, cSt) / (Viscosity of the Original Material @ 60C).
9.2.3 Recycled Asphaltic Concrete Mixes:

Unless stated in the Special Specifications or Contract Documents, the asphaltic concrete type
shall be prepared according to Item 8.5.3 in these General Specifications and according to hot-mix
recycling Asphalt Institute Series Manual (MS-20), with the following considerations:
R A P: One test for the asphalt content, gradation, and reclaimed asphalt penetration shall be done for
every one thousand (1000) cubic meter of RAP, with minimum of five (5) tests in all cases.
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Added Aggregate: The added aggregate, when blended with the RAP, shall conform to all quality
requirements specified in Table (7.3.1) (types 1, 2, 3) in these General Specifications. The gradation shall be
determined with the RAP according to the targeted gradation.
A s ph a lt M ate r ia ls: Type, grade, and quantity of asphaltic material, and recycling agent (when used),
shall be determined according to the following criteria:
It must help to conform the specific requirements of Asphaltic mixture.

The combined asphaltic material in the final mixture shall have a penetration not
less than forty-five (45) and not greater than fifty-five (55). The variation in
penetration, at production, shall be within plus or minus five (5) units.
The Contractor shall furnish and submit a technical report including the JMF prepared by an skilled agency
approved by the Ministry. The report shall include, but not limited to, the following:
The originals of the laboratory test results on the mix.

The originals of the laboratory test results on the RAP and added materials.
The percentage of RAP to be used, by total weight of mix.
The percentage of added aggregate to be used, by total weight of mix.

The gradation of added aggregate to be blended with the RAP and the gradation of the final
aggregate.
The type, penetration, or viscosity, and percent of asphaltic material to be added, by total
weight of mix.
The type, penetration, or viscosity, and percent of recycling agent to be added, by total
weight of mix.
The penetration or viscosity of the final asphaltic material to be used in the mix.
The type and amount of mineral filler, chemical admixture, and asphalt modifier to be
added by total weight of mix.
The type and location of plants to be used for mixing each mix to be furnished.
Construction method.
The proposed beginning date for producing hot-mix recycled asphaltic concrete mixtures.
The Engineer shall be provided access to the materials sampling and testing operations at all times.

The Ministry shall review the JMF and all related matters, shown in previous Sub item, submitted
by the Contractor according to the following steps:
1. Assure that the report contains all requirements. I f it does not contain all required information, it shall
be returned within seven (7) days to the Contractor for further action and resubmission by the
Contractor.
2.
I f the proposed JMF contains all required information but fails to meet all of the requirements
specified, it shall not be accepted by the Engineer and will be returned to the Contractor within fourteen
(14) days. The Contractor shall prepare and submit to the Engineer a revised JMF conforming to the
requirements specified.
3.
The fist-day work shall be considered as a field control strip. It shall be assured that mix is
constructible in terms of spreading, compaction, and smoothness level.
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The Contractor shall not alter the methods of manufacturing, screening, mixing, stockpiling of aggregate, or
production of asphalt mixtures since this alteration will mandate evaluation of JMF.
Changing JMF shall not be permitted without retesting and resubmission of a proposed (revised) JMF in
accordance with all the steps in Sub-item 9.2.3.1.
9.2.4 Equipment:
The Contractor shall furnish suitable equipment to execute the recycling work. The number and the
production capacity of this equipment shall be within the Contract time in accordance with his Program of
Work as approved by the Engineer. This equipment shall be, but not limited to, the following:
9.2.4.1 Cold Milling Machine:

The cold milling equipment shall be self-propelled, equipped with a rotating cutting cylinder and
replaceable cutting teeth and be of such size and capacity as may be required to perform the milling work in
accordance with required depth. The equipment shall have a water tank, pump and spray bar for applying
cooling water to the teeth during cutting and for control of dust. The cold milling machine shall be equipped
with an electronically controlled leveling device which will produce the grade and cross-slope specified, and
it shall be able to ride-over obstacles such as manhole covers.
9.2.4.2 Heater and Scarifier:

The equipment used to heat and scarify the asphaltic surface shall be self-propelled, equipped to
burn liquid petroleum gas (LPG) or natural gas. Diesel fuel shall not be allowed. The combustion chamber
shall be insulated to avoid the flame to contact the asphalt rear wheel positioned, and equipped with calibrated
burners which is capable of heating the asphaltic surface to a temperature of one hundred and fifty (150)
degrees Celsius plus or minus ten ( 10) degrees Celsius to a depth between twenty and thirty (20-30)
millimeters. The machine shall be equipped with two (2) rows of spring-equalized scarifier-leveling rakes
which will automatically ride over obstructions in the surface such as man-hole covers. Additional heater
units, without scarifier rakes, shall be operated in advance for preliminary heating. Heater-scarifying
equipment shall be capable of being adjusted to heat widths between two and four (2-4) meters.
9.2.4.3 Crushers:
Big lumps RAP shall be crushed, using special crushers to obtain the required gradation.
9.2.4.4 Mixing Plants:

Mixing plants shall conform to the requirements specified in Section 8.5 in these General
Specifications. The plants shall be equipped with devices to raise the RAP temperature by induction with
the added aggregates without contacting the flame. These plants may be a batch plant, continuous mix
pugmill, or dryer-drum mixing plant. Plants shall be equipped with controls to feed the RAP to pugmill or
drum directly within the allowable limits.
9.2.4.5 Spreaders:
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Asphalt spreader, whether independent or attached to heating and scarifier unit, shall conform to all
requirements specified in Section 8.5 in these General Specifications, and shall be self-propelled and
capable to control the levels and slopes.
9.2.4.6 Rollers:
All used pneumatic or steel wheels rollers shall conform to all requirements specified in Section
8.5 in these General Specifications, and shall be capable to compact the pavement to the required density in
a fast and easy manner. It shall be self-propelled and equipped with scraper to clean the tires from any
adherent materials and steering mechanism shall operate readily and permit the roller to be directed on the
alignment desired.
Roller shall have a capacity and weight compatible with the thickness of the layers to be
constructed.
Hand-operated rollers may be used provided they have adequate weight to compact the pavement
sides to the same level of the pavement body.

Weather limitations specified in Item 8.5.5 in these General Specifications shall be applied.
9.2.6 Construction:
9.2.6.1 Central Plant Mixing:
When the central plant mixing is used, the following considerations shall be applied:
1.
The exact locations of the areas to be recycled along with the respective thicknesses thereof
shall be determined and delineated by the Engineer immediately prior to the start of the Work.
2.
Surface to be recycled shall be cleaned from untreated base soils and other deleterious
materials.
3.
The existing asphaltic pavement layer shall be removed in such a manner as to prevent the
mixing of the asphalt-bound materials with soils and other deleterious materials, or damage the
remaining pavement course or sublayers (base, subbase, or subgrade). The surface shall be
smooth conforming to the required levels and slopes.
4.
The surface shall be thoroughly checked before placing the asphaltic concrete. I f the
Contractor finds and defect on the surface or in the sub layers, he shall inform the Engineer, in
writing, detailing the extent of the problem, it possible causes, and the remedy method. Defect
found due to the Contractors removal operations, as determined by the Engineer, shall be
repaired by the Contractor at his own expense and prior to the placement of the recycled layer.
Deficient parts of base course or subgrade that are to be restored, as shown on the plans or
directed by the Engineer prior to start of the removal operations, shall be repaired and paid for
separately as specified in the pertinent sections of the Contract documents and Bill of
Quantities.
5.
RAP materials shall be reduced, without grinding the aggregates, to a size smaller than thirty
seven and one half (37.5) millimeters as specified in Item 9.2.1 in this Section.
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6.
RAP materials shall not be exposed to flame for heating or mixing purpose at any time.
7.
Reclaimed aggregate, after being reduced to the required size and prior to their use in the
recycled mixture, shall be segregated into two sizes: course retained on No. 4 sieve (4.75
millimeter), and fine passing a No. 4 sieve (4.75 mm), when using central plant mixing.
8.
The used mixing plant shall be suitable to feed all mix components at their proportions in
the JMF, and heating the RAP to the required temperature by heat transfer with the added
aggregates so as not to damage the asphalt binder, and be capable to produce uniform
asphaltic concrete conforming to the specifications
9.2.6.2 In-Site Mixing:

When the recycling construction is-site mixing is selected, the asphaltic concrete shall be done in
layers suitable to the maximum size aggregate as specified in Table (8.5.5) in these General
Specifications. When the work requires construction in layers, the top layers shall be removed and
properly stored, then the bottom layer is scarified or milled, heated, and mixed with other components
specified in the JMF, then the top layer shall be brought, heated, mixed, spread, and compacted. This
process is repeated for other layers.
I f approved by field trail to obtain asphaltic concrete conforming to the specifications, the
added aggregates and asphalt cement may be mixed in central plant, then hauled the mixture and mix it
with RAP by a mobile mixing plant after heating and adding the recycling agent. It may also be
applicable to spread the aggregate, cold or hot, coated or uncoated, before the scarifier, so that it collects it
and mixes it with RAP and conveys it to mobile mixing plant. The recycling agent may be sprayed, at the
predetermined amount, before or after pavement removal, while stockpiling, or while mixing provided it
serves the purpose of its utilization.
9.2.6.3 Surface Smoothness:

The recycled asphaltic concrete wearing course shall conform to the requirements specified in
Sub item 8.5.6.10 in these General Specifications.
9.2.6.4 Determining Aggregate Gradation and Asphalt Content in Recycled Mixes:

The asphaltic concrete aggregate gradation and asphaltic content will be sampled, tested and
evaluated in accordance AASHTO T-164. The asphalt penetration or viscosity is determined by Abson
method according to AASHTO T-170. The limit for payment purposes are as follows:
1.
Aggregate gradation: The upper and lower specification limits are the approved JMF target
values plus or minus the allowable deviations shown in Table (8.5.1) multiplied by one plus the
ratio of reclaimed asphalt pavement (RAP) material to the total mixture. Round to the nearest
percent except for the 0.075 mm (No. 200) sieve that is rounded to the nearest 0.10%.
Example: I f thirty percent (30%) of the mixture is reclaimed asphalt pavement material, then all
allowable deviation from target value for percent of aggregate passing the 0.075 mm (No. 200)
sieve is 2x (1.30) = 2.6%. Use plus 0.3% and minus 0.3% from the approved JMF target value for
percent passing the 0.075 mm (No. 200) sieve.
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2.
Asphaltic material content. The upper and lower specification limits are the
approved job-mix formula target value 0.4 x (1 + the ratio of the reclaimed asphalt
pavement material to the total mixture rounded to the nearest 0.10%).
Exam ple: I f thirty percent (30%) of the mixture is reclaimed asphalt pavement material,
then the allowable deviation from target value for percent asphalt content is 0.4x(1 .30) =
0.52%. Use plus 0.5% and minus 0.5% from approved JMF target value for asphaltic
material content.
3.
A s ph a ltic penetration. The minimum allowable limits are equal to the approval
JMF plus or minus fifteen (15) units.

The Contractor shall take effective action to allow safe traffic operations when using the
recycling work as specified by Item 8.5.7 in these General Specifications.

The Contractor shall apply quality control procedures for all recycled asphaltic concrete works to
ensure that the materials used and the executed work conform to these General Specifications and other
Contracts Documents.
The Ministry shall assure the quality of production by checking that the Contractor is performing
the quality control procedures in correct manners. The Ministry may have a direct supervision on the
quality control system or by applying quality assurance procedures in an independent unbiased way, on
adequate number of samples to judge the execution level and decide whether to accept or reject the work.
Division 17 in these General Specifications shall be used for this purpose, unless stated otherwise in the
9.2.8.1 Quality Control Procedures:

The Contractor shall perform all required tests and measurements, and shall collect, document,
and draw the critical property diagrams to ensure that the raw materials at source, materials while work
execution, recycled asphaltic concrete produced, and the executed work are within acceptable limits. The
tests may be performed at The Contractors laboratory or at an independent laboratory, approved by the
Ministry. The Contractor shall submit copies of all test results to the Engineer. Table (9.2.3) shows the
tests that the Contractor shall perform on raw materials and mixes, the frequency of these tests, and the
allowance limits. The Contractor shall submit copies of all tests to the Engineers and shall apply all
requirements detailed in Item 17.1.1 in these General Specifications.
9.2.8.2 Quality Assurance Procedures:

by performing or ordering the Contractor to perform, under its direct supervision, some or all quality control
tests that are shown previous Sub item 9.2.8.1. The Ministry has also the right to inspect all Contractors'
in these
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General Specifications. Ministry may inspect Contractor's laboratory, devices, technical staff, and
testing methods to assure the full adequacy and capability of the Contractor to execute the work
according to standard approved methods.
9.2.9 Measurements:
The quantity of each lot and course of hot-mix recycled asphaltic concrete pavement shall be
measured by the cubic meter or as stated in Special Specifications, as placed and compacted to the
required density, within the lines and grades, and thickness shown on the plans or directed by the
Engineer. No measurement will be made for extra thickness or areas of pavement placed outside
authorized limits.
Asphalt cement and modified asphalt cement shall be considered subsidiary to the
construction of each lot of asphaltic concrete pavement unless specifically stated in the Special
Specifications and listed in the Bill of Quantities. When they are listed separately they shall be
measured in liters.
Hot-mix asphaltic recycling agent shall not be measured separately unless specifically stated
in the Special Specifications and the item is listed in the Bill of Quantities, in which case it will be
measured in liters.
Mineral fillers, chemical admixtures and asphalt modifiers used by the Contractor to meet the
Job Mix Formula (JMF) requirements will be considered subsidiary to the construction of the asphaltic
concrete layers and will not be measured separately unless specifically stated in the Special
Specifications and listed in the Bill of Quantities. When they are listed separately they shall be
measured as in the specific specifications Section 8.3.
Prime coat shall be measured as specified in Section 8.2, in these General Specifications. Tack
coat shall not be measured for payment purposes.
9.2.10 Payment:
Payment shall be made at the contract unit price, or adjusted contract unit price, per cubic
meter measured as described in the pervious Item for each grading and class of recycled asphaltic
concrete listed in the Bill of Quantities.
The above prices and payment shall cover and be full compensation for furnishing labor,
materials, equipment, tools and incidentals necessary for completing all work involved in construction
of asphaltic concrete pavement, payment will be made according to Table (9.2.4).
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Table 9.2.3: Quality control requirements for hot-mix recycling

Work
Raw
materials
Material
at
use
Road
Finishing
Properties
Test Method
Sample
location
Sampling frequency
Requirement
s
Asphaltic
material
Quality
requirements
tests
Certification of
compliance and supply
and source change
Table 7.2.1
New Aggregates
Quality
requirements
tests
Three (3) tests at start of

work or source change
Table 7.3.1
Recycling
agents
Quality
requirements
tests
Certification of
compliance at start of
Table 9.2.1
RAP
AASHTO T27

Item 9.2.2
(RAP)
Mineral Filler
Quality
requirements
tests
Certification of
and source change
Contract
documents
Chemical
admixture and
modifiers
Quality
requirements
tests
Certification of
and source change
Table 7.3.2
Aggregate
gradation
AASHTO
T-164/T-27
AASHTO
T-164/T-170
JMF
Asphalt content
One (1) test every five

hundred (500) ton
produced or for each
working day whichever
the minimum
Viscosity of the
asphalt materials
AASHTO T201
Penetration of
the asphalt
materials
AASHTO T 49
One (1) test every five

thousand (5000) ton
produced or for each
working day whichever
the minimum
JMF
Compaction
AASHTO T2726
Minimum one (1) test

every 1000 cubic square
meters from each layer
Sub item
8.5.6.8
Minimum one (1) test

every 1000 cubic square
meters from each layer
Sub item
8.5.6.6
Source
project
site
Thickness
ASTM D
3549
Surface
roughness
Approved
device
Five (5) measuring per

day or thousand (1000)
meter whichever the
minimum for each lane.
Sub item
8.5.6.10
Contract
documents
Transverse segments
every 25 meters or five
segments every 1000
meters, whichever the
maximum
Contract
documents
Level,
dimensions,
slopes, and
smoothness
Project
site
Project
site
Table 9.2.4: Hot-mix recyclin g pay items

No.
9.2.1
Pay Item
Hot-mix recycling type
Pay units
gradation
Cubic meter
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9.3 Cold-Mix Recycling:

9.3.1 Description:
This Section consist of furnishing and mixing new aggregate, pulverized asphaltic concrete
pavement, asphaltic material (emulsified and non-emulsified) and/or asphaltic recycling agent, mixing these
components, hauling, spreading, and compacting the mixture on a prepared surface, all as shown on the
plans, specified in these General Specifications or the Special Specifications. The recycled pavement, by
this method, is used in asphaltic concrete base course in the same site or different sites. These base layers
shall be covered by a surface treatment or an asphaltic wearing course. There are two construction methods:
1.
In-place cold-mix recycling: it is used at roads with low traffic volumes or in

remote areas away form central mixing plants.
2.
C old-mixing in central mixing plant: it is used when high production rates and
precise control are required.
9.3.2 Materials:
The cold-mix containing RAP shall conform to the materials requirements for cold mixes specified
in Section 7.2 and Section 7.3 in these General Specifications, unless otherwise specified in Contract
Documents. These requirements shall include the following:
R A P: RAP shall be pulverized or crushed (without being ground), and reduced, in size so that all
particles pass one hundred (100) percent from sieve size thirty-seven and one half (37.5) millimeters.
N e w Aggregate: When specified in the Special Specifications or required by the Job Mix Formula,
new aggregate shall be blended with RAP. The new aggregate, when combined with the RAP materials,
shall conform to the fracture, gradation and quality requirements as necessary to produce the specified base
course
A s p halt M ate r ia ls: The types and grades of asphaltic materials shall conform to the grade listed in
the Special Specifications and requirements specified in the Tables (7.2.2) through (7.2.5) in these General
Specifications.
A s p halt- R e cycling Agent: Recycling agent shall conform to the requirements listed in Table
(9.2.2) or as specified in the Special Specifications. Test results and Certificate of Compliance shall be
submitted with each shipment of the recycling agent.
9.3.3 Job Mix Formula:
9.3.3.1 Proposing Job Mix Formula:
The procedure outlined in Sub item 9.2.3.1 shall be followed for proposing the JMF. The
Contractor shall submit to the Engineer his proposed method of operation and test data confirming that the
aggregate will conform to all specified fracture, gradation and quality requirements.
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The revision and acceptance of the cold-mix recycled asphaltic mixture job mix formula shall be in
accordance with Sub item 9.2.3.2.
9.3.4 Equipment:
The Contractor shall furnish suitable equipment to execute the recycling work. The number and the
production capacity of this equipment shall be within the Contract time in accordance with his Program of
Work as approved by the Engineer, and shall include equipment detailed in Item 9.2.4 in this Division.

Cold mix recycled asphaltic materials shall not be mixed or placed during rainfall, dust or sand
storms, when the ambient temperature is less than five (5) degrees Celsius or when weather conditions
prevent specified mixing and compaction requirements.
9.3.6 Construction:
The exact locations of the areas to be recycled along with the respective thicknesses thereof shall be
determined and delineated by the Engineer immediately prior to the start of the Work. The construction
process shall involve pulverization, mixing, and compaction.
9.3.6.1 Pulverization:
The Contractor shall submit to the Engineer prior to the start of the work the proposed
pulverization method for the existing pavement and the addition and mixing in place of any required new
aggregate and new asphalt or recycling agent. The resultant mixture shall be spread, compacted, and
finished.
The Contractor shall pulverize the existing pavement to the required size and shall add any amount
of new aggregate and asphalt required by JMF.
Undesirable contamination of the reclaimed materials with underlying untreated base course or
subgrade materials, clay, silt, or other deleterious matter shall not be accepted. Should such undesirable
contamination occur, as determined by the Engineer, the materials shall be discarded as directed and shall be
replaced with new approved materials, all at the Contractors expense.
9.3.6.2 Mixing :
Mixing asphaltic materials and/or recycling agent with RAP shall be uniform using any of the
following methods:
1.
The asphaltic material and/or recycling agent may be applied through the machine used to
cold mill the asphaltic surface as a part of the liquid used to cool the cutter teeth, provided it is
applied uniformly across the width of cut and results in a complete and uniform blending of all
materials.
2.
The asphaltic material and/or recycling agent may be applied through a mixing machine
capable of mixing a windrow of RAP and other materials on the road side.
3.
The asphaltic material and/or recycling agent may be added through a paving machine that is
capable of mixing and placing the recycled asphaltic base in its final position for compacting.
283
4. The cold mix recycled asphaltic base may be produced using a continuous operation consisting of
an interconnected cold milling device, portable crusher mounted on a trailer, cold mixing
pugmill mounted on a trailer, paving machine, materials transfer belts for moving the
materials from milling equipment through to the paving machine and compaction
equipment. When new aggregates are required they shall be spread uniformly at the
approved quantity on the road surface in advance of the cold milling machine.
Regardless of which method is used, mixing equipment shall have accurately meter the planned
amount of asphaltic material and/or recycling agent into the RAP and aggregate.
When directed by the Engineer, water shall be added to the RAP to facilitate uniform mixing with
asphaltic materials. Water may be added prior to or concurrently with adding the asphaltic materials, as
approved by the Engineer.
9.3.6.3 Placing and Compaction:

The recycled mixture shall be compacted using pneumatic or steel-drum tandem roller (vibratory
or normal) until the compacted density of recycled mixture is at least ninety-six (96) percent from the
Marshall laboratory compacted specimen determined from ASTM D 2726.
After the recycled mixture has been spread and compacted, it shall be allowed to cure for at least
three (3) days to reduce the moisture content prior to placing a wearing surface. Additional curing time
may be required by the Engineer in the event that the recycled mixture becomes wet during rainfall. Any
damage to the recycled mixture shall be repaired by and at the Contractor's expense and to the
satisfaction of the Engineer.
9.3.6.4 Surface leveling:

After each working day, the final surface after completion of compaction shall tested for
leveling, and shall have no depressions under a four (4) meter straightedge greater than three (6)
millimeters when laid parallel or transverse to the centerline.

The Contractor shall take effective action to allow safe traffic operations when using the
recycling work as specified by Item 8.5.7 in these General Specifications.

The Contractor shall apply quality control procedures for all cold-mix recycled asphaltic
concrete works to assure that the materials used and the executed work conform to these General
Specifications and other Contracts Documents.
The Ministry shall assure the quality of production by checking that the Contractor is
performing the quality control procedures in correct manners. The Ministry may have a direct
supervision on the quality control system or by applying quality assurance procedures in an independent
unbiased way, on adequate number of samples to judge the execution level and decide whether to accept
or reject the work.
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Division 17 in these General Specifications shall be used for this purpose, unless stated otherwise in the
9.3.8.1 Quality Control :

The Contractor shall perform all required tests and measurements, and shall collect, document, and
draw the critical property diagrams to ensure that the raw materials at source, materials while work
execution, cold-mix recycled asphaltic concrete produced, and the executed work are within acceptable
limits. The tests may be performed at The Contractors laboratory or at an independent laboratory,
approved by the Ministry. The Contractor shall submit copies of all test results to the Engineer. Table
(9.3.1) shows the tests that the Contractor shall perform on raw materials and mixes, the frequency of these
tests, and the allowance limits. The Contractor shall submit copies of all tests to the Engineers and shall
apply all requirements detailed in Item 17.1.1 in these General Specifications.

by performing or ordering the Contractor to perform, under its direct supervision, some or all quality
control tests that are shown previous Sub item. The Ministry has also the right to inspect all Contractors'
in these General Specifications. Ministry may inspect Contractor's laboratory, devices, technical staff, and
testing methods to assure the full adequacy and capability of the Contractor to execute the work according
to standard approved methods.
9.3.9 Measurements:
The quantity of each lot and course of cold-mix recycled asphaltic pavement shall be measured by
the cubic meter, as placed and compacted to the required density, within the lines and grades, and thickness
shown on the plans or directed by the Engineer. No measurement will be made for extra thickness or areas
of pavement placed outside authorized limits.
Cold-mix asphaltic recycling agent shall not be measured separately unless specifically stated in
the Special Specifications and the item is listed in the Bill of Quantities, in which case it will be measured
in liters.
9.3.10 Payment:
Payment shall be made at the contract unit price, or adjusted contract unit price, per cubic meter
measured as described in the pervious Item for each grading and class of recycled asphaltic concrete listed
in the Bill of Quantities.
The above prices and payment shall cover and be full compensation for furnishing labor, materials,
equipment, tools and incidentals necessary for completing all work involved in construction of asphaltic
concrete pavement. Payment will be made according to Table (9.3.2).
285
Table 9.3.1: Quality control requirements for cold-mix asphaltic concrete mixes
Work
Properties
Raw
materials
Material
at use
Road
Finishing
Test
Method
Sample
location
Sampling frequency
Requirements
Asphaltic
material
Quality
requirements
tests
Certification of compliance
and supply and source
change
Tables 7.2.2.A
to 7.2.5
New
Aggregates
Quality
requirements
tests

Table 7.3.1
Recycling
agents
Quality
requirements
tests
change
Table 9.2.1
RAP
AASHTO T27

Item 9.3.2
(RAP)
Aggregate
gradation
AASHTO T 164/T-27
two (2) tests every 2000

square meters from each
layer or each working day
JMF
Minimum one (1) test every

1000 cubic square meters
from each layer
Sub item
9.3.6.3
Minimum one (1) test every

1000 cubic square meters
from each layer
Contract
documents
Straight edge for each

working day
Sub item
9.3.6.4

25 meters or five segments
every 1000 meters,
Contract
documents
Asphalt
content
AASHTO T164/T-170
Compactio
n
ASTM D
2726
Thickness
ASTM D
3549
Surface
roughness
Level,
dimensions,
slopes, and
smoothness
Source
Project
site
Project
site
Contract
documents
Project
site
Table 9.3.2: Cold-mix recycling pay items

No.
9.3.1
Pay Item
Cold-mix recycling type
Pay units
gradation
Cubic meter
286
SURFACE TREATM ENTS
289
Single And M ultiple Surface T reatm ents
289
289
DIVISION 10
10 .1 10 .2Scope
10.2.1 Description
10.2.2 Materials
10.2.3 Recycled Asphaltic Concrete Mixes
10.2.3.1 Job Mix Formula Proposal
10.2.4 Equipment
10.2.4.1 Asphalt Sprayer
10.2.4.2 Aggregate Spreaders
10.2.4.3 Pneumatic Rollers
10.2.5 Application Rates For Asphaltic Material
10.2.8 Construction
10.2.8.1 Surface Preparation For Asphaltic Surface Treatments
10.2.8.2 Application Temperatures For Asphaltic Material 10.2.8.3
Calibration And Adjustment Of The Distributor 10.2.8.4 Production
Start-Up Procedures For Surface Treatment 10.2.8.5 Procedures For
Pre-Coating
10.2.8.6 Procedures For Applying Asphaltic Materials 10.2.8.7
Procedures For Spreading Aggregate Screenings 10.2.8.8 Adding
Asphaltic Material And Aggregate Screenings 10.2.8.9 Correction Of
Defects
10.2.8.10 Calculation Of Asphalt Content And Aggregate
Gradation
10.2.9 Surface Maintenance And Facility Protection
10.2.11 Measurements
10.2.12 Payment
10 .3
Slurry Seal And M icro-Surfacing

10.3.1 Description
10.3.2 Materials
10.3.4 Equipment
10.3.4.1 Slurry Seal/Micro-Surfacing Mixing Machine 10.3.4.2
Slurry Seal/Micro-Surfacing Spreading Machine 10.3.5 Weather
Limitations
289
289
290
290
290
291
291
291
291
291
292
292
293
293
294
294
294
294
295
295
295
295
297
297
297
298
298
299
299
300
300
300
301
301
302
302
303
303
303
304
304

10.3.7 Construction
10.3.8 Surface Skid Resistance
10.3.9.1 Quality Control Procedures 10.3.9.2 Quality Assurance
Procedures 10.3.10 Measurements
304
304
305
10.3.11 Payment
10.4 Fog Seal
305
306
10.4.1 Description
10.4.2 Materials
10.4.4 Equipment
10.4.5 Construction
10.4.5.3 Test Sections
10.4.5.4 Application Of Asphalt Material And Blotter Sand
10.4.5.5 Maintenance Of Fog Seal Layer
10.4.6 Traffic Control 10.4.7
Weather Limitations 10.4.8
Work Acceptance
10.8.9 Measurements
10.4.10 Payment
306
306
306
306
306
306
306
307
307
307
307
307
308
308
308
308
309
Division 10 - Surface Treatments
DIVISION 10
SURFACE TREATMENTS
10.1 Scope:
This Division consists of furnishing and construction surface treatments using
asphalt or asphalt-aggregate mixes for less than twenty-five (25) millimeter layers. It
specifies the requirements for materials, equipment, and construction methods. Surfaces
treatments usually don not increase the structural adequacy of the pavement, but they
provide protection to it. Surface treatments are prepared in central mixing plants or mixed
directly on roads.
Surface treatments are used for: seal coat for low volume roads of less that one
hundred (100) vehicles per day, seal coat for roads in remote areas which is difficult to
have central plants, provide temporary asphalt layer over a new asphalt base course,
provide a skid resistant surface, provide tack coat between asphaltic concrete layers,
provide water-proof layer over the asphaltic layers, rejuvenate old asphalt surfaces, seal
pavement cracks, and as dust palliative. This Division contains the following surface
treatments:
1.
Prime coat: It shall be constructed according to Section 8.3 in these General
Specifications.
2.
Tack coat: It shall be constructed according to Section 8.3 in these General
Specifications.
3.
Single and multiple surface treatments.
4.
Slurry seal/Micro-surfacing.
5.
Fog seal.
10.2 Single and Multiple Surface Treatments:
10.2.1 Description:
This Section consists of placing single or double applications of asphaltic material
and aggregate screenings over a stable surface which capable to the expected traffic. This
surface may be base or subbase layers or existing road surface.
10.2.2 Materials:
Asphalt Materials: It shall be one of the following:
1.
Asphalt cement (modified or unmodified) of 40/50 or 60/70 penetration grade
conforming to the quality requirements specified in Table (7.2.1) in these General
Specifications. When asphalt modifiers are used, they shall conform to the quality
requirements specified in Item 7.2.4.
2.
Liquid asphalt of rapid curing type RC-800 or RC-4 conforming to the quality
requirements specified in Table (7.2.3.A) and (7.2.3.B), respectively in these
General Specifications.
3.
Emulsified asphalt of rapid setting type RS-2 or CRS-2 conforming to the quality
requirements specified in Table (7.2.4) and (7.2.7), respectively in these General
Specifications.
289
Aggregate: unless stated otherwise in the Special Specifications or Contracts Documents,

it shall conform to the gradation requirements specified in Table (7.3.7) and shall conform
to quality requirements specified in Tables (7.3.1) (type 8) in these General
Specifications.
M in era l Filler: Mineral filler shall conform to the requirements specified in Item 7.3.4 in
these General Specifications.
Pre-coating A ggregates Materials: The proportion of adhesion agent used is generally one
(1) percent by volume of the asphaltic materials used in treatment. Materials used for
pre-coating aggregate to promote adhesion may be one of the following types:
1.
Asphalt based materials include medium curing cutback (MC) asphalt and
special refinery prepared cutback asphalt which may include an adhesion agent.
2.
Oil based materials for pre-coating usually comprises an adhesion agent
dissolved in petroleum oil such as distillate, or kerosene, or water.
10.2.3 Recycled Asphaltic Concrete Mixes:
10.2.3.1 Job Mix Formula Proposal:
A proposed Job Mix Formula (JMF) shall be formulated by the Contractor and
submitted to the Ministry for approval at least thirty (30) days before producing the
asphaltic surface treatment. The information shall include, but not be limited to the
following:
1.
The source or sources and gradation of the aggregate for each mix to be furnished.
2.
The source or sources of the asphaltic materials for each mix to be furnished.
3.
Original test data and a written certification signed and stamped by the
Contractor, that the aggregates to be furnished conforms to all of the quality
requirements.
4.
Original test data of the type and properties of the asphalt materials with a written
certification signed and stamped by the Contractor.
5.
The proposed beginning date for producing asphaltic surface treatment mixes.
6.
List of all equipment to be used in constructing surface treatments
7.
Supply the adequate amounts of aggregates, asphalt materials for checking
purposes.
The Ministrys representatives shall be provided access to the materials sampling and
testing operations at all times.
The Ministry the JMF and all related matters, submitted by the Contractor
according to the following steps:
1.
Contractor submits a JMF proposal as described above.
2.
The Ministry shall review the JMF to assure that it contains all requirements. If it
does not contain all required information, it shall be returned within seven (7) days
to the Contractor for further action and resubmission by the Contractor.
3.
If the proposed JMF contains all required information but fails to meet all of the
requirements specified, it shall not be accepted by the Engineer and will be
returned to the Contractor within fourteen (14) days. The Contractor shall prepare
and submit to the Ministry a revised JMF conforming to the requirements
specified.
290
4. The fist-day work shall be considered as a field control strip. It shall be assured that
mix is constructible. The Contractor shall not start the work without written
acceptance fro the Engineer according the first-day work.
The Contractor shall not alter the methods of manufacturing, screening, mixing,
stockpiling of aggregate, or production of asphalt mixtures since this alteration will
mandate evaluation of JMF.
Changing JMF shall not be permitted without retesting and resubmission of a proposed
(revised) JMF in accordance with all the steps in Sub item 8.6.3.1 in these General
Specifications.
10.2.4 Equipment:
The Contractor shall furnish suitable equipment with the skilled trained technical
staff to operate and execute the surface treatment work. This equipment shall include
power brooms, suitable aggregate spreader, rollers, heating equipment, and asphalt
sprayers. The number and the production capacity of this equipment shall be within the
Contract time in accordance with his Program of Work as approved by the Engineer. This
equipment shall be, but not limited to, the following:
10.2.4.1 Asphalt Sprayer:
The asphaltic material shall be applied using a truck-mounted distributor capable
of spraying evenly heated asphalt through an adjustable full circulation spray bar. It shall
also have precise controls including tachometer, thermometer, pressure gage, and volume
measuring device on calibrated tank to uniformly deposit asphalt over the full width at the
required rate. Prior to beginning any work specified in this Section, and at all times during
the performance of the work, the Contractor shall demonstrate, in the presence of the
Engineer, that the distributor spray bar has been maintained and adjusted so that the
nozzles provide a true triple lap without ridges or voids, that all nozzles are functioning as
intended and that the distributor is capable of applying asphaltic material within
eight-hundredth (0.08) liters per square meter of the specified rate.
10.2.4.2 Aggregate spreaders:
Aggregate spreaders shall be self-propelled and capable of spreading aggregate
uniformly to full lane widths.
10.2.4.3 Pneumatic Rollers:
Rollers shall be light self-propelled pneumatic-tired and two-axle smooth-drum
tandem steel rollers. The light self-propelled pneumatic-tired rollers shall be constructed
so that they may be loaded to provide a gross weight of at least forty (40) kilograms per
centimeter of width of tire tread. The tires on the front and rear axles shall have wide
smooth treads and shall be staggered to provide complete coverage of the entire area over
which the roller travels. The tires shall be inflated to a pressure that has been approved by
the Engineer and the pressure shall be reasonably uniform in all tires. The Contractor shall
provide a suitable gauge for determining air pressure in the tires.
10.2.5 Application Rates for Asphaltic Material:
The exact application rates shall be directed by the Engineer which, in his judgment, will
provide the results contemplated by the specifications. Tables (10.2.1)
291
and (10.2.2) shows the application rates specified for single and multiple surface
treatments.
Table 10.2.1: Application rates for single surface treatment materials
Type and grade of
asphaltic material
RC-800 (RC-4)
RS-2, CRS-2
RC-800 (RC-4)
RS-2, CRS-2
Asphaltic layer
final thickness,
(mm)
Asphaltic
rate
(liter/m 2)
Aggregate
gradation
(Table 7.3.7)
Aggregate rate
(Kilogram/m 2)
12
12
16
16
1.5-2.0
1.6-2.2
1.8-2.3
2.0-2.5
3
3
2
2
14-18
14-18
20-28
20-28
Table 10.2.2: Application rates for multiple surface treatment materials

Type and grade of
asphaltic material
Asphaltic layer
final thickness,
(mm)
First application
Second application
25
First application
Second application
25
Asphaltic
rate
(liter/m 2)
RC-800 (RC-4)
1.1-1.8
1.6-2.1
RS-2, CRS-2
1.2-1.9
1.8-2.3
Aggregate
gradation
(Table 7.3.7)
Aggregate rate
(Kilogram/m 2)
1
4
20-28
12-16
1
4
20-28
12-16

Asphaltic material shall not be sprayed during sand or dust storms, rainfall, or
before any imminent storms that might damage the construction. Following shall be
considered before spraying asphaltic materials:
1.
The air and surface temperature shall be at least fifteen (15) degrees
Celsius.
2.
The air temperature shall be at least twenty (20) degrees Celsius when falling and
the wind shall be less than ten (10) kilometers per hour.
3.
No asphaltic material shall be applied which cannot be covered with aggregate
screenings one hour before darkness.
4.
The Engineer may require the Contractor to delay application of asphaltic
material until the atmospheric and roadway conditions are satisfactory.
The Contractor shall take effective action to prevent all traffic from using the
asphaltic surface treatments surfaces until such time as the Engineer has given approval
for traffic to use the pavement. All traffic control work shall be done in accordance with
the Manual of Traffic Control through Work Zones issued by the Ministry of
Municipalities and Rural Affairs in 1421H (2001). When the roadway being paved is
open to traffic, the following additional requirements shall apply:
1.
The Contractor shall assure the safety and convenience of public traffic and protect
the residents and property owners adjacent to the project during all asphaltic surface
treatment operations. He shall erect and maintain signs, barricades, and other traffic
control devices and shall take effective action to exclude traffic of any description
from the roadway surface for as long as may be required in the judgment of the
Engineer.
2.
When traffic is restricted to a one-way basis, the Contractor shall provide such
flagmen and pilot cars as deemed necessary for the protection of traffic and the
292
treated surface. Traffic may be detoured around the construction in conformance

with detailed detour plans including layout, signing, marking and other traffic
control devices approved by the Engineer. Detours shall be properly constructed and
maintained throughout the period traffic uses the detour. When it is necessary to
provide for traffic across the asphaltic surface treatment, the crossing shall be blotted
with sand to the extent approved by the Engineer before the crossing is opened to
traffic.
3. While construction of a asphaltic surface treatment is in progress, the treated surface of
the roadway shall not be used by the Contractor, his agents or others until the
Engineer is satisfied that the treated surface will not be damaged by traffic and has
given approval for traffic to use the treated surface.
10.2.8 Construction:
10.2.8.1 Surface Preparation for Asphaltic Surface Treatments:
Treated Surfaces:
The existing treated surface shall be swept with a rotating broom until the surface
is free from dust, dirt or other deleterious material.
Surface holes and depressions of high severity, according to Distress Manual issued by
the Ministry of Municipalities and Rural Affairs in 1424-1425H, shall be patched. Holes
two (2) centimeters in depth or more shall be patched asphaltic concrete materials used in
the asphaltic wearing course, while holes less than two (2) centimeters in depth shall be
patched with multiple applications of asphaltic material and aggregate screenings. The
holes and depressions shall be swept clean, a tack coat applied and patching completed.
Patching work shall be completed at least seven (7) days prior to beginning application of
the asphaltic surface treatment.
When shown on the plans, specified in the Special Specifications or directed by
the Engineer, reshaping the roadway cross section and reducing the depth of longitudinal
sags shall be accomplished by pre-leveling with asphaltic concrete wearing material in
accordance with the requirements in Section 8.5 in these General Specifications.
All areas patched and pre-leveled with asphaltic concrete wearing course material,
after completion of compaction, shall receive a fog seal (Section 10.4 in this Division),
diluted with additional water as approved by the Engineer, and applied at an undiluted rate
between 0.20 and 0.50 liters per square meter.
Untreated Surfaces:
The surface to receive an asphaltic surface treatment, immediately prior to the first
application of asphaltic material, shall conform to the specified compaction and surface
elevation tolerance and be free of organic and other deleterious material.
A prime coat and tack coat shall be applied in accordance with the requirements of Sections 8.3
and 8.4 in these General Specifications, where a prime coat is applied it shall be allowed to cure
for a minimum period of forty-eight (48) hours before proceeding with a second application of
asphaltic material.
293
10.2.8.2 Application Temperatures for Asphaltic Material:

Asphaltic materials shall be heated to a uniform temperature as directed by the
Engineer within the limits shown in Table (10.2.3).
Table 10.2.3: Recommended temperature limits for spraying asphalt materials

Asphaltic material type
and grade
RC-800 (RC-4)
RS-2, CRS-2
All Grades
Distributor spraying temperature, Degree Celsius

Minimum
Maximum
Liquid asphalt
95
125
Emulsified asphalt
50
85
Asphalt cement
180 or below that at which
130
fogging occurs
10.2.8.3 Calibration and Adjustment of the Distributor:

At the beginning of each day's operations, the Contractor shall make checks,
tests, and calculations as necessary to confirm that the application rate is uniform and
within five (5) percent of the specified rate, at all points across the roadway width and
for at least three hundred (300) meters in length. The information collected shall be
reported to the Engineer in writing. The Contractor shall also calibrate the asphalt
distributor spray bar height, nozzle angle and pump pressure and check contractual and
transverse spread rates weekly according to ASTM D-2995.
10.2.8.4 Production Start-Up Procedures for Surface Treatment:
The Contractor shall provide seven (7) calendar days advance notice before
constructing all asphalt surface treatments. The following start-up procedures shall be
repeated when resuming production after work has been terminated due to
non-conformance or any other reason.
On the first day of production, the contractor shall construct a one hundred fifty
meter (150) long control strip that is one lane wide. The control strip shall be located on
the project as designated to confirm the application rates and execution method using
materials, placement and compaction procedures intended for the remainder of the
surface treatment. Production shall cease after construction of the control strip until the
material and the control strip are evaluated and accepted. Acceptable control strips may
remain in place and will be accepted as a part of the completed surface treatment.
10.2.8.5 Procedures for Pre-coating:
is freshly pre-coated with oil-based materials the fluid pre-coating material
tends to cut back the binder in contact with the aggregate and the reduction in viscosity
lessens the ability of the binder to hold the aggregate. This effect, which is accentuated by
over pre-coating, usually applies for a short time, during which instability or stripping can
occur.
When cutback asphalt is used for pre-coating it is an advantage to allow it to dry on the
aggregate before being used. To achieve this, pre-coating should be done at least
294
one (1) week before use but it may be done up to about two (2) months before the
aggregate is used providing that dust is not blown over the stockpile thus reducing the
effectiveness of the pre-coating. For oil-soluble material the usual procedure is to mix the
required quantity of adhesion agent with the appropriate amount of oil by circulating in a
tank. When the adhesion agent is either in a paste or solid form it will be necessary to
melt the agent before mixing. Under cold conditions it may be necessary to warm the oil.
Complete dispersion of the adhesion agent throughout the oil is essential. Following steps
shall be followed in pre-coating process:
1.
Prepared pre-coating materials are supplied in drums or bulk and need no further
preparation in the field.
2.
Aggregate shall be pre-coated when it is completely dry, and stockpiles away
from moistures after pre-coating.
3.
Safety precautions shall be strictly followed when dealing with adhesion agents
may be injurious to health and gloves and eye shields should be worn at all times
by personnel handling these materials. Manufacturers directions an guidelines
shall be followed.
4.
Adhesion agents may settle out after some time in solution. Containers should be
checked regularly and agitated if necessary.
5.
If pre-coating is to be fully effective, all aggregate particles must be completely
but thinly coated. The quantity needed to obtain this result will vary with the
nature of the aggregate, the efficiency of the pre-coating methods, the absorptive
properties of the aggregates, the amount of moisture and dust present, and the type
of pre-coating material. Generally four (4) to twelve (12) liters per cubic meter
will be necessary. The pre-coating material is usually applied as a fine spray on a
moving stream of aggregate.
6.
Normally the aggregate shall be stockpiled and checked for quantity and quality
some time before being used. Immediately before the work commences, a check
on the aggregate should be made to see if further pre-coating or other treatment is
necessary.
In some areas aggregate is pre-coated at the crushing site by running the freshly
crushed and screened aggregate through a pugmill fed with a asphalt-based pre-coating
material.
10.2.8.6 Procedures for Applying Asphaltic Materials:
Asphaltic material shall be applied at the specified rates upon the prepared surface
using asphalt distributors. Areas missed during the application of asphaltic material shall
be immediately covered using the hand held nozzle and the same type and grade of
asphaltic material. The area covered with asphaltic material shall be no larger than can be
covered with aggregate within five (5) minutes from the time of application on any part of
the roadway.
Where application of asphaltic material begins at the end of a previous
application of asphaltic material, and when directed by the Engineer, the Contractor shall
cover the full width of the end of the previous application with building paper at least
eighty (80) centimeters wide. The application of asphaltic material shall begin on the
paper when the distributor is advancing at a speed that provides for uniform distribution
of the asphaltic material. The building paper shall be removed before application of
aggregate screenings begins.
295
10.2.8.7 Procedures for spreading Aggregate Screenings:

After the asphaltic material has been evenly spread over the roadway surface,
aggregate of the grading specified shall be evenly applied to the roadway surface by a
self-propelled spreader box.
The aggregate shall be spread in one operation on one-half of the roadway in such
a manner that a twenty (20) centimeters strip of asphaltic material is left exposed along
the center line of the roadway. Where necessary, thin or open spots in the spread of
aggregate shall be corrected by hand spreading or by other methods as may be approved
by the Engineer.
As soon as the aggregate has been spread on the first one-half of the roadway, it
shall be rolled as directed by the Engineer with self-propelled pneumatic-tired or
smooth-drum steel rollers. The aggregate shall be rolled at speeds not in excess of seven
(7) kilometers per hour in such a manner that the aggregate surface receives three (3)
complete coverage. All rolling on any area shall be completed within thirty (30) minutes
after the aggregate screenings were applied.
After the application of asphaltic material and aggregate to the first half of the
roadway, the remaining half shall be prepared and treated in the same manner as
described for the first half. Where there is an excess of aggregate, it shall be distributed
evenly over the adjacent roadway or picked up by shoveling into trucks.
Where specified, subsequent applications of asphaltic material and aggregate shall
proceed as directed by the Engineer. When multiple applications of asphaltic material and
aggregates are specified, no one application of aggregate shall precede a second
application of aggregate by more than two thousand (2000) meters.
When the final application of aggregate has been placed over any length of the
full-width of roadway, rolled as specified and inspected by the Engineer, it shall be
broomed to remove excess aggregate. When traffic is allowed to use the completed
surface treatment, it shall be broomed for five days following application of the
aggregate, as directed by the Engineer, to reduce the detrimental effects from free
aggregate particles.
Trucks hauling aggregates shall operate in a manner and at reduced speeds so that
no damage is done to the surface treatment, as determined by the Engineer.
10.2.8.8 Adding Asphaltic Material and Aggregate Screenings:
If the application of asphaltic material or aggregate screening, or both, placed on
any portion of the roadway is insufficient for the required results, the Engineer may direct
the Contractor to make additional applications of one or all materials in accordance with
these specifications.
10.2.8.9 Correction of Defects:
All areas unsprayed by the distributor or damage to the treated surface of any
application shall be immediately repaired by hand patching. Holes which develop in the
surface shall be repaired in a similar manner. All costs incurred in making said repairs
shall be at the Contractor's expense.
296
Defects such as raveling, bleeding of asphaltic material, lack of uniformity, or

other imperfections caused by faulty workmanship or materials shall be corrected as
directed by the Engineer and new work shall not be started until such defects and the
causes of the defects have been remedied.
All improper workmanship and defective materials shall be removed from the
roadway by the Contractor and replaced with approved materials and workmanship at the
Contractor's expense. The removed materials shall be disposed of as specified in Division
5 in these General Specifications.
10.2.8.10 Calculation of Asphalt Content and Aggregate Gradation:
The uniformity and rate of application of asphaltic material at locations selected by
the Engineer is tested using test pads that shall consist of three (3) pieces of building
paper each thirty (30) centimeters by sixty (60) centimeters attached to plywood strips
sixty (60) centimeters by ninety (90) centimeters by one and one-quarter (1.25)
centimeters, or other materials as may be approved by the Engineer. The building paper
shall be weighed accurately before being attached to the plywood strips. Testing shall be
done as follows:
1. The sixty (60) centimeter by ninety (90) centimeter by one and one-quarter (1.25)
centimeters plywood strips and building paper shall be placed at three (3) randomly
selected roadway locations for each five thousand (5,000) square meter lot of surface
treatment to be placed. The distributor shall apply asphaltic material to the test pads
during routine operations. Placement of screenings shall proceed as specified.
2. After collecting the asphaltic material, the building paper shall be carefully removed
from the plywood strips and weighed. The rate of application on each thirty (30)
centimeter by sixty (60) centimeter test pad shall be within ninety and one hundred
ten (90 and 110) percent of the approved rate.
Aggregate gradation shall be tested by taking five (5) samples from the spreader
discharge at random intervals during the construction of each one thousand (1,000) square
meter or a one-day work, whichever minimum. The sample shall be tested immediately
and the results reported to the Engineer.
10.2.9 Surface Maintenance and Facility Protection:
The Contractor shall maintain completed surface treatments and all damage
resulting from any cause shall be repaired by the Contractor at his expense within the first
year from project completion and before the final acceptance of the executed work. All
bridge handrails, curbs, road signs or other facilities shall be protected from splashing of
the asphaltic material. The Contractor shall immediately remove asphaltic material from
said facilities. Protection and cleaning shall be accomplished at the Contractor's cost.
The Contractor shall apply quality control procedures for all asphaltic surface
treatments works to ensure that the materials used and the executed work conform to
these General Specifications and other Contracts Documents. The Ministry shall assure
the quality of production by checking that the Contractor is performing the quality
control procedures in correct manners. The Ministry may have a direct supervision on
the quality control system or by applying quality assurance procedures in an independent
unbiased way, on adequate number of samples to judge the execution level
297
and decide whether to accept or reject the work. Division 17 in these General
Specifications shall be used for this purpose, unless stated otherwise in the Special
Specifications or Contracts Documents.
at source, materials while work execution, asphaltic surface treatments produced, and the
executed work are within acceptable limits. The tests may be performed at The
Specifications.
supervision, some or all quality control tests that are shown previous Subitem. The
Ministry has also the right to inspect all Contractors' quality control test records and
compare them with its quality assurance test done according to Division 17 in these
General Specifications. Ministry may inspect Contractor's laboratory, devices, technical
staff, and testing methods to assure the full adequacy and capability of the Contractor to
execute the work according to standard approved methods.
Table 10.2.4: Quality control requirements for surface treatments

Work
Properties
Asphalt
materials
Aggregates
Raw
materials
Pre coating
materials
Mineral
Filler
Aggregate
gradation
Test Method
Quality
requirements
tests
Quality
requirements/
Gradation
Quality
requirements
tests
Quality
requirements
tests
Sample
location
supply and source change
Sub item
10.8.8.10
Section 7 2
Three (3) tests at start of work or

source change
Tables 7.3.1
and 7.3.7
Certification of compliance and

Item 10 2 2

Project
site
Asphalt
content
Requirements
Source
AASHTO T164/T-27
Material at
use
Sam pling frequency

one random samples at material

discharge every one thousand (1000)
square meters from the completed
work
One (1) test every discharge every two
thousand (2000) square meters from
each completed layer or a day work
Item 7 3 4
JMF
requirements
JMF
requirements
298
Each type of asphaltic surface treatment specified and completed within the lines
shown on the plans or ordered by the Engineer shall be measured in square meters surface
treatment placed outside authorized limits shall not be measured for payment purposes.
Mineral fillers, chemical admixtures and asphalt modifiers used by the contractor to
meet the Job Mix Formula (JMF) requirements will be considered subsidiary to the
construction of the asphaltic surface treatments and will not be measured separately unless
specifically stated in the Special Specifications and listed in the Bill of Quantities. When
they are listed in the Bill of Quantities and specified in the Special Specifications they
shall be measured in liters, kilograms, or tons.
Pre-coating aggregates shall be measured by square meter and include the areas
where the aggregates were acceptably pre-coated with asphalt cement and incorporated
into the asphaltic surface treatment when pre-coating is required by the Special
Specifications and listed in the Bill of Quantities.
Asphaltic wearing course material furnished and placed for reshaping the roadway
cross-section as shown on the plans, specified or directed by the Engineer shall be
measured in cubic meters in accordance with the methods described in Section 8.5 in
these General Specifications unless otherwise considered subsidiary to the construction of
the asphaltic surface treatments.
10.2.12 Payment:
Payment shall be made at the contract unit price, or adjusted contract unit price, per
square meter measured as described in the pervious Item for each grading and class of
surface treatments listed in the Bill of Quantities.
labor, materials, equipment, tools and incidentals necessary for completing all work
involved in construction of asphaltic concrete pavement. Payment will be made according
to items shown in Table (10.2.5), unless stated otherwise in the Special Specifications or
Contracts Documents.
Table 10.2.5: Surface treatments pay items

No.
10.2.1
10.2.2
10.2.3
10.2.4
Pay Item
Single surface treatment
Multiple surface treatments
Aggregate pre-coating
Surface preparation and correcting defects
Pay units
Square meter
Square meter
Square meter
Square meter
299
10.3 Slurry Seal and Micro-Surfacing:

10.3.1 Description:
This Section consists of mixing emulsified asphaltic material, aggregate, water
and specified additives and spreading the mixture on a clean surface after filling cracks
and holes (if any) within the lines shown on the plans, as specified in these
specifications and the Special Specifications, and as directed by the Engineer: The
slurry seal is used in preventive and corrective maintenance of asphaltic pavements.
When used in old pavements, it closes cracks effectively, stops the disintegration, proofs
water, and promotes skid resistance. The slurry seal is executed in three (3) to six (6)
millimeters depth. There are three types of slurry seal according to the aggregate
gradation shown in Table (7.3.6), in these General Specifications and according to the
asphalt residue in the mix. These types are shown in Table (10.3.1).
Table 10.3.1: Asphalt residue in slurry seal mixes
Slurry seal type
Type I (gradation 1)*
Type II (gradation 2)*
Type III (gradation 3)*
Percent of asphalt residue by

weight of the total mix
10-16
7.5-13.5
6.5-12
(*) From Table (7.3.6)
Micro-surfacing surface treatment is produced by modifying the emulsified

asphalt by polymer. Micro-surfacing is used for pavements that require quicker opening
to traffic than the normal slurry seal mixes.
10.3.2 Materials:
Asphalt Materials: It shall be an emulsified asphalt of type SS-1h, CSS-1h, QS-1H, or
CQS-1H conforming to quality requirements specified in Tables (7.2.6) and (7.2.7) in
these General Specifications. The polymer-modified emulsified asphalt of type CSS-1h is
used to produce micro-surfacing mixes.
Aggregate: It shall be according to the slurry seal type (I, II, or III) conforming to
gradation requirements specified in Table (7.3.6) (gradations 1, 2, and 3), and shall
conform to the quality requirements specified in Table (7.3.1) (Type 7) in these General
Specifications. Gradations 1 and 2 are used to produce micro-surfacing mixes, which
shall conform to the quality requirements shown in Table (10.3.2).
Table 10.3.2: Quality requirement for micro-surfacing aggregate
Test
Los Angeles Abrasion Test, Max. (percent)
Sand Equivalent. M in. (percent)
Soundness. (percent) by:
Sodium Sulfate:
Magnesium Sulfate , Max:
Test method
AASHTO T-96
AASHTO T-176
AASHTO T-104
Requirement
30
65
15
25
300
Water: Water shall be of such quality that the asphaltic material will not separate from the
emulsion before the slurry seal is in place in the work.
M in era l Filler: Mineral filler shall conform to the requirements specified in Item 7.3.4 in
Chemical Admixtures and Asphalt Modifiers: The types and amounts of chemical
admixtures/asphalt modifiers used shall be limited to those listed in the Special
Specifications or proposed by the Contractor and approved by the Ministry. They shall
conform to the requirements specified in Table (7.2.4) in these General Specifications.
The Contractor shall prepare a technical report about JMF according to ASTM
D-3910 by a qualified and a Ministry authorized laboratory and not less than fourteen (14)
days before the work is scheduled to commence. The report shall detail the mix design
covering the specific materials and proportions of each to be used. The Contractor shall
also furnish to the Engineer samples of each of the materials to be used, sufficient to
produce fifty (50) kilograms of slurry seal mixture. The Engineer will make additional
tests at his option. When the Engineer is satisfied with the materials to be used, the
mixture proportions and the test results, he shall notify the Contractor in writing of his
approval of the mix design.
Slurry seal shall conform to the quality requirements shown in Table (10.3.3).
The laboratory shall report the quantitative effects of moisture content on the unit
weight of the combined aggregates. The mix proportions shall include:
1. Type pf asphalt material to be used.
2. Percent by dry weight of aggregate.
3. Maximum and minimum quantity of mineral filler (if used) as a percent of the dry
weight of aggregate.
4. Maximum and minimum quantity of water as a percent of the dry weight of
aggregate.
5. Quantity of emulsified asphaltic material as a percent of the dry weight of
aggregate.
6. The type and quantity of mineral fillers and/or chemical admixtures/asphalt
modifiers to be used.
The mixture shall be capable of uncontrolled traffic no more than three (3) hours after
placement. The mixture shall not exhibit bleeding, raveling, separation, or other distress.
10.3.4 Equipment:
The Contractor shall furnish suitable equipment, tools, and devices to design, test,
and execute the slurry seal/micro-surfacing work within the Contract time in accordance
with his Program of Work as approved by the Engineer. The equipment shall always be in
good operational conditions. This equipment shall include the following:
301
Table 10.3.3: Quality requirements for slurry seal/micro-surfacing mixes

Requirements
Test
Slurry Seal Consistency, millimeter
Wet-track Abrasion Loss, gram per
square millimeter, Maximum
Excess Asphalt, gram per square
millimeter
Wet Stripping Test
Compatibility at minimum temperature
Quick Set Emulsion
Wet Cohesion, kg-cm, maximum
Displacement, Max. (percent)
Classification Compatibility, Minimum
Test Method
ISSA(*) TB-106
ISSA TB-100 (**)
ISSA BT-109 (**)
ISSA TB-114
ISSA TB-115
ISSA TB-102
Slurry seal
Micro-surfacing
20-30
One hour = 540

Six days = 810
800
500-700
540 Max
Pass
Pass
Pass
Pass
After 30 min. = 12
After 60min. = 20
Lateral = 5
Vertical = 10
11 classification points
ISSA TB-139
ISSA TB-147
ISSA TB-144
(*) ISSA: International Slurry Seal Association

(**) Tests ISSA TB-109 and TB-100 are used to determine optimum asphalt content. In lieu of these test, the Ministry
may require the use of a modified Marshall Stability Test (ISSA TB-140) or Hveem Cohesionmeter Test (ASTM
D 1560) to determine optimum asphalt content.
10.3.4.1 Slurry seal/Micro-surfacing Mixing Machine:

The slurry seal/micro-surfacing mixing machine shall conform to the following
requirements:
1.
It shall be a self-propelled continuous flow mixing unit. The mixing unit shall be
capable of proportioning emulsified asphaltic material, water, aggregate and
additives by volume.
2.
Each feeder unit shall be calibrated at different gate settings for each
slurry-mixing units used in the work. The Contractor shall be provide balances for
weighing the aggregate, water, and emulsified asphaltic material so that the
accuracy of the pumps and feeder units may be checked at daily intervals during
the production of slurry seal/micro-surfacing.
3.
The slurry seal/micro-surfacing machine shall be capable of proportioning and
mixing individual materials within the following tolerances:
Emulsified asphaltic material content approved by the Ministry is within
plus or minus one (1) percentage point
The percent of aggregate passing each specified sieve shall not vary more
than plus or minus four (4) percent from the approved job mix formula.
The percent of aggregate passing each sieve shall not go from the high limit
to the low limit for any two (2) successive sieves.
The slurry consistency (ISSA TB-106) shall not vary more than five (5)
millimeters from the approved mix design after field adjustments approved by
the Engineer.
10.3.4.2 Slurry Seal/Micro-surfacing Spreading Machine:
The spreader machine shall conform to the following requirements:
1. It shall be equipped with a box connected to the mixing machine to prevent loss of
slurry mixture along all sides and have a flexible strike-off rubber belt. The
spreader box shall be capable of placing a uniform surface over the width of one
lane. It shall have a means for adjusting to deviations in the
302
2.
3.
pavement surface being sealed. Replacement flexible strike-offs shall be

available at all times during the placement of slurry seal/micro-surfacing.
The spreading machine shall be capable of spreading the specified rate of
slurry materials within a tolerance of plus or minus fifteen (15) percent of the
dry aggregate weight.
The spreading device shall be kept clean and build-up of slurry materials shall
not be allowed.

Slurry seal/micro-surfacing shall not be mixed or placed when the temperature of
the surface on which the slurry seal/micro-surfacing is to be placed is less than fifteen (15)
degrees Celsius. Slurry seal/micro-surfacing shall not be placed during dust or sand
storms, when there is a chance for rain within two (2) hours or when freezing may occur
within twelve (12) hours.
All traffic control work shall be done in accordance with the Manual of Traffic
Control through Work Zones issued by the Ministry of Municipalities and Rural Affairs
in 1421H (2001). No traffic shall be allowed on the slurry seal for at least three (3) hours
after placement, while the surface may be opened to traffic only one (1) hour after the
micro-surfacing layer is placed.
Slurry seal/micro-surfacing shall be placed in the following steps:
1. The surface to be slurry sealed or micro-surfaced shall be thoroughly cleaned by
brooming, blowing with high-pressure air or with a suitable vacuum. The
distresses in this surface (if any) such as cracks shall be repaired before covering
the surface.
2. When specified in the Special Specifications, a tack coat consisting of SS-1h or
CSS-1h emulsified asphaltic material mixed in the proportion of one (1) part
emulsified asphaltic material to three (3) parts water shall be spread at a rate
between two-tenths and four-tenths (0.2-0.4) liters per square meter. The exact rate
shall be determined by the Engineer.
3. The surface to receive the slurry seal/micro-surfacing shall be pre-wetted by
spraying with water at a rate determined by the Engineer. Flowing water in front
of the spreading device shall not be allowed.
4. Slurry seal/micro-surfacing material shall be placed based on dry aggregate weight
within the rates shown in Table (10.3.4). The exact rate shall be as specified in the
Special Specification.
Table 10.3.4: Slurry seal/micro-surfacing application rates
Slurry seal type
Type-I (Gradation 1)*
Type-II (Gradation 2)*
Type III (Gradation 3)*
Materials application rate

(kilograms persquare meter)
Slurry seal
Micro-surfacing
3.3 to 5.4
5.4 to 8.2
5.4-10.8
8.2, or more
8.2-16.3
(*) Table (7.3.6), in these General Specifications.
303
5. The slurry seal/micro-surfacing mixture shall be smooth and homogeneous after

spreading on the surface to be sealed and show no evidence of separation of
aggregate and emulsified asphaltic material after break setting.
6. Hand tools shall be used to remove spillage. Ridges and bumps in the slurry
seal/micro-surfacing surface shall not be permitted. Joints shall be worked with an
appropriate hand operated fabric drag and no excessive build-up of slurry mixture,
uncovered areas or unsightly appearance shall be permitted on longitudinal and
transverse joints.
7. Areas inaccessible to the slurry seal/micro-surfacing mixing and spreading
machine may be slurry sealed using hand operated fabric drags.
10.3.8 Surface Skid Resistance:
The surface received slurry seal/micro-surfacing shall conform to the minimum
requirements of skid resistance. Unless otherwise stated in the Special Specifications, the
minimum acceptable limit of skid resistance according to the International Friction Index
(IFI) of the surface shall be thirty five (35) measured by any equipment approved by the
Ministry and calculated using the ASTM E-1 960.
The Contractor shall apply quality control procedures for all slurry seal/microsurfacing works to ensure that the materials used and the executed work conform to these
General Specifications and other Contracts Documents.
10.3.9.1 Quality Control Procedures:
at source, materials while work execution, slurry seal produced, and the executed work are
within acceptable limits. The tests may be performed at The Contractors laboratory or at
an independent laboratory, approved by the Ministry. The Contractor shall submit copies
of all test results to the Engineer. Table (10.3.5) shows the tests that the Contractor shall
perform on raw materials and mixes, the frequency of these tests, and the allowance
limits. The Contractor shall submit copies of all tests to the Engineers and shall apply all
10.3.9.2 Quality Assurance Procedures:
supervision, some or all quality control tests that are shown previous Sub item.
304
Slurry seal/micro-surfacing shall be measured in square meters for the area upon
which the slurry seal/micro-surfacing was actually placed within the lines shown on the
plans, specified or ordered by the Engineer. Surface preparation in terms of crack
sealing and patching shall be measured in square meters.
10.3.11 Payment:
per square meter measured as described in the pervious Item for each type slurry
seal/micro-surfacing listed in the Bill of Quantities.
The above prices and payment shall cover and be full compensation for
furnishing labor, materials, equipment, tools, and incidentals necessary for completing
all work involved in construction and acceptance of slurry seal/micro-surfacing.
Payment will be made according to items shown in Table (10.3.6).
Table 10.3.5: Quality control requirements for slurry seal/micro-surfacing mixes
Work
Properties
Asphalt materials
Aggregates
Raw
materials
Chemical admixture
and modifiers
Mineral Filler
Aggregate
before
mix
Slurry
seal mix
Gradation (Dry mix)

Los Angeles
Abrasion
Sand equivalent for
passing Sieve No. 4
Soundness, Sodium
or Magnesium
Sulfate
Slurry seal mix
Aggregate gradation
Application rate
Asphalt content
Test Method
Quality
requirements
tests
Quality
requirements/
Gradation tests
Quality
requirements
tests
Quality
requirements
tests
AASSTO T-27
Sample
location
Source
Sam pling frequency

Certification of
and source change
Start of work or source
change
Certification of
and source change
Certification of
and source change
Requirements
Tables 7.2.4
and 7.2.5
Tables 7.3.1
and 7.3.6
Contract
documents
Table 7.3.2
AASHTO T-96
AASHTO T-176
Plant
One (1) test every

month or when the mix
properties change
Quality
requirements
Table 7.3.1
AASHTO T-104
ISSA tests
AASHTO T 164/T-27
Item 10.3.7
Sub item 10.3.3.1
Table 10.3.1
Project
site
One (1) test every

production day
Table 7.3.6
Table 10.3.3
JMF
Table 10.3.6: Slurry seal/micro-surfacing pay items

No.
10.3.1
10.3.2
10.3.3
10.3.4
Pay Item
Slurry seal layer
Micro-surfacing layer
Surface preparation (crack seal)
Surface preparation (leveling and patching)
Pay units
Square meter
Square meter
linear meter
Square meter
305
10.4 Fog Seal:

10.4.1 Description:
This Section consists of constructing the fog deal, materials used, application
rates, and defect repaired in the fog seal surface treatments. Fog seal consists of spraying a
light application of slow setting emulsified asphalt diluted with water over an existing
surface to soften and rejuvenate this surface and seal the cracks in it.
10.4.2 Materials:
Asphalt Materials: It shall be an emulsified asphalt of type SS-1, SS-1h, CSS-1 or CSS-1h
conforming to quality requirements specified in Tables (7.2.6) and (7.2.7) in these
B lotter Sand: It shall be natural sand, manufactured sand, or combinations of both that are
free from organic matter or clay, having a grading consisting of one hundred(100) percent
passing the 4.75 millimeter (No. 4) sieve and not more than five (5) percent passing the
0.150 millimeter (No. 100) sieve.
The approved undiluted application rate shall be determined from test sections
constructed using specified materials with the range of three tenth to seven tenth (0.3 to
0.7) liters per square meter depending on the conditions of the existing surface.
10.4.4 Equipment:
The Contractor shall furnish and operate sufficient equipment to complete the
work within the Contract time in accordance with his Program of Work as approved by
the Engineer.
Equipment shall include rotary type power brooms, asphalt material distributors,
equipment for heating asphalt material, and air compressors.
Asphalt material shall be applied using a truck-mounted distributor capable of uniformly
spraying asphalt material full lane widths. Distributor shall be equipped with controls for
application rates and asphalt temperature.
Immediately prior to application of the fog seal, the surface shall be clean and free
of dust, organic, and other deleterious material.

The asphalt material shall be uniform throughout the distributor tank and be heated
to the application temperatures required. Table (10.4.1) shows recommended heating
temperatures. Prior to spraying, the emulsified asphalt of the types CSS-1h or SS-1h may
be mixed with water by one to one (1:1) ratio or any ratio approved by the Engineer.
306
Table 10.4.1: recommended heating temperatures for fog seal

Material type
CSS-1h/SS-1h
CSS-1/SS-1
Temperature (degrees Celsius)

20 - 70
20 - 70
10.4.5.3 Test Sections:

The Contractor shall construct two (2) test sections with at least three (3) meters
wide by one hundred (100) meters long. Contactor shall establish application rates for fog
seal material based on the following:
On the date scheduled or any day prior to beginning fog seal, the Contractor shall
apply two (2) or more rates of asphalt material to two consecutive test sections. When the
test sections are completed, the fog seal operation shall be halted for a minimum of four
(4) hours to allow the Engineer to assess the suitability of the rates applied. Test sections
receiving insufficient fog seal shall receive an additional application of fog seal; test
sections receiving excess fog seal shall be blotted with sand, when ordered by the
Engineer.
10.4.5.4 Application of Asphalt Material and Blotter Sand:
The asphalt material coverage shall be uniform without streaking or uncoated
spots. When streaking occurs, the application of asphalt material shall cease until
adjustments are made to the distributor and application procedures, which will result in
elimination of streaking. Uncoated spots shall be coated using the hand held nozzle.
Traffic should not be permitted on surfaces which have been fogged until
approved by the Engineer. Fog seal shall be allowed to penetrate undisturbed for at least
two (2) hours until the emulsified asphalt breaks and is substantially absorbed into the
existing surface. Remaining spots of excess asphalt shall be lightly covered with blotter
sand before opening the surface to traffic.
The emulsified asphalt shall be re-heated, if necessary. The heating temperature
shall be more than seventy (70) degrees Celsius after loading the materials to the tanker,
unless approved by the Engineer. Stirring the emulsified asphalt shall be continued to
avoid localized heating.
10.4.5.5 Maintenance of Fog Seal Layer:
When the Engineer feels necessary, and after forty-eight (48) hours, a thin blotter
sand layer shall be sprayed for areas not completely dried.
All traffic control work shall be done in accordance with the Manual of Traffic
Control through Work Zones issued by the Ministry of Municipalities and Rural Affairs
in 1421H (2001). Additionally, the Contractor shall implement the requirements included
in Item 10.2.7 in this Division.
Fog seal shall not be applied to any surface when the air and surface temperature is less
than fifteen (15) degrees Celsius or during rain, dust or sand storms. Smoking,
307
starting fires of any kind, and all safety precautions shall be observed by the staff working
in fog seal sites.
The Contractor shall apply quality control procedures for all fog seal works to
ensure that the materials used and the executed work conform to these General
10.4.8.1 Quality Control :
at source, materials while work execution, fog seal produced, and the executed work are
supervision, some or all quality control tests that are shown previous Sub item.
Table 10.4.2: Quality control requirements for fog seal mixes
Work
Raw
materials
Materials
in use
Properties
Asphalt emulsion
Blotter sand
Graduation
Blotter sand
Fog seal application
rate
Test Method
Quality
requirements
AASHTO T27
When needed
Item 10.4.3
Sam ple
location
Source
Project
Site
Sam pling frequency

and supply and source change
At start of work or source
change
As needed
One (1) test every day
Requirements
Tables 7.2.6
and 7.2.7
Item 2.4.10
As needed
Item 10.4.3
Fog seal shall be measured in square meters for the area upon which the fog seal was
actually placed within the lines shown on the plans, specified or ordered by the Engineer. Blotter
sand shall not be measured for payment purposes.
308
10.4.10 Payment:
per square meter measured as described in the pervious Item for each type fog seal listed
in the Bill of Quantities.
involved in construction and acceptance of fog seal. Payment will be made according to
items shown in Table (10.4.3).
Table 10.4.3: Fog seal pay items
No.
10.4.1
Pay Item
Fog seal layer
Pay units
Square meter
309
DIVISION 11
11.1 Scope
11.2 A sphaltic Concrete Friction Layer
11.2.1 Description Of Work
11.2.2 Materials
11.2.3 Mix Design Requirements
11.2.3.2 Acceptance Procedures Of Job Mix Formula
11.2.4 Equipment
11.2.5 Weather Conditions
11.2.6 Construction
11.2.8 Surface Skid Resistance
11.2.10 Measurement
11.2.11 Payment
11.3 Stone M astic A sphalt
11.3.1 Description
11.3.2 Materials
11.3.3.1 Acceptance Procedures For Job Mix Formula
11.3.3.2 Quality Requirement For Job Mix Formula
11.3.4 Equipment
11.3.5 Construction
11.3.5.1 Mixing Process
11.3.5.3 Hauling The Mix To Project Site
11.3.5.4 Tack Coat
11.3.5.6 Final Thickness Of Pavement Layers
11.3.6 Weather Conditions
11.3.9 Measurement
11.3.10 Payment
313
313
313
313
313
313
313
314
314
314
314
315
315
315
315
315
316
317
317
317
317
318
318
318
319
319
319
320
320
320
320
320
320
321
321
321
311
321
321
Division 11 - Special Asphaltic Works
DIVISION 11
11.1 Scope:
This Division consists of furnishing and construction friction course and stone
mastic asphalt as special asphaltic works needed by some requirements that the asphaltic
concrete mixes detailed in Division 8 can not provide, or when these special works
provide better properties than other asphalt mixes, such as higher skid resistance, better
surface drainage, and higher rutting resistance. These works shall be constructed over an
asphaltic surface course conforming to the roughness requirements.
11.2 Asphaltic Concrete Friction Layer:
11.2.1 Description of Work:
This work consists of furnishing and mixing aggregate and asphaltic material in a
central mixing plant (batch, continuous pugmill or dryer-drum mixing), hauling,
spreading, and compacting the mixture on a prepared surface, as shown on the plans, in
accordance with these specifications and the Special Specifications and as directed by the
Engineer.
11.2.2 Materials:
Asp halt M aterial: It shall be 40/50 or 60/70 penetration grade or any grade specified in
the Special Specifications conforming to quality requirements specified in Table (7.2.1), in
these General Specifications. When the asphalt modifiers are used, they shall conform to
quality requirements specified in Table (7.2.3) in these General Specifications.
Aggregate: unless stated in the Special Specifications or Contacts Documents, the
combined aggregate gradation shall conform to gradation requirements shown in Table
(7.3.8) and shall conform to the quality requirement stated in Table (7.3.1) (type 9) in
M in era l Filler: mineral filler shall conform to the requirement stated in Item 7.3.4 in
C hem ical A dm ixtures and Asphalt Modifiers: The types and amounts of chemical
admixtures/asphalt modifiers used shall be limited to those listed in the Special
Specifications or proposed by the Contractor and approved by the Ministry. When used,
these materials including the anti-striping agents shall be completely mixed with the
asphaltic materials.
11.2.3 Mix Design Requirements:
The Contractor shall submit a technical report containing the
accordance with the requirements of Federal Highway Administration Technical Memorandum
Number (T-5040.31) which shall contain the following:
313
1.
2.
3.
4.
Determination of asphalt content.

Determination of mixing temperature which shall be between seven hundred
and nine hundreds (700-900) Centistokes.
Determination of the percent air voids.
Determination of resistance of the mix to the effect of water as obtained
according to the test methods AASHTO T-182, T-165, and T-167.
11.2.3.2 Acceptance procedures of Job Mix Formula:

The requirements and procedures stated in Sub item 8.5.3.2 shall be applied here
in addition to the requirements stated in previous Sub item. However, the Marshall test is
not required.
11.2.4 Equipment:
asphaltic concrete work within the Contract time in accordance with his Program of Work
as approved by the Engineer. This equipment shall be, but not limited to, the equipment
specified in Item 8.5.4.
11.2.5 Weather Conditions:
Asphaltic concrete friction course shall not be placed on any wet or frozen surface,
during dust or sand storms, when wind or other weather conditions prevent the proper
handling of the asphaltic mixture or when the average temperature of the surface on which
the mixture is to be placed is less than twenty-five (25) degrees Celsius.
The asphaltic surface friction course construction work shall be done according to
Item 8.5.6 with the following amendments:
1.
When discharged from the mixing plant, the temperature of the asphaltic
concrete friction course shall not exceed one hundred thirty-five (135) degrees
Celsius.
2.
Trucks used in hauling asphaltic concrete friction course material shall be
equipped with approved covers for the total area of load. When the air
temperature is less than twelve (12) degrees Celsius and the length of haul
exceeds ten (10) kilometers, asphaltic concrete friction course material shall be
covered.
3.
Asphaltic concrete friction course material shall be dumped directly into the
hopper of a self-propelled paving machine. Dumping directly on the surface shall
not be permitted.
4.
Asphaltic concrete friction course material shall be spread at a temperature not
less than ninety-five (95) degrees Celsius and not more than one hundred twenty
(120) degrees Celsius, measured in the hopper of the paving machine. Asphaltic
concrete friction course shall be spread at a rate between forty-five (45) and sixty
(60) kilograms per square meter as necessary to provide a compacted thickness,
which is not less than eighteen (18) millimeters.
5.
Asphaltic concrete friction course shall be rolled only with a steel-tired, two (2)
axle-tandem roller weighing not less than ten thousand (10,000) kilograms. Initial
or breakdown rolling shall consist of three (3) passes of the layer of asphaltic
concrete friction course and begin immediately after spreading of the material.
Finish rolling shall follow breakdown rolling without delay and continue until the
surface is smooth, without ridges or indentations.
314
6.
7.
All pavement distresses such as cracks, rutting, and bleeding shall be corrected
before applying the friction course.
The old asphaltic layer shall be sprayed by a tack coat as specified in Section
8.4 in these General Specifications, before spreading the asphaltic concrete
friction course.

The Contractor shall take effective actions to permit traffic to safely pass through
asphaltic surface friction course construction work zones as specified in Item 8.5.7 in
11.2.8 Surface Skid Resistance:
Surface of asphaltic concrete friction course shall conform to the minimum acceptable
skid resistance level. Unless specified by Special Specifications, the minimum acceptable
skid number shall be thirty-five (35) according to the International Friction Index (IFI)
when measured by equipment approved by the Ministry and calculated according to
ASTM E-1960.
The Contractor shall apply quality control procedures for all asphaltic concrete
friction course works to ensure that the materials used and the executed work conform to
at source, materials while work execution, asphaltic concrete friction course produced,
and the executed work are within acceptable limits. The tests may be performed at The
Specifications.
executed work by performing or ordering the Contractor to perform, under its direct supervision,
some or all quality control tests that are shown previous Sub item (11.2.9.1). The contractor
must do the all require procedures of Asphaltic concrete friction layer works quality control to
insure that the used materials and construction
315
methods and executing works are satisfying the quality requirements which mention in
these general specification and contract documents.
The Ministry shall assure the quality of production by checking that the
Contractor is performing the quality control procedures in correct manners. The Ministry
may have a direct supervision on the quality control system or by applying quality
assurance procedures in an independent unbiased way, on adequate number of samples to
judge the execution level and decide whether to accept or reject the work according to the
principles details in division (17) in these General Specifications unless stated otherwise in
the Special Specifications or Contracts Documents.
Table 11.2.1: Quality control procedures for asphaltic concrete friction layer
works
Work
Raw
materials
M aterial
at use
Road
Finishing
Properties
Test Method
Asphalt
materials
Aggregates
Sam ple
location
Sam pling frequency
Requirements
Quality
requirements
tests
change
Table 7.2.1
Quality
requirements/
Gradation tests
Start of work or source

change
Quality
requirements in
Tables 7.3.1
and 7.3.8
Source
Chemical
admixture
and
modifiers
Quality
requirements
tests
change
Item No.7.3.4
Mineral
Filler
Quality
requirements
tests
change
Requirement
in the Contract
documents
Aggregate
gradation
Asphalt
content
Skid
resistance
AASHTO T164 / T-27

AASHTO T164 / T-170
Approved
device
one (1) test every one

thousand (1000) square
meters or a day work for
each layer
Mix design
requirements
(Sub item
11.2.3.1)
Skid resistance test for

each working day
Item 11.2.8

twenty-five (25) meters or
five segments every one
thousand (1000) meters,
Requirement
in the Contract
documents
Level,
dimensions,
slopes, and
smoothness
Contract
documents
Project
site
Project
site
11.2.10 Measurement:
Asphaltic concrete friction course specified and completed within the lines shown on
the plans or ordered by the Engineer shall be measured in square meters. Any area paved by
asphaltic concrete friction course outside authorized limits shall not be measured for payment
purposes.
Unless specifically stated in the Special Specifications, all components of asphaltic concrete
friction course including asphalt modifiers and tack coat will be
316
considered subsidiary to the construction of the asphaltic concrete friction course and will
not be measured separately for payment purposes.
11.2.11 Payment:
Payment shall be made at the contract unit price, or adjusted contract unit price, per
square meter measured as described in the pervious Item for asphaltic concrete friction
course when listed in the Bill of Quantities.
involved in construction of asphaltic concrete pavement. Payment will be made according
to Table (11.2.2).
No.
11.2.1
Table 11.2.2: Works Items Asphaltic concrete friction layer

Pay Item
Pay units
Asphaltic concrete friction course
Square meter
11.3 Stone Mastic Asphalt:

11.3.1 Description:
Stone mastic asphalt (SMA) is a hot asphaltic concrete mixture consists of asphalt
binder, crushed fine and coarse aggregates, mineral filler, and stabilizing agent. This SMA
mixture strength relies on stone-to-stone contact in a rich asphalt mortar to provide
durability.
This Section consists of furnishing and mixing aggregate with asphalt materials in
a central mixing plant, haul, spread, and compact the mix on a prepared surface as shown
on the plans, specified in these General Specifications, the Special Specifications, and
other Contract Documents.
11.3.2 Materials:
Asp halt M aterial: unless stated in the Special Specifications or Contact Documents,
asphalt materials shall be 40/50 or 60/70 penetration grade or any grade specified in the
Special Specifications conforming to quality requirements specified in Table (7.2.1), in
these General Specifications. When the asphalt modifiers are used, they shall conform to
quality requirements specified in Item (7.2.4) in these General Specifications.
A g greg ate: It shall be conforming to gradation requirements specified in Table (7.3.9),
and shall conform to the quality requirements specified in Table (7.3.1) (Type 10) in these
M in era l Filler: mineral filler shall conform to the requirement stated in Item 7.3.4 in
Stab ilizin g A gent: Due to the high asphalt content in SMA mortar, a stabilizing additive of
cellulose or mineral fiber shall be used to hold mortar on the coarse aggregate during hauling and
placement. It is used to stabilize the asphalt mortar on the aggregate particles during hauling and
spreading process. Unless specified in Special Specifications, the amount of stabilizing agent
shall be between three to four (3-4)
317
percent of the total weight of the mix. The stabilizing agent shall conform to the
requirements specified in Table (11.3.1) and the related notes.
Table 11.3.1: Quality requirements for fiber stabilizing agent
Property
Sieve Analysis (Method A) ( 1 )
Fiber Length, mm, maximum
Passing sieve No. 100 (0.150 mm), %
Mesh Screen Analysis (Method B) ( 2 )
Fiber Length, mm, maximum
Passing sieve No. 20 (0.850 mm),%
Ash Content, % ( 3 )
PH ( 4 )
Oil Absorption ( 5 )
Maximum Moisture Content, % ( 6 ) by weight
(1)
(2)
(3)
(4)
(5)
(6)
Requirement
6
60-80
6
75-95
55-75
20-40
13-23 (non-volatile)
6.5-8.5
4-6 (times fiber weight)
5
Method A Alpine Sieve Analysis. This test is performed using and Alpine Air Jet Sieve (Type 200
LS). A representative five gram sample of fiber is sieved for 14 minutes at a controlled vacuum of 5
kPa (11 psi) of water. The portion remaining on the screen is weighed.
Method B Mesh Screen Analysis. This test is performed using standard 0.850, 0.425, 0.250, 0.180
and 0.106 millimeter sieves, nylon brushes, and a shaker. A representative 10 gram sample of fiber is
sieved, using a shaker and two nylon brushes on each screen. The amount retained on each sieve is
weighed and the percentage passing calculated. Repeatability of this method is suspect and needs to be
verified.
Ash Content A representative 2 3 gram sample of fiber is placed in a tarred crucible and heated
between 595 and 650 Degree Celsius for not less than two hours. The crucible and ash are cooked in
desiccators and weighed.
pH Test Five grams of fiber is added to 100 milliliter of distilled water, stirred and let sit for 30
minutes. The Ph is determined with a probe calibrated with a pH 7.0 buffer.
Oil Absorption Test Five grams of fiber is accurately weighed and suspended in an excess of
mineral spirits for not less than 5 minutes to ensure total saturation. It is then placed in a screen mesh
strainer approximately 0.5 square millimeter opening size and shaken on a wrist action shaker for 10
minutes at 240 shakes per minute. The shaken mass is then transferred without touching to a tarred
container and weighed. Oil Absorption calculated by the number of times its own weight.
Moisture Content Ten grams of fiber is weighed and placed in a 121 Degree Celsius forced air oven
for two hours. The sample is then re-weighed immediately upon removal form the oven.
11.3.3 Job Mix Formula:

11.3.3.1 Acceptance Procedures for Job Mix Formula:
All steps followed in Item 8.5.3 for proposing and accepting the JMF shall be
adopted for the SMA mixture JMF.
11.3.3.2 Quality Requirement for Job Mix Formula:
The SMA JMF shall conform to the following requirements:
1.
The total aggregate shall conform to the tolerance limits shown in Table (11.3.2).
2.
The Marshall mix design shall conform to quality requirements shown in Table
(11.3.3).
3. Mixing and compaction temperature shall be according to AASHTO T-245.
318
4. When anti-stripping agents used, they shall conform to requirements in Item 7.2.4 in
Table 11.3.2: Tolerance allowance in SMA job mix formula
Percent tolerance allowance in JM F
Sieve Size
Nominal maximum size 16 mm

(Gradation No. 1 in Table 7.3.9)
Nominal maximum size 19 mm

(Gradation No.2 in Table 7.3.9)
19 mm
16 mm
12.5 mm
9.5 mm
4.75 mm
2.36 mm
0.075 mm
Asphalt content, %
+5
+5
+4
+4
+2
+ 0.50
+5
~~~
+5
+4
~~~
+4
+2
+ 0.50
Table 11.3.3: Quality requirements for the SMA mix

Test
Number of blows in Marshall compaction
Marshall Stability at 60 degrees Celsius, Kg, minimum
Air Voids in the mix, %, minimum
Tensile Strength Ratio (TSR), %, minimum (According to
AASHTO T-283)
Asphalt content by weight of mix, %
Voids in mineral aggregate, VMA, %, minimum
Drain down at production temperature, %, maximum (According
to ASTM D 6390)
Requirement
50 for each side
635
4
80
6-7
17-18
0.30
11.3.4 Equipment:
asphalt stone mastic mix work within the Contract time in accordance with his Program of
Work as approved by the Engineer. This equipment shall be, but not limited to, those
stated in Item 8.5.4.
11.3.5.1 Mixing Process :
SMA mixtures shall be produced in batch plant, continuous pugmill, or dryer-drum
mixing plant. Proportioning of aggregates may be by hot or cold feed control for the first
and second type, and cold feed for the drum type, at the option of the Contractor and the
approval of the Engineer.
Cellulose fiber stabilizing agent shall preferably be added to the batch and
continuous pugmill mixing plants automatically using special equipment for feeding loose
fibers at dry mix step.
The pellets stabilizing agent may be added manually or using feeding belts to the drum
mixing plants.
11.3.5.2 Experimental Section:
319
The constructability of the SMA mix, in terms of placement and compaction, shall
be determined according to the first day production.
11.3.5.3 Hauling the Mix to Project Site:
The SMA mix shall be transported to project site by clean trucks and free from any
dirt, dust, or any materials, which may affect the properties of, asphalt mixtures. The
following shall also be considered:
1.
The SMA mix shall not be stored in mixing plant more than thirty (30)
minutes.
2.
The transportation time from mixing plant to the project site shall be less than
one (1) hour.
11.3.5.4 Tack Coat:
If SMA mix is placed on an existing pavement, a tack coat of a slow setting (SS)
emulsion shall be applied according to Section 8.4 in these General Specifications. The
application rate for the tack coat shall be fourteen to twenty-one of the hundred (0.14 0.21) liter per square meter.
Following requirements shall be considered when spreading and compacting SMA:
1.
2.
3.
4.
5.
6.
7.
The initial temperature of the mix at the job site should not be less than one
hundred forty (140) degrees Celsius.
Compaction shall be completed before the SMA temperature drops below one
hundred-fifteen (115) degrees Celsius for polymer modified SMA mixes, and
below one hundred-fifteen (110) degrees Celsius for other SMA mixes.
Rolling shall be performed using a two (2) or three (3) steel-wheeled static
rollers. No vibrator roller in the vibratory mode or rubber tire roller will be
allowed.
The rolling shall commence immediately after placement and all rollers will
remain within 150 meters of the paver.
Roller speed shall be between one and six tenth to four and eight tenth (1.5 5) kilometer per hour.
The rollers shall be equipped with a watering or soapy watering system that
prevents material from sticking to the roller wheels.
Mix shall be compacted to ninety-four (94) percent of the maximum
theoretical density.
11.3.5.6 Final Thickness of Pavement layers:

The compacted SMA pavement thickness shall be as shown in planes, Contract
documents, or Special Specifications, and shall not be more than forty (40) millimeters.
11.3.6 Weather conditions:
SMA pavement shall not be placed on any wet or frozen surface, during dust or
sand storms, when wind or other weather conditions prevent the proper handling of the
SMA mixtures (spreading or compaction) or when the average surface temperatures are
less than ten (10) degrees Celsius.
320

The Contractor shall take effective actions to control traffic according to the
requirements specified in Item 8.5.7 in these General Specifications.
The Contractor shall apply quality control procedures for all SMA works to ensure
that the materials used and the executed work conform to these General Specifications and
other Contracts Documents.
at source, materials while work execution, SMA produced, and the executed work are
executed work by ordering under its direct supervision or performing testing of Stone
Mastic Asphalt (SMA) materials and inspect executed work, for all or some Items of
quality control that are shown previous Sub item (11.3.8.1).
11.3.9 Measurement:
SMA shall be measured by the cubic meter of mix acceptably placed or according
to the special Specifications.
The measurement must be within the dimensions and limits specified in the special
specifications and contract documents. Measurement for payment purposes will be
according to that limits unless stated by the engineer.
11.3.10 Payment:
per square meter measured as described in the pervious Item for each type SMA listed in
the Bill of Quantities.
materials, equipment, tools, and incidentals necessary for completing
321
all work involved in construction and acceptance of SMA. Payment will be made
Table 11.3.4: Quality control procedures for SMA Works
Work
Properties
Test Method
Quality
Asphalt
requirements
Binderl
tests
Quality and
Gradation
Aggregate
requirements
tests
Quality
Mineral Filler requirements
tests
Quality
Stabilizing
requirements
Agent
tests
Aggregate AASHTO T gradation
164 / T-27
Mix design AASHTO Trequirements 164 / T-1 70
Thickness ASTM D 3549
Raw
materials
Materials
during
usage
Compaction
Road
Skid resistance
Finishing
Level,
dimensions,
slopes, and
smoothness
measurement
Sample
location
Requirements

Table 7.2.1
Three (3) tests at start of work or

source change
Source
Project
site
Approved
device
Project
site
Quality
requirements in
Tables 7.3.1 and
7.3.9

Item 7.3.4

Table 11.3.1
One (1) test every 500 tons from

each mixing plant or a day work.
ASTM D 2726
Contract
documents
Sampling frequency
Minimum one (1) test every one

thousand (1000) square meters
from each layer
Skid resistance test for each
working day
twenty-five (25) meters or five
segments every one thousand
(1000) meters, whichever the
maximum
Table 11.3.2
Table 11.3.3
Sub item
11.3.5.5
Item 11.2.8
Requirements in
the
Contract
documents
Table 11.3.5: Stone mastic asphalt works items

Item No.
Type of work
Measurement unit
11.3.1
Stone mastic asphalt
Cubic meter
322
DIVISION 12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
325
Preface
Description
Materials
12.3.1 Asphalt Materials
12.3.2 Aggregate
12.3.2.1 Quality Requirements For Combined Aggregate
12.3.2.2 Gradation Of Total Aggregate
M ix Design
12.4.1 Job-Mix Formula Requirements
12.4.2 The Design Job-Mix Formula
12.4.3 Procedures For Acceptance Of Job-Mix Formula
C onstruction
Traffic Control
Works Acceptance
12.7.1 Quality Control
12.7.2 Quality Assurance
M easurem ent and Payment
325
328
328
328
330
331
332
335
336
336
337
337
338
338
339
339
341
General Specifications of Urban Roads Construction ______ Division 12-Superior performance asphalt pavement
DIVISION 12
12.1 Preface:
Design of Superior Performance Asphalt Pavements (Superpave) has been developed
on the basis of intensive research conducted to limit failures and distresses in asphalt
pavements during different stages of their service life. Superpave (which will be defined later
in this specification as the superior performance pavements) is an abbreviation to SUperior
PERformance Asphalt PAVEment.
Superpave system consists of requirements and specified methods for selection of
asphalt binder and aggregates which shall be met in the design and construction of superior
performance pavement layers. The Superpave system also consists of the asphalt mix design
method in three levels; the first level is defined as the volumetric design in addition to tests for
determination of performance in the second and third levels which are still in the development
phase.
The Superpave specifications depend on the environmental factors, layer location from
pavement surface and actual traffic volume on the road.
The physical characteristics of the asphalt binder, which directly affect its performance in the
road, are measured by a series of specified tests at temperatures which simulate the maximum
and minimum temperatures to which the asphalt binder is subjected to during mixing,
spreading, compaction and service (pavement service life). Table (12.2.1) shows these tests
which are used to determine the type of the asphalt binder on the basis of performance grade
(PG). The identification consists of suffix numbers to these two letters (PG) indicating the
maximum and minimum temperatures within which the asphalt binder is expected to perform
satisfactorily. For example the grade PG76-10 is expected to resist rutting at maximum
temperature of seventy six (76) degree Celsius and resist thermal cracking at minimum
temperature of minus ten (-10) degree Celsius.
The real difference between the specifications of Superpave and the traditional
specifications (penetration and viscosity) is in the performing of tests at different temperatures,
which suit the operational conditions of the project, in order to obtain the target value in the
specifications instead of fixing the test temperature and changing that value.
Tests on asphalt binder or on asphalt mix are performed at temperatures simulating
those to which the asphalt mix is subjected during the pavement service life and the behavior or
performance of the asphalt binder depends on the temperatures and the prolonging or shortening
of the traffic loading period.
The Superpave combined these two factors loading period and temperature- by their mutual
effect on the asphalt binder and the asphalt mix where the slow loading rate is simulated by the
high temperatures and the quick loading rate by the low temperatures.
The specifications of the Superpave require obtaining records of temperatures in the project area
for twenty (20) years for determination of the adequate performance
Ministry of Municipal & Rural Affairs - Kingdom of Saudi Arabia
325
grade, where the minimum daily temperature and the maximum seven days average temperature
shall be determined during the approved monitoring period in the General and/or Special
Specifications.
Table 12.2.1: Asphalt Binder Tests

No.
1
Test
Rolling Thin Film Oven Test
(RTFO)
Pressurized Aging Vessel (PAV)
Dynamic Shear Rheometer (DSR)
Rotational Viscosity (RV)
Bending Beam Rheometer (BBR)
Aim
Simulation of short term aging of asphalt
binder (< two years)
Simulation of long term aging of asphalt
binder (>seven years)
Measurement of asphalt binder
characteristics at intermediate and higher
temperatures
characteristics at higher temperatures
characteristics at lower temperatures
Direct Tension Tester (DTT)
The adequate performance grade or type of the asphalt binder for the project area is
determined according to the following steps:
1- Determination of the minimum pavement temperature using the minimum air temperature
in the monitored period or by applying the following formula:
Low, Tp a v = - 1.56+0.72Ta i r 0.004Lat2+6.26
Log10
(H+25) - Z (4.4+0.52a i r 2)0.5
Where;
Tp a v = Minimum pavement design temperature C at H mm depth from the surface.
(minimum expected pavement temperature degree during the design period.
Ta i r = Minimum daily air temperature, C
Lat = Geographical location of the project (latitude) in degrees. Z
= Reliability factor = 2.055 at reliability 98 %
H = depth to the surface.
a i r = standard diviation of minimum air daily temperature.
,
2- Determination of the maximum pavement temperature as the temperature at a depth of

twenty (20) millimeters from the pavement surface, which is determined from approved
mathematical formulas by using the average air temperature for the hottest seven days
during the monitoring period and the geographical location of the project (latitude), using
the following equation :
High,
=54.32+0.78Tair0.0025Lat2-15.14
Tpav
Log10
(H+25)+Z (9+0.61 a i r 2
)0. 5
326
Where;
Tp a v = Maximum pavement design temperature at H mm depth from pavement surface,
C.
Ta i r = Average hottest seven days air temperature, C.
Lat = Geographical location of the project (latitude) in degrees.
Z
= Reliability factor = 2.05 5 at reliability 98 %
H = depth to the surface.
a i r = standard deviation of maximum seven day air temperature.
3- The reliability used in determination of the maximum or minimum temperature shall not be
less than ninety eight (98) percent. This implies increasing the average maximum
temperatures and decreasing the average minimum temperatures by twice the standard
deviation value of the average temperatures for twenty years period.
The aggregate plays an important role in the performance of asphalt mixes at high
temperatures and high humidity. This role is less important at low temperatures in fatigue cracking
and low thermal cracking problems. The characteristics of aggregates are classified in the
Superpave specifications into three groups as follows:
1- Consensus Properties: Consensus properties are used for determination of the angularity
of the fine and coarse aggregate grains and the degree of fracture and number of fractured
faces and are considered as one of the important factors in obtaining the required
performance of the asphalt mix. Specific requirements in these properties shall be satisfied
on the basis of traffic volume and location of the layer from pavement surface. These
properties are :
- Coarse Aggregate Angularity - Fine
Aggregate Angularity - Flat and
Elongated Particles - Clay content
2- Source Properties: Source properties are used in judgment of suitability of the source of
aggregates used in production of the Superpave, for its importance in quality assurance.
These properties include the following:
- Toughness
- Soundness
- Deleterious Materials
3- Gradation Properties: Superpave has developed methodology for determination of
aggregate gradation in asphalt mixes by considering the gradation curve of sieve sizes
raised to the power 0.45. This curve consists of a straight line joining the point of the
100% passing at the maximum size and the zero point, called the maximum density line.
Two additional properties have been added to the maximum density line, which are :
- Control Points. - Restricted Zone.
Control points are upper and lower limits for the percentage passing from
definite sieves. These Sieves are the maximum size, the maximum nominal size, the
327
General Specifications of Urban Roads Construction _________ Division 12-Superior performance asphalt pavement
intermediate size 2.36 mm and the minimum size 0.075 mm. The control point value in each
sieve differs by the variation of the maximum nominal size of the aggregate. The restricted
zone is a zone where the gradation curve is not recommended to pass through, since the
gradation passing through this zone will have insufficient voids in the mineral aggregate
(VMA) and is considered to be highly sensitive to any increase or decrease in asphalt content.
The aggregate gradation selected for Superpave is known as the Design Aggregate
Structure and should preferably pass below the restricted zone.
The performance of the asphalt mixes is determined from series of tests on prepared
laboratory specimens using gyratory compactor and by measurements of the volumetric
properties which include air voids, voids in the mineral aggregate and voids filled with
asphalt and then use these properties and measurements in performance models for estimation
of the number and shape of pavement distresses on the basis of time and traffic factors.
12.2 Description:
This section includes provision of the asphalt binder which satisfies the required
performance specifications for the project area and selection of the suitable aggregate in terms
of gradation and quality requirements for production of an asphalt mix which satisfies the
performance requirements and design conditions stated in the this General or Special
Specifications and hauling , spreading and compacting the mix for construction of the
superior performance asphalt pavement layers in accordance with the plans , Special
Specifications , contract documents and this General Specifications .
12.3 Materials:
12.3.1 Asphalt Materials:
The asphalt materials used in the Superpave consist of the modified or unmodified asphalt
binder which shall satisfy the quality requirements shown in Table (12.3.1) of this general
Specification. Unless otherwise defined in the contract documents or in the Special
Specifications, the contractor shall submit a study, prepared by a specialized authority, which
shows the suitable performance grade of the asphalt binder for the project area.
The performance grade shall be determined according to the sequence followed in the
standard AASHTO PP-6 The Standard Method of Approving the Suppliers Grade of the
Asphalt Binder and Specifications of Performance grade of the Asphalt Binder AASHTO
MP-1 standard.
The performance grade of the asphalt binder shall be selected on the basis of temperatures
of the project location in any zone in the Kingdom, using the equations in item 12.1 of this
division and in case there is no information about the project the performance grade shown in
Figure (12.3.1) Temperature Zones of the Kingdom shall be use. This selected grade shall be
increased by the performance degrees shown in Table (12.3.2), according to the speed and the
design traffic volume in ESA Ls in the design lane for twenty (20) years. The properties of the
selected asphalt binder shall conform to the requirements shown in Table (12.3.1).
328
When the available asphalt binder does not satisfy the performance requirements,
the Contractor shall modify the asphalt binder by using one of the approved and common
modifiers (Polymers) in the Kingdom. He shall also submit technical report, prepared by
specialized authority, showing the proposed polymer type, its percentage, method of addition
and test results which verify the satisfaction of the asphalt binder type to the quality
requirements shown in Table (12.3.1).
Table 12.3.1: Quality Requirements of Performance Grades of Asphalt Binder

Test
Description
Specification
Requirements
New Asphalt
AASHTO T-248
230 0C (min)
AASHTO
Rotational Viscosity
3 Pa.sec (max)
At 135 0C
TP-48
Dynamic Shear (DSR)
At the higher
AASHTO
1 kPa (min)
G*/sin at 10 rad /sec
temperature
TP-5
Specimens of Asphalt Residue from RTFO
AASHTO T% loss (RTFO)
1% (max)
At 1630 C
240
Dynamic Shear (DSR),
At the higher
AASHTO
2.2 kPa (min)
G*/sin
temperature
TP-5
Specimens of Asphalt Residue from RTFO and PAV
Dynamic Shear (DSR),
At the median
AASHTO
5000 kPa
G*sin
temperature *
TP-5
(max)
At minimum
Creep
AASHTO
temperature
+10
300 Mpa (max)
Stiffness
(S)
TP-1
Bending
C for 60 sec
Beam
At minimum
Rheometer
AASHTO
m-value
temperature +10
0.3 (min)
TP-1
C for 60 sec
Direct Tension
At minimum
AASHTO
1% (min)
temperature
TP-3
Flash point
* NOTE: see Table 1 in Appendix 2.
Table 12.3.2: Increase of Performance Degree of Asphalt Binder on the Basis of

Traffic Volume and Speed
Design Traffic
Volume
(million ESALs)
< 0.3
0.3 - <10
10 - <30
Increase of
<20 kph
Degree According
20 70 kph
to Traffic Speed
>70 kph
No need
Two degrees
~30
One degree
No need
degree(optionally
)
One degree
329
Figure 12.3.1: Temperature Zones of the Kingdom

The selected performance grade shall be modified on the basis of climate temperature
in the project area in accordance with Section 12.2 or as determined from Figure (12.3.1), by
increasing the maximum temperature only by the amount of the performance degrees shown in
Table (12.3.2) (each performance degree equals six (6) degrees Celsius), according to the speed
and design volume of traffic on the road. The minimum temperature in the performance grade
shall not be modified. For example, if the selected performance grade for a project, according
to the pavement temperature, is PG70-10 and the design traffic speed is greater than seventy
(70) kph and the design raffic volume is between ten (10) to thirty (30) million ESAL in the
design lane, the performance grade of the asphalt binder shall be increased one degree to be of
the type PG76-10.
The Contractor shall use modified asphalt binder in construction of Superpave asphalt
concrete according to the ministry request in any of the Kingdom zones and taking into
consideration that the performance degree of that asphalt binder is increased according to traffic
volume and speed in the target project as shown in figure (12.3.1) and Table (12.3.2). The
contractor has the right to request about the modification cost if it is not mentioned in the
contract documents, but if the ministry does not request that and it is not mentioned in the
contract documents the Contractor has no right to claim any additional compensation
accordingly.
12.3.2 Aggregate:
The aggregate used in production of Superpave shall meet all stated requirements in
this section of the General Specification, unless otherwise stated in the Special Specifications.
The Contractor shall, at his own responsibility, define the source(s) and the aggregate
quantities suitable for work in accordance with the requirements of this General Specifications
or the Special Specifications.
330
The different aggregate sizes shall be stockpiled on stable clean leveled surface and
in spaced heaps of not less than ten (10) meters apart or in wall-separated heaps. The
aggregates shall be hauled from stockpiles locations by equipments which are approved by
the Engineer. The hauling and/or stockpiling method shall not lead to pollution of the
environment or aggregate or particle segregation.
The Contractor is allowed to use up to 15% by weight of total aggregates of non
fractured fine aggregate for production of Superpave, provided that the total mix of the
fractured and non fractured fine aggregate shall conform to the fine aggregate angularity which
is based on the uncompacted air voids of this General Specifications or the Special
Specifications.
The mineral filler used in Superpave shall be a product of rock powder or rock dust
with plasticity index not more than 4%. It may also be of furnace slag and/or metal raw or
Portland cement or hydrated lime or any other material which will satisfy the quality
requirements as in AASHTO M-85 or AASHTO M-240 for Portland cement and ASTM C
207 for hydrated lime.
12.3.2.1 Quality Requirements for combined Aggregate:
The combined aggregate shall satisfy all consensus properties shown in Table
(12.3.3), and the flat and elongated particles test shall be performed on materials retained on
sieve 4.75 mm while the percent of air voids test on the uncompacted fine aggregate shall be
performed on materials passing sieve 2.36 mm, according to the method defined in the above
mentioned Table.
Not contradicting the Special Specifications, the source properties of the aggregate
used in Superpave production, shall conform to all requirements listed in Table (12.3.4),
according to the defined test method.
All tests listed in Tables (12.3.3) and (12.3.4) of this General Specifications shall be
performed on the blended aggregate which is selected for production of Superpave concrete,
except the Los Angeles Abrasion Test which may be performed on the blended aggregate or
for each source / stockpile alone.
Table 12.3.3: Aggregate Consensus Properties Requirements
Coarse
Aggregate
Percent of Air Voids in

fine Aggregate (passing
Flat and
Sand
(At least Angularity
Elongated
%)
4.75 mm sieve)
Equivalent
Particles***
(At least %)
(min)
(min)
Layer Location from Pavement Surface*
<100 mm
~100 mm
<100 mm
~100 mm
<0.3
-/55
-/40
0.3 -<3
-/75
-/50
40
40
40
10
3 - <10
80/85**
-/60
45
40
45
10
10 -<30
90/95
75/80
45
40
45
10
~30
100/100
100/100
45
45
50
10
* Layer location from pavement surface is considered to be less than 100 mm if the layer is the surface layer or if
quarter of its thickness lies within the upper 100 mm of the pavement surface.
** 85/80 denotes that 85 % of the coarse aggregate has one fractured face and 80% has two or more
fractured faces.
*** Criterion based on 5:1 maximum to minimum ratio.
Design
Traffic
Volume
(ESAL)
(million)
331
Table 12.3.4: Requirements of the Aggregate Source Properties

Aggregate Properties
Los Angeles Abrasion
(max)
Soundness (loss in Sodium
Sulphate) (max)
Clay lumps and friable
particles (max)
Test Method
Requirements %
AASHTO T-96
40
AASHTO T-104
20
AASHTO T-112
0.25
12.3.2.2 Gradation of Total Aggregate:

The combined aggregate of Superpave shall satisfy one of the gradation
requirements shown in Tables from (12.3.5) to (12.3.9) which is classified according to the
nominal maximum size of the aggregate.
The percent of aggregate used in the asphalt mix shall be determined by the use of the
average gradation results of five representative and independent samples taken from each
stockpile and/or cold bins and/or hot bins, and at least three trials shall be performed for
different gradations within the specification limits of the approved gradation for each
Superpave mix in order to determine the design aggregate structure and the percentages of
the different aggregate sizes.
Satisfaction of the aggregate sizes to quality and gradation requirements shall be
checked whenever the source and /or method of fracture change. The maximum nominal
size shall not be greater than half the pavement layer thickness.
Table 12.3.5: Gradation of combined Aggregate

(Maximum Nominal Size is 9.5 mm)
Sieve
Size
(mm)
12.50
9.50
4.75
2.36
1.18
0.600
0.300
0.150
0.075
Control Points (%)
Restricted Zone (%)
Minimum
Maximum
Minimum
Maximum
100
90
32
2
100
90
67
10
47.2
31.6
23.5
18.7
-
47.2
37.6
27.5
18.7
-
Target
Design
Values*(%)
*
*
*
*
*
Tolerance
Limits (%)
6
6
4
3
2
* represents target values which the Contractor shall determine during the asphalt mix design to the nearest
0.1% , and tolerance limits shown are the permissible deviation from target values.
** It is better if the total gradation avoid the restricted zone and that according to the engineer acceptance.
332

Sieve Size
(mm)
19
12.50
9.50
4.75
2.36
1.18
0.600
0.300
0.150
0.075
Control Points (%)

Minimum
Maximum
100
90
100
90
28
2
58
10
Restricted Zone (%)

Minimum
Maximum
Target
Design
Values*(%)
39.1
25.6
19.1
15.1
-
39.1
31.6
23.1
15.1
-
*
*
*
*
*
Tolerance
Limits (%)
6
6
4
3
2

(Maximum Nominal Size is 19 mm)
Sieve
Size
(mm)
25
19
12.50
9.50
4.75
2.36
1.18
0.600
0.300
0.150
0.075
Control Points (%)
Restricted Zone (%)
Minimum
Maximum
Minimum
Maximum
100
90
23
2
100
90
49
8
34.6
22.3
16.7
13.7
-
34.6
28.3
20.7
13.7
-
Target
Design
Values*(%)
*
*
*
*
*
*
Tolerance
Limits (%)
6
6
4
3
2
* represents target values which the Contractor shall determine during the asphalt mix design to the
nearest
333

(Maximum Nominal Size is 25 mm)
Sieve
Size
(mm)
37.5
25
19
12.50
9.50
4.75
2.36
1.18
0.600
0.300
0.150
0.075
Control Points (%)
Restricted Zone (%)
Minimum
Maximum
Minimum
Maximum
100
90
19
1
100
90
45
7
39.5
26.8
18.1
13.6
11.4
-
39.5
30.8
24.1
17.6
11.4
-
Target
Design
Values*(%)
*
*
*
*
*
*
Tolerance
Limits (%)
6
6
4
3
2

Control Points (%)
Restricted Zone (%)
Sieve Size
(mm)
Minimum
Maximum
Minimum
Maximum
50
37.5
25
19
12.50
9.50
4.75
2.36
1.18
0.600
0.300
0.150
0.075
100
90
15
0
100
90
41
6
34.7
23.7
15.5
11.7
10
-
34.7
27.3
21.5
15.7
10
-
Target
Design
Values*(%)
*
*
*
*
*
*
Tolerance
Limits (%)
6
6
4
3
2
334
12.4 Mix Design:

Design of superior performance asphalt mix shall be in accordance with the Asphalt
Institute method shown in Superpave Series No. 2 (SP-2) Mix Design of Superpave Asphalt
concrete. The Appendix (2) of this General Specifications shows an example of Superpave
volumetric mix design method.
The design steps of the asphalt mix, as in level one of the superior performance asphalt
pavement mix Design by the Volumetric Method, include the following:
1- Selection of the asphalt binder which satisfies the approved requirements as in
item 12.3.1 of this Specification.
2- Selection of the aggregate which satisfies the specifications of the defined source and
consensus properties and meets the required gradation according to the maximum
nominal size by performing three different trail blends and comparing them with the
combined gradation requirements.
3- Estimation of the preliminary optimum asphalt binder content for each blend.
4- Determination of the temperature range for each of the mixing and compaction by
performing the Rotational Viscosity test as in AASHTO TP-48 such that the suitable
mixing viscosity of the asphalt binder will in the range of (0.17 0.02) and for
compaction will be in the range (0.28 0.03) Pa.sec .
5- Selection of the optimum asphalt binder content as follows:
- Mixing asphalt with the different aggregate blends and heating (aging) the mix in
the oven at compaction temperature specified by rotational viscosity test for
two hours if the aggregate absorption does not exceed 2% and for four hours if
the absorption exceeding this value, then compacting the specimens by the
gyratory compactor as in AASHTO TP-4 method, The Standard Method for
Preparation and Determination of the Specific Gravity of Compacted Specimens
by the Gyratory Compactor.
- Analysis of the volumetric properties of the compacted mix and comparing them
with the volumetric properties as in Superpave system and selection of the best
results as design aggregate structure according to the specification AASHTO
PP- 19 The Standard Volumetric Analysis Method for Compacted Hot Mix.
- Compaction of specimens from the design aggregate gradation with different
asphalt contents, plotting the asphalt binder versus the air voids in the compacted
specimens curve and determination of the design asphalt binder content at four
(4) percent air voids.
- Determination of the volumetric properties using the optimum asphalt content
from the plotted curves of; asphalt binder content versus the volumetric
properties of the asphalt mix (Voids in the Mineral Aggregate (VMA), Voids
Filled with Asphalt (VFA), density at initial (Ni n i) , design (Ndes) and maximum
(Nmax) compaction levels and then comparison with the requirements of the
volumetric properties shown in Table (12.4.2).
6- Evaluation of the resistance of the selected asphalt mix to water effect according to
AASHTO T-283 method.
Table (12.4.1) shall be considered as guidelines for the selection of the required
compaction level in the laboratory for the asphalt mix on the basis of the design traffic volume
in EASLs in the design lane for twenty (20) years.
335
Table 12.4.1: Superpave Compaction levels

Design
ESAL
(million)
< 0.3
0.3 - < 3
Maximum
Nm a x
75
115
No of gyrations
Design
Nd e s
50
75
Initial
Ni n i
6
7
3 - < 30
160
100
~ 30
205
125
Road Class
Residential
Collector
Expressway Arterial / Industrial
Regions
Expressway / Truck Parking /
Decent Lanes / Intersections
12.4.1 Job-Mix Formula Requirements:

The asphalt binder shall satisfy the quality requirements shown in Table (12.3.1), and
the Contractor shall define and verify the target values of the gradation of the total aggregate of
the Superpave within the allowed limits shown in Table (12.3.5) or Table (12.3.6) or Table
(12.3.7) or Table (12.3.8) Table or (12.3.9) according to the nominal maximum size of the
aggregate provided that the quality requirements shown in Tables (12.3.3) and (12.3.4) shall
be satisfied. The asphalt mix shall also satisfy the volumetric properties shown in Table
(12.4.2).
The ratio of the average tensile resistance of the compacted specimens subjected to
environmental conditioning to average tensile resistance of the compacted specimens not
subjected to environmental conditioning shall not be less than seventy five (75) percent as
determined by AASHTO T-283 test Resistance of the compacted bituminous Mixture to
moisture induced Damages.
Table 12.4.2: Requirements of the Volumetric Properties of Superpave
Voids in the Mineral
Ratio of Required
Density to Maximum
ESALs
(million)
<0.3
0.3 - <3
3 - <30
~30
Theoretical Density
(%Gm m )
Nm a x
-
Nd e s
-
<98
96
Ni n i
<91.5
<90.5
<89
Voids
Aggregate (VMA)
(at least %)
Nominal Maximum Size
(mm)
9.5
-
12.5
-
19
-
25
-
37.5
-
15
14
13
12
11
Filled
with
Asphalt
(VFA)
**
70-80
65-78
65-75
65-75
Ratio of
Percentage
Passing Sieve
0 075 mm to
Asphalt
Binder
Content *
0.6 1.2
Note on Table (12.4.2):

* This range may be increased to 0.8% - 1.6% for coarse gradation which pass below the restricted zone.
** The range of VFA for the maximum nominal size of 9.5 mm shall be between 73% to 76% for the traffic
volume greater than or equal to 3 million ESALs, and the minimum limit for these voids shall be 67% for
the maximum nominal size of 25 mm when the traffic volume is less than 0.3 million ESALs and 64%
for the maximum nominal size of 37.5 mm for all traffic volumes.
12.4.2 The Design Job-Mix Formula:

The Contractor shall prepare a detailed technical report about the proposed jobmix formula and submit to the ministry for approval thirty (30) days prior to commencement of
asphalt mix production on site. The report shall include the source(s)
336
of materials used in the asphalt mix production, material proportions, original test results of
consensus properties, source properties required for aggregate materials which proves conformity
with the specified requirements and the original test results of the designed asphalt mix in the
laboratory which shall include; gradation, specific gravity for aggregate sizes, test results of the
asphalt binder, grade, type and percentages of used modifiers, mixing method, plant location
and test results of plant production.
12.4.3 Procedures for Acceptance of Job-Mix Formula:
The job-mix formula furnished by the Contractor shall be revised by the ministry and
shall be accepted or retuned to the Contractor for modifications within two weeks. The
Contractor shall prepare once again and resubmit to the ministry, for approval, a new job-mix
formula which will satisfy the specified requirements. The Contractor shall not change sources
or aggregate production methods or asphalt material mixing after approval of the job-mix except
after repeat of material testing and submission of new mix.
12.5 Construction:
Unless otherwise stated in the Special Specifications or otherwise conflicting with what
is listed in this section, the construction requirements shown in item 8.5.6 Construction shall
be applied to the items related to preparation of asphalt materials, aggregates, asphalt concrete
mix and joint.
The Contractor shall ensure surface preparation (any type) on which Superpave mix
will be placed. He shall clean the surface from dust, loose material and any foreign material and
apply tack coat or prime coat by the method and equipment approved by the Engineer and in
accordance with the requirements listed in this General Specifications and the Special
Specifications. The Contractor shall also fill the cracks and patch potholes if the surface is
asphalt concrete, as shown in plans and contract documents. The central plants used in
Superpave production, shall satisfy the requirements listed in the specification AASHTO M
156 designation for the "Requirements of Hot Mix Asphalt Plants.
The Contractor shall haul, place and spread the Superpave asphalt concrete to the
thickness specified in plans and by the manner and equipments stated in the Special
Specifications and this General Specifications. The asphalt mix temperature during discharge
from the plant into the truck shall not be less than one hundred and sixty (160) degrees Celsius
and not greater than one hundred and eighty (180) degrees Celsius.
All Superpave layers shall be spread and initially compacted, in the initial coverage, in
temperatures not less than one hundred and thirty five (135) degrees Celsius. All compaction works
shall be finished before the mix temperature is reduced to less than ninety (90) degrees Celsius. The
compaction shall be in the form of consecutive or sequential passes by approved rollers. The pass is
defined as the movement of one roller in any direction. The number of passes which cover the full
width of pavement by compaction is defined as the coverage. Table (12.5.1) may be used as guidelines
for determination of the degree of compaction, roller type and number of coverage's.
Longitudinal joints shall be compacted first, and then compaction may be started at the
lower side towards the higher side (road center line) using self propelled steel or pneumatic
rollers. The weight of each of these rollers shall not be less than ten (10) tons
337
and the Contractor shall take care of these rollers, maintain and operate in the manner which
will lead to the required purpose.
Table 12.5.1: Degree of Compaction and Number of Coverage
Degree of
Compaction
Initial
Intermediate
Final
First Alternative
Roller Type
Steel Roller
Pneumatic Roller
Steel Roller
Second Alternative
Number of
Coverage **
1
4
1-3
Roller Type
Vibratory Roller
Vibratory Roller
Steel Roller
Number of
Coverage **
1
24*
1-3
* Depends on Roller Weight

** The number of coverages shall be selected on the basis of the experimental section.
The number of tires of the pneumatic roller shall not be less than seven tires and the tires shall be capable of
applying an air pressure of 258 kg/cm2 or ninety (90) pounds / square inch. The air pressure in any tire shall
not vary by more than 14 kg/cm2 or five (5) pounds / square inch from the approved pressure and the weight
of each tire shall not be less than 2222 Kilograms or five thousand (5000) pound.
The longitude and latitude joints shall be compacted first, after that compaction start
from edges to the road axis using mechanical steel or pneumatic rollers and their weights
must not be less than ten (10) tons and the contractor shall operate, repair and take care about it
as to achieve its purpose.
The adequate number of rollers shall be provided and the compaction shall continue
till the required field density is reached. The compaction degree shall determine on the basis
of the experimental section results as in the standard method AASHTO T-310 or the method
AASHTO T-168. The degree of compaction shall not be less than 91% of the maximum
theoretical density defined by the standard method AASHTO T-209.
12.6 Traffic Control:
The Contractor shall take the effective measures to prevent all types of traffic from
using the Superpave layers unless approved by the Engineer and he shall take the approval of
the concerned authorities in this respect and follow the requirements shown in item 8.5.7 of
this General Specifications.
12.7 Works Acceptance:
Contractor shall apply quality control for superpave asphalt concrete production by
carrying out all the required arrangements to ensure that the used materials, construction
methods and the executed works achieve the quality requirements, indicated in the standard
specifications, special specifications, these general specifications and other contract
documents.
The Ministry shall apply the quality assurance works by verifying that the contractor
has carried out quality control procedures properly either through direct supervision of the
quality control procedures or by undertaking quality assurance procedures neutrally on
representative samples and with adequate numbers to judge the execution and to decide in
accepting or not accepting the completed work according to the principles detailed in Division
17 of this general specifications except otherwise specified in special specification or other
contract documents.
338
12.7.1 Quality Control:

The Contractor shall furnish a plan for the quality control system which he will follow
during the contract period at his own expense in his laboratories, as part of the daily work
follow up, or in other independent laboratories which are approved by the ministry, thirty (30)
days prior to commencement of the asphalt concrete production for approval. The Contractor
shall not start production and construction prior to obtaining written acceptance of the plan by
the Engineer. He shall be committed to the plan during the contract period. That plan shall
include the number, qualifications of the work staff and a list of devices, equipments,
calibration methods, finished calibration certificates from approved authority, number of
available tests, and number of samples, their weight and frequency.
The Contractor shall conduct the quality control tests for the materials at their source,
during use, when preparing the mix design and on the site as shown In Table (12.7.1).
The total aggregate, including fine aggregate, mineral filler and asphalt binder, shall
conform to the approved proportions in the job mix formula within the allowed tolerances
listed in item 12.3.2 of this General Specifications. When these percentages are not conforming
to the approved job mix formula within the allowed tolerances, the mix production shall be
suspended for recalibration.
At least two specimens from the produced asphalt mix shall be compacted by the
gyratory compactor as in AASHTO TP-4 method. And the maximum theoretical specific
density shall be performed for each mix intended for compaction in the laboratory as in ASTM
D 2041 method and according to the frequency stated in Table (12.7.1) at the design
compaction level (Ndes) in order to ensure that the volumetric properties of the asphalt mix are
within the following limits:
- The air voids and the voids in the mineral aggregate of the produced asphalt mix shall not
vary by more than one (1) percent from what has been specified in the job mix formula.
- The voids filled with asphalt shall not vary by more than five (5) percent from what has been
specified in the job mix formula.
- The ratio of the average tension resistance of the compacted and subjected to environmental
conditioning specimens to the average tension resistance of the compacted specimens, not
subjected to environmental conditioning shall not be less than seventy five (75) percent as
determined by AASHTO T-283 test.
- The gyratory compaction test shall be performed at the maximum compaction level (Nm a x ) for
each four days production to ensure that the density ratio at this level of compaction is less
than ninety eight (98) percent of the maximum theoretical specific density (Gm m ).
12.7.2 Quality Assurance :
Ministry at any time has the right to assure the quality of materials and executed works
through carrying out or ordering others under its direct supervision to select materials and
check executed works for all or part of the quality control items specified in 12.7.1 subsection.
Ministry has the right to review contractors quality control records and compare these
statistically with its results to insure quality according to what is specified in
339
division 17 of these general specifications. It has the right to inspect the contractors
laboratory and its equipments, its technical staff, methods of testing and construction method
to insure the efficiency of the contractors technical staff and equipments and compliance of
his inspection methods, testing and construction method with the approved methods.
Table 12.7.1: Quality control procedures for Superpave asphalt concrete mixes
Work
Asphalt
binder
Properties
Quality requirements
and PG classification
Consensus properties
Aggregate
Source properties
Testing method
Location
of
Sampling
One test In the beginning of

supply, during the mix design
and whenever the source or mix
properties are changed.
Tests indicated in
Table 12.3.1
Tests indicated
in Table 12.3.3
Tests indicated in
Table 12.3.4
At
Source
Specific gravity (Gsb)

and
absorption
Materials
during
construction
Aggregate gradation
(dry mix)
Specific gravity (Gsb)
and
absorption
Source properties
Consensus properties
Asphalt mix
tests
Aggregate gradation
and asphalt content
Volumetric properties
using Gyratory
compaction at design
number of Gyrations
(Nd e s )
Percent of max density
Gm m using Gyratory
compaction at
maximum number of
Gyrations ( Nm a x )
3 tests on different samples from

each source at source approval
and design job mix formula or
when source is changed or when
noticing a change in constructed
works properties, and 5 tests on
different randomly time selected
samples for each 5000 cubic
meters from each source during
construction.
3 samples during mix design and
one test for each week or when
mix properties are changed.
AASHTO T-19
AASHTO
T-27

AASHTO T-19
Tests indicated in
Table 12.3.4
Sampling frequency
at
Requirements
Table 12.3.1
Table 12.3.3
Table 12.3.4
Tables from
12.3.5 to
12.3.9
Tables from
12.3.5 to
12.3.9
Tables from
12.3.5 to
12.3.9
One test each month or when

Table 12.3.4
One test each month or when

mix properties are changed..
Table 12.3.3
At least one samples for each for

each 500 cubic meters or one for
each daily production from each
constructed layer.
Tables from
12.3.5 to
Tables 12.3.9
AASHTO TP-4
At least three tests at approval of

design aggregate structure or
when properties or mix
aggregate are changed and one
test for each 500 cubic meters
from each Plant or for each
working day which is the lesser.
Section 12.3
and 2.4,
Table 12.4.1
and 12.4.2
AASHTO TP-4
One Test for every four

production days or one test for
each 500 cubic meters from each
Plant which is the less
Table 12.4.2
Stock Piles
Tests indicated
in Table 12.3.3
AASHTO
T-27/T-164
T-308/T-3 10
At least three tests at approval of

Maximum theoretical
specific gravity (Rice)
AASHTO
T-209/
ASTM D 2041
design aggregate structure or

when properties or mix
aggregate are changed and one
test for each 500 cubic meters
from each Plant or for each
working day which is the lesser.
Item 12.7.1
340
Constructed
works
One test when design and

approval of job mix formula or
when the mix properties are
changed.
AASHTO
T-283
Mixture sensitivity to
moisture induced
damage
Compaction
ASTM D-2726
Thickness
ASTM D-3549
Skid resistance on
surface layer
Skid resistance
measurement
Surface layer roughness
Road roughness
measurement
Levels, dimensions
and, slopes
measurements.
Contract
documents
At site
Item 12.7.1
one test for each 1000 square

meters from each constructed
layer or working day which is
the lesser.
One test from each 1000 square
meters from each constructed
layer or working day which is
the lesser.
Skid measurements for each
working day.
Using measurement methods
indicated in special
specifications for each working
day.
Cross section measurements
each 25 meters or 5 sections
each 1000 square meters
Section 12.5
Section 12.5
Section 12.5
Section 12.5
Requirements
stated in
contract
documents
The requirements including in division seventeen (17) in these general specifications

shall apply to accept constructed superpave asphalt concrete works. On application of the
statistical system, the elements of pay factor determination shall include; the thickness,
gradation, surface smoothness, asphalt binder content and compaction. The number of samples
and the lot amount shall be as shown in Table (17.3.1) of this General Specifications.
The quality assurance procedures shall be applied as shown in sub item 8.5.8.2 and
table (8.5.6), which is concerned with compaction requirements, thickness of the constructed
asphalt concrete - as decided on plans -, aggregate gradation, asphalt binder content and evenness
of the surface layer. The allowed tolerances limits for gradation shall be as shown in Tables
(12.3.5), (12.3.6), (12.3.7), (12.3.8) and (12.3.9), and the asphalt binder content shall be in the
range 0.4 % from the approved design content.
12.8 Measurement and Payment:
Each lot quantity of the Superpave concrete layer shall be measured in cubic meters
compacted to the specified density ratio and in accordance with the thickness shown on plans.
The payment shall be according to the contract unit price or the modified unit price per cubic
meter for any constructed layer of asphalt concrete. No measurement shall be made for
quantities and areas placed outside the allowed limits for payment purposes. Payment and
prices shall be full compensation against provision of labor, materials, equipments, tools and all
other items necessary for work completion as shown in this General Specifications and this
Special Specifications.
341
DIVISION 13
13.1 Scope
13.2 On-R oad Cold M ix Pavem ent
13.2.1 Description
13.2.2 Materials
13.2.3 Job Mix Requirements
13.2.4 Equipment
13.2.5 Construction
13.2.5.2 Mixing Soil With Asphalt And Compaction
13.2.5.3 Pavement Surface Isolation
13.2.5.4 Finishing
13.2.8 Measurements
13.2.9 Payment
13.3 On-R oad Hot M ix Pavem ent
13.3.1 Description
13.3.2 Materials
13.3.3 Job Mix Requirements
13.3.4 Equipment
13.3.5 Construction
13.3.5.2 Mixing Soil And Asphalt
13.3.5.3 Hauling, Spreading, And Compacting
13.3.5.4 Finishing
13.3.8 Measurements
13.3.9 Payment
13.4 A sphalt M acadam
13.4.1 Description
13.4.2 Materials
13.4.3 Equipment
13.4.4 Construction
13.4.5 Finishing
13.4.7 Measurements
13.4.8 Payment
345
345
345
345
345
345
345
345
345
346
346
346
346
346
346
347
347
347
348
348
348
348
348
348
348
348
349
349
349
349
349
350
350
350
350
350
351
351
351
353
353
353
354
354
354
Division 13 - Remote Areas Pavement Work
DIVISION 13
13.1 Scope:
This Division consists of furnishing and construction asphalt pavement using
locally available materials mixed with liquid asphalt for remote residential complexes or for
low-volume roads over a well-prepared surface according to Division 6 in these General
Specifications. These works includes on-road cold-mix and hot-mix pavements and
asphalt Macadam pavement.
13.2 On-Road Cold Mix Pavement:

13.2.1 Description:
This work consists of furnishing and paving a layer by mixing available soil with
liquid asphalt by mobile plants or leveling grader on-site, spreading, and aerating the mix
after the diluting materials to evaporate, compacting the mix as shown on the plans, in
accordance with these specifications and the Special Specifications, and as directed by
the Engineer.
13.2.2 Materials:
Asp halt M aterials: It shall be liquid asphalt or emulsified asphalt conforming to the
quality requirements specified in Tables (7.2.2) to (7.2.7) in these General Specifications.
A ggregates or Soil: It shall be from the best available materials with minimum
requirements of AASHTO A-3 soil classification and with a maximum plasticity index of 6.
The materials passing sieve number 200 shall not be less than twenty-five (25) percent of
the total weight of aggregate or soil.
13.2.3 Job Mix Requirements:

Before commencing the work, the Contractor shall submit a technical report containing
the proposed source, types, mixing proportion, and execution plans for the Engineers
approval.
13.2.4 Equipment:
The Contractor shall furnish and operate sufficient equipment to execute the asphaltic
concrete work within the Contract time in accordance with his Program of Work as
approved by the Engineer. This equipment shall the following:
1.
2.
3.
Trucks to haul the mix from the mixing site to the pavement site.
Mixing and spreading equipment and hand tools.
Rollers with suitable weights to achieve the required compaction levels.
Prior to haul the mix to the project site, the road surface shall be stable,
conforming to the longitudinal and transverse levels, conforming to the compaction
requirements, and executed according to the Special Specifications and these General
345
Specifications. The levels shall be identified by poles and sticks when the grader
equipment is used.
13.2.5.2 Mixing Soil with Asphalt and Compaction:

When the grader is used for mixing, the soil may be stockpiled in longitudinal or
transverse piles or may be spread on the surface. Required percentage of asphalt
material shall be added, and the mixing by grader shall be continued to obtain a uniform
mix and to let the diluting materials evaporate from the liquid asphalt.
The mixing process may be done in specified off-road sites; the mix is transported
and spread by the paver or the grader; the mix shall be compacted by the suitable rollers
to the required thickness and density, as in the special specifications or contract
documents.
13.2.5.3 Pavement Surface Isolation:

When stated in the Special Specifications, the pavement surface shall be isolated
by spraying an asphalt layer from the same materials used in the mix at a rate of one (1)
kilogram per square meter, or as specified by the Special Specifications. This layer shall
be applied after the asphalt material is cured (liquid asphalt) or set (emulsified asphalt).
13.2.5.4 Finishing:
The road surface shall be acceptably leveled. The un-evenness (bumps and
sags) of the surface is measured by a three (3) meter straight edge. The deviations of six
(6) millimeters in the longitudinal direction or ten (10) millimeters in the transverse
direction are allowed. The Contractor shall repair all portion in the pavement surface with
deviations higher than these specified ones.

on-road cold mix pavement construction work zones.

The Contractor shall apply quality control procedures for all on-road cold mix
pavement works to ensure that the materials used and the executed work conform to
The Ministry shall assure the quality of production by checking that the Contractor is
performing the quality control procedures in correct manners. The Ministry may have a
procedures in an independent unbiased way, on adequate number of samples to judge
the execution level and decide whether to accept or reject the work. Division 17 in these

collect, document, and draw the critical property diagrams to ensure that the raw
materials at source, materials while work execution, on-road cold mix pavement
produced, and the executed work are within acceptable limits. The tests may be
performed at The Contractors laboratory or at an independent laboratory, approved by
346
the Ministry. The Contractor shall submit copies of all test results to the Engineer. Table
(13.2.1) shows the tests that the Contractor shall perform on raw materials and mixes,
the frequency of these tests, and the allowance limits.
The Contractor shall submit copies of all tests to the Engineers and shall apply
all requirements detailed in Item 17.1.1 in these General Specifications.
Table 13.2.1: Quality control requirements for on-road cold mix pavement
Work
Properties
Asphalt materials
Raw
materials
Soil
Material at
use
Job mix
requirements
Finishing
Level,
dimensions,
slopes, and
smoothness
Test Method
Sample
location
Sampling frequency
Requirements
Tables 7.2.2
to 7.2.7
Three (3) tests at start of work

or source change
Item 13.2.2
Project
site
One test per day work
Job mix
requirements
Project
site

maximum, Use the straight
edge for smoothness
Contract
documents and
Subitem
13.2.5.4
Quality
requirements
tests
Quality
requirements
tests
Source
Geometric
measurement
s

supervision, some or all quality control tests that are shown previous Subitem.
On-road cold mix pavement specified and completed within the lines shown on
the plans or ordered by the Engineer shall be measured in square meters.
13.2.9 Payment:
per square meter measured as described in the pervious Item for on-road cold mix
pavement when listed in the Bill of Quantities.
materials, equipment, tools and incidentals necessary for completing all work involved in
construction of on-road cold mix pavement. Payment will be made according to Table
(13.2.2).
Table 13.2.2: On-road cold mix pay items

No.
13.2.1
Pay Item
On-road cold mix layer
Pay units
Square meter
347
13.3 On-Road Hot Mix Pavement:

13.3.1 Description:
This work consists of furnishing and paving a layer by mixing available soil with
liquid asphalt by mobile plants, spreading, and after the diluting materials evaporate,
compacting the mix as shown on the plans, in accordance with these specifications and
the Special Specifications, and as directed by the Engineer.
13.3.2 Materials:
A sp halt M ate r ia ls: unless stated in the Special Specifications or Contact Documents,
asphalt materials shall be 60/70 penetration grade conforming to table (7.2.1), in these
General Specifications. When the asphalt modifiers, such as anti-stripping agents, are
used, they shall conform to quality requirements specified in Item 7.2.4 in these General
Specifications.
A ggregates or Soil: It shall be from the best available materials with minimum
requirements of AASHTO A-3 soil classification and with a maximum plasticity index (PI)
of 6. The materials passing sieve number 200 shall not be less than twenty-five (25)
percent of the total weight of aggregate or soil.
M in era l F ille r: mineral filler, i f required, shall conform to the requirements stated in
Item 7.3.4 in these General Specifications.
13.3.3 Job Mix Requirements:

Before commencing the work, the Contractor shall submit a technical report
containing the proposed source, types, mixing proportion, and execution plans for the
Engineers approval.
13.3.4 Equipment:
The Contractor shall furnish and operate sufficient equipment to execute the asphaltic
concrete work within the Contract time in accordance with his Program of Work as
approved by the Engineer. This equipment shall include those shown in Item 13.2.4 in
This Division.
13.3 .5.1 Surface Preparation:
Prior to haul the mix to the project site, the road surface shall be stable,
conforming to the longitudinal and transverse levels, conforming to the compaction
requirements, and executed according to the Special Specifications and these General
Specifications. The levels shall be identified by poles and sticks when the grader
equipment is used.
13.3.5.2 Mixing Soil and Asphalt:

The soil or aggregate shall be heated and dried and the asphalt binder shall be
heated before both are mixed in a mobile site mixing plant capable of heating the soil
and asphalt. The mixing shall continue till all aggregate or soil particles are completely
covered by asphalt.
348
13.3.5.3 Hauling, Spreading, and Compacting:

The mix shall be transported to the project site by dump trucks with clean boxes
free from dust or deleterious materials. The mix shall be dumped directly in paver ( if
available). Otherwise, the mix shall be directly dumped on the surface and spread by the
grader.
Initial compaction shall start directly after spreading the mix by steel rollers. The
compaction shall continue by steel and pneumatic rollers till the required density is
achieved.
13.3.5.4 Finishing:
deviations higher than these specified ones

on-road hot mix pavement construction work zones.

The Contractor shall apply quality control procedures for all on-road hot mix
pavement works to ensure that the materials used and the executed work conform to

materials at source, materials while work execution, on-road hot mix pavement produced,
and the executed work are within acceptable limits. The tests may be performed at The
Contractors laboratory or at an independent laboratory, approved by the Ministry.
The Contractor shall submit copies of all test results to the Engineer. Table
(13.3.1) shows the tests that the Contractor shall perform on raw materials and mixes,
the frequency of these tests, and the allowance limits. The Contractor shall submit copies
of all tests to the Engineers and shall apply all requirements detailed in Item 17.1.1 in
349
Table 13.3.1: Quality control requirements for on-road hot mix pavement
Work
Properties
Asphalt materials
Raw
materials
Soil
M aterial at
use
Finishing
Job mix
requirements
Level, dimensions,
slopes, and
smoothness
Test Method
Quality
requirements
tests
Quality
requirements
tests
Quality
requirements
tests
Geometric
measurements
Sample
location
Sampling frequency
Requirem ent
s

Table 7.2.1
Three (3) tests at start of work

or source change
Item 13.3.2
One test per working day
Job mix
requirements
Source
Project
site
Project
site

maximum
Contract
documents
and Subitem
13.3.5.4

On-road hot mix pavement specified and completed within the lines shown on the
plans or ordered by the Engineer shall be measured in square meters for payment
purposes.
13.3.9 Payment:
per square meter measured as described in the pervious Item for on-road hot mix
pavement when listed in the Bill of Quantities.
involved in construction of on-road hot mix pavement. Payment will be made according to
Table (13.3.2).
Table 13.3.2: On-road hot mix pay items

Pay Item
No.
13.3.1
On-road cold mix layer
Pay units
Square meter
13.4 Asphalt macadam:

13.4.1 Description:
This Section consists of furnishing asphalt Macadam layer by laying a layer of big
crushed stones with sharp angularity over a prepared surface; level this layer, spry it with
asphalt binder heated to the proper temperature, fill the voids by small size angular
aggregates, then compact the resulted layer adequately for vehicular use.
350
This methodology is used in areas where plenty crushed stones are available and
the hot-mix asphalt is no feasible either the area is far away form the hot-mixing plants or
the project site is small in remote rural complexes.
13.4.2 M aterials:
A sp halt M ate r ia ls: unless stated in the Special Specifications or Contact Documents,
asphalt materials shall be 60/70 penetration grade, medium curing (MC) liquid asphalt, or
rapid setting (RS) emulsified asphalt conforming to quality requirement Tables of Section
7.2 in these General Specifications. Tables (8.3.1) to (8.4.1) show the asphalt cement
application rate or the asphalt residue for liquid or emulsified asphalt.
A g greg ate: It shall be clean, durable, angular, with uniform characteristics, free from
any dissolvable materials, with a maximum Los Angeles abrasion of 45%, and
conforming to gradation requirements specified in Tables (8.3.1) and (8.4.1) for coarse
and fine aggregate sizes.
13.4.3 Equipment:
asphalt stone mastic mix work within the Contract time in accordance with his Program of
Work as approved by the Engineer. This equipment shall include the following:
1. Dumping truck for aggregate hauling
2. Aggregate spreader
3. Steel rollers with minimum weight of ten (10) tons
4. Asphalt heating equipment
5. Asphalt distributors
6. Power broom or power blower
7. Hand tools such as brushes and hand shovels
Before starting Macadam pavement construction, the road surface shall be stable,
conforming to the longitudinal and transverse levels, and conforming to the compaction
requirements. When the grader equipment is used, the subgrade levels shall be identified
by poles and sticks.
The construction shall be done according to the following steps:
1.
The coarse aggregates shall be hauled from their sources by trucks and
spread on a prepared surface by power spreader or manually. The spreading
shall be uniform, without aggregate segregation, and by the thickness
specified by the Special Specifications.
2.
The spread aggregate shall be compacted by steel rollers. The compaction

shall be in the parallel direction and shall start at the outer edge of the road
and progress towards the center. The compaction shall continue to obtain a
smooth surface, free from any waves, and shall have evenly distributed voids.
3.
The coarse aggregate layer shall be completely dry and the air temperature
shall be at least fifteen (15) degrees Celsius before applying the heated
asphalt. The asphalt shall be heating in special heaters and distributed over
the compacted aggregate layers by one application using pressure distributor.
4.
After asphalt application and before the air temperature drops, the fine
aggregate layer is spread over the compacted layer to fill the voids, and this
layer is compacted until all voids are filled and surface is firm and smooth.
351
Table 13.4.1: Gradation requirements for Macadam layer thickness 90-100

m illim eters
Percent
Sieve size
passing
77 mm (3 in.)
Coarse stone
100
Fine stone
-
63.5 mm (2.5 in.)
90 - 100
50.8mm (2 in.)
35 70
38 mm (1.5 in.)
0 - 15
25.4 mm (1 in.)
100
19 mm (4/3 in.)
0-5
90 - 100
12.5 mm (2/1 in.)
9.7 mm (8/3 in.)
20 - 55
0-5
4.75 mm (No. 4)
2.36 mm (No. 8)
Asphalt application rate (liter/square
t )
0 - 10
5.5-8

m illim eters
Percent passing
Sieve size
63.5 mm (2.5 in.)
Coarse stone
100
Fine stone
-
50.8mm (2 in.)
95 - 100
38 mm (1.5 in.)
35 - 70
25.4 mm (1 in.)
0 - 15
100
19 mm (4/3 in.)
12.5 mm (2/1 in.)
0-5
90 - 100
-
9.7 mm (8/3 in.)
20 - 55
4.75 mm (No. 4)
2.36 mm (No. 8)
0-5
0 - 10
Asphalt application rate (liter/square meter)
4.5 - 7

m illim eters
Percent passing
Sieve size
50.8mm (2 in.)
Coarse Stone
100
Fine stone
-
38 mm (1.5 in.)
90 - 100
25.4 mm (1 in.)
20 - 55
19 mm (4/3 in.)
0 - 15
100
12.5 mm (2/1 in.)
90 - 100
9.7 mm (8/3 in.)
0-5
40 - 75
4.75 mm (No. 4)
5 - 25
2.36 mm (No. 8)
0 - 10
1.18 mm (No. 16)
0-5
Asphalt application rate (liter/square meter)
3.5 - 6
352
When the Special Specifications stated to seal the compacted Macadam, liquid asphalt is
spayed at a rate of one (1) kilogram per square meter or as specified in the Special
Specifications.
13.4.5 Finishing:
deviations higher than these specified ones.

The Contractor shall apply quality control procedures for asphalt Macadam works
to ensure that the materials used and the executed work conform to these General

materials at source, materials while work execution, asphalt Macadam produced, and the
executed work are within acceptable limits. The tests may be performed at the
tests that the Contractor shall perform on raw materials and mixes, the frequency of
these tests, and the allowance limits. The Contractor shall submit copies of all tests to the
Specifications.
Table 13.4.4: Quality control requirements for Asphalt Macadam

Work
Raw
materials
Finishing
Properties
Asphalt
materials
Test Method
Sample
location
Quality
requirements tests
Sampling frequency
Requirement
s
Tables of
Section 7.2
Source
Aggregate
Quality
requirements tests
Level,
dimensions,
slopes, and
smoothness
Geometric
measurements
Thee (3) tests at start of work

or source change
five
Project twenty-five (25) meters or
site
maximum
Tables 13.4.1
to 13.4.3
Contract
documents
and Subitem
13.4.5
353
Asphalt Macadam shall be measured by the square meters of work acceptably
placed according to the requirement of this Section of the General Specifications.
13.4.8 Payment:
per square meter measured as described in the pervious Item for each type Asphalt
Macadam listed in the Bill of Quantities.
involved in construction and acceptance of Asphalt Macadam. Payment will be made
Table 13.4.5: On-road hot mix pays items

No.
13.4.1
Pay Item
Asphalt macadam pavement
Pay units
Square meter
354
DIVISION 14
CEM ENT PAVEMENT LAYERS
14.1 Scope
357
357
14.2 Materials
14.2.1
14.2.2
14.2.3
14.2.4
14.2.5
14.2.6
Cement
Aggregate
Water
Admixtures & additives
Chemical curing compounds
Reinforcement materials
14.2.6.1 Steel Re-bars
14.2.6.2 Fabricated Bar mats
14.2.6.3 Steel wire fabric reinforcement
14.2.6.4 Tie bars
14.2.6.5 Dowel bars
14.2.6.6 Reinforcement fibers
14.2.7 Joints fill materials
14.2.7.1 Prefabricated fills
14.2.7.2 On site cast fills
14.2.8 Plastic sheet
14.3 Cement concrete

14.3.1
14.3.2
14.3.3
14.3.4
14.3.5
14.3.6
14.3.7
14.3.8
357
Description
General requirements
Concrete mix design
Design job mix formula
14.3.4.1 Acceptance procedures of job mix formula
Mixing
Transportation
Concrete handling
Weather condition limitations
14.4 On site cast cem ent concrete

14.4.1 Normal concrete
14.4.1.1 Description
14.4.1.2 Materials
14.4.1.3 Equipments
14.4.1.4 Qualitative requirements and mixes
14.4.1.5 Design job mix formula
14.4.1.7 Joints
14.4.1.8 Joint construction
14.4.1.9 Remedial measures
14.4.2 Reinforced concrete
14.4.2.1 Description
14.4.2.2 Materials
14.4.2.3 Equipments
14.4.2.4 Cement concrete mixes
14.4.2.5 Construction 14.4.3
Roller compacted concrete
14.4.3.1 Introduction
357
359
360
361
362
362
363
363
363
363
363
363
363
364
364
364
364
364
365
367
368
369
370
371
371
371
372
372
372
372
372
374
374
374
380
382
384
386
386
386
386
386
386
388
388
14.4.3.2 Materials
14.4.3.3 Equipments
14.4.3.4 Quality requirements and mixes
14.4.3.5 Job mix formula
14.4.3.6.1 Surface preparation
14.4.3.6.2 Experimental section
14.4.3.6.3 Concrete spreading and compaction
14.4.3.6.4 Curing of compacted concrete 14.4.3.7
Joints
14.5 Pavem ent layers from pre-cast concrete

14.5.1 Pre-cast concrete slabs 14.5.1.1 Description 14.5.1.2
Materials 14.5.1.3 Equipments
14.5.1.4 Qualitative requirements
14.5.1.5 Manufacturing 14.5.1.6 Construction
14.5.1.6.1 Surface preparation
14.5.1.6.2 Installation
14.5.1.7 Joints
14.5.2 Pavement layers from overlapping concrete bricks
14.5.2.1 Manufacturing 14.5.2.2 Installation
14.6 W ork Acceptance 14.7 Measuring
14.8 P aym ent
388 388
390
390
391
391
392
392
394
394
395
395
395
395
396
396
396
397
397
397
397
397
398
398
398
401
401
Division 14 - Cement pavement Layers
DIVISION 14
C E M E N T P A V E M E N T LAYERS
Cement pavement layers are used in constructing pavement layers of urban roads of different
types whether highways, arterial, collectors and local. The selection of the used layer type depends on the
road classification, environmental conditions and prevalent/ expected traffic loads.
The cement pavement layers shall be of high quality, they should be resistant to heavy traffic
loads, loads arising from the environment and its fluctuations, and shall be of considerable continuity that
gives them the characteristic durable pavement layers. Their surface shall be resistant to polishing under
the effect of vehicle tires so that they maintain suitable friction factor, and they should be free from
distortions that affect safe driving and the smooth driving on the road.
14.1 Scope:
This division contains description of construction requirements of cement pavement layers in
urban areas by using on-site cast cement concrete or pre-cast cement concrete products. Also, it determines
the design of producing and supplying cement concrete mixes including requirements for all its
compositions. In addition, it includes construction materials and methods of the following types of
cement pavement layers:
a- On-site cast cement concrete that include:
- Normal cement concrete.
- Reinforced cement concrete.
- Compacted cement concrete.
b- Pre-cast cement concrete that include:
- Pre-cast slabs from normal & reinforced cement concrete.
- Overlapping pavers block.
14.2 Materials:
14.2.1 Cement:
Cement used in the construction of cement pavement layers works shall be one of the types listed in
Table (14.2.1), except otherwise indicate special specifications or other contract documents.
Table 14.2.1: Types of cement used in the construction cement pavement layers
Cement type
Normal Portland cement type I, I I , I V , I I I
Normal Portland cement type V
anti Sulphate
Portland Pozzolan cement type IP
Pozzolan Modified Portland I(PM) cement
Specification requirements
ASTM C-150
ASTM C150 or SASO570
ASTM C-595-94a
ASTM C-1157-94a
The type of the selected cement shall be suitable for prevalent local environment as to being
exposed to harmful chemical materials in natural soil or underground water or sewage water. Special
specifications shall indicate the type to be used. Also, it is
357
possible, except otherwise stipulate special specifications a specific type, to choose the type of cement
from Table (14.2.2) on the basis of classification of chemical environment effect levels. Contractor shall
submit a certificate cement testing results, which confirm fulfillment of the requirements of Table
(14.2.1) i f the source of cement was not known, or when there is doubt that the cement was improperly
stored.
Table 14.2.2: Classification of harmful chemical environment in natural soil, or

ground water or sewage water, and type of suitable cement.
(As per the requirements of European Specifications No. E N 206.1)
Chemical Properties
Low
Effect level of harmful chemical environment

Medium
High
Rate of impurities in water
Sulphate contents
S O 4 (mg/liter.)
N H 4 content
(mg/liter.)
PH
200-600
601-3000
3001-6000
15-30
31-60
61-100
5.5-6.5
4.5-5.4
4.0-4.5
Material rates in natural soil in contact
S O 4 content
( m g/litr.)
Suitable cement
type
2000-3000
Normal Portland
cement type I, or a
mixture of cement
and pozzolan type
IP, I(PM)
3001-12000
12001-24000
Sulphate resistant Portland cement, type

V, and it is possible to add pozzolan to it
with the approval of the Engineer.
Contractor, after he obtains acceptance from the Engineer, may mix Portland cement with
pozzolan at the concrete mixing location, after he ensures availability of the required capabilities,
provisions and control for achieving the mixing rates within the allowable variations, and on the basis of
laboratory testing results compliance with the requirements of Table (14.2.1) which enhance mix
suitability for producing the required cement concrete.
When it is necessary, it is possible to execute sulphate resistant concrete in chemically harmful

environment whether medium or high level. In case sulphate resistant cement type V is not available a
sulphate resistant concrete mix formula may be prepared by using normal Portland cement type I or
cement and pozzolan mixture type IP or I(PM) providing that the following provisions are taken:
- To increase cement content to 400 kg/m3 of concrete.
- To reduce water cement rate to 0.35.
- To use suitable mineral applications when using normal Portland cement type I
according to ASTM C-1240 specifications and testing method ASTM C-1012.
- To apply the necessary curing techniques to avoid random cracks resulting from
using high cement rates.
358
Contractor shall verify the resistance of the mix against sulphate by applying testing method
ASTM C-1012 and to verify fulfillment of ASTM C-618 requirements. The design job mix formula shall
stipulate type of cement to be used and obtaining the Engineer's acceptance for that.
When there is a great need for reaching high level of resistance at an early period, and with the
acceptance of the engineer, it is possible to use rapid hardening Portland cement compliant with ASTM
C-150 I I I . In such case, the necessary measures shall be taken to avoid the effect of the great shortage in
available time for casting, operating and finishing concrete to avoid the increasing possibility of random
cracking of concrete because of using this type of cement.
It is totally prohibited to use cement that contain diluted lumps or cement in which dilution
started. Cement shall be stored away from moisture such that it may be used promptly. Type of cement
shall be written clearly on storing silo. Bulk cement shall be left for a sufficient period in the storing silo
until it cools down to the suitable temperature specially when mixed in hot weather.
14.2.2 Aggregate:
The aggregate used in producing cement concrete shall be clean, solid, hard, low porous, and
non-affected by chemically harmful environment. It shall be compliant with standard specification
requirements of ASTM C-33, except if that contradicts with special specifications or these general
specifications or other contract documents. Also, possibility of aggregate reaction with alkali shall be
evaluated according to ASTM C-1260.
Aggregate used in cement concrete shall achieve the qualitative requirements shown on Table
(14-2-3) except otherwise indicated in the special specifications.
Coarse aggregate shall be composed of natural gravels or crushed stones. Fine aggregate shall be
composed of crushed or uncrushed natural sand of good gradation providing that it fulfils the relevant
qualitative requirements stipulated in Table (14.2.3).
When using cement concrete type (A) or (B) or (C) or (D) according to Table (14.3.2), aggregate
shall be composed of two main types: coarse aggregate (retained on sieve No.(4) and fine aggregate
(passing on sieve No. 4). But when using roller compacted cement concrete type (M1) or (M2) shown on
table (14.3.2), it shall achieve requirements of gradation No.(4) listed in Table (14.2.4), except otherwise
stipulate special specifications. Aggregate from gradation No.(4) shall be supplied in three separate sizes
which are size 25 mm, size 12.5 mm and size 9.5 mm. Fine aggregate shall achieve requirements of
gradation No.(3) indicated in Table (14.2.4) Coarse aggregate shall achieve requirements of aggregate
gradation No.( 1) or No. (2), indicated in Table (14.2.4) or any other gradation stipulated in the
specifications. Aggregate from gradation No. (1) shall be supplied in two separate sizes, the first retained on
sieve size 19 mm and the second passing from it, however, coarse aggregate from gradation No.(2) may
be supplied according to the required gradation without separating it into two sizes.
I f it was extremely needed, and after the possibility of obtaining a cement mix that achieves the
qualitative requirements indicated in Table (14.2.3) and concrete
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workability at site have been ascertained through testing; and after the Engineer's acceptance, Contractor
can use aggregate that has a gradation which does not meet all gradation requirements indicated in Table
(14.2.4); providing that it achieves the highest strength, the least permeability and the highest possible
workability for concrete.
Aggregate shall be piled in layers to avoid grain segregation. Also, aggregate shall be moistened
before use by using water sprayers for two purposes the first: cooling it when the weather hot and the
second: moisture content conformity within limits (less or more) close to Saturated Surface Dry State.
Contractor shall ensure provision of aggregate quantities, which are sufficient for producing cement
concrete for a period not less than (2) continuous working days to ensure continuity of concrete
production.
Table 14.2.3: Aggregate qualitative requirem ents

Index
Test No.
Limit value
Los Angeles Abrasion Test 500 cycles.
AASHTO T96
Maximum
50%
Soundness by Sodium Sulphate solution (5 cycles)
AASHTO T104
Maximum
12%
Clay lumps and friable particles percentage in

coarse aggregate
Maximum
3%
Clay lumps and friable particles percentage in

fine aggregate
Passing percentage from sieve No. 200 in coarse
aggregate
ASTM C-33
Maximum
1%
Maximum
3%
Passing percentage from sieve No. 200 in fine

aggregate
Sand equivalent of fine type aggregate
AASHTO T 176
Minimum 75
Crushed faces percentage one face
ASTM D5821
Minimum
50%
Organic materials percentage
AASHTO T21
Maximum
2%
BS812:
Sec105.2
Maximum
40%
AASHTO T290
Maximum
1%
Elongation factor (elongated & flat particles)

Sulphate percentage
14.2.3 Water:
Water used in mixing and curing cement concrete, and in cooling aggregate shall be clean,
clear and free from materials harmful to lean and hardened cement concrete properties; such as
oils, alkali, acidic materials. Also, shall be free of plantation and organic materials. It shall fulfill
conditions indicated in Table (14.2.5), regardless of its source. Setting time test shall be performed
only when using non-fresh water or potable water with changed color or taste or secondary treatment
sewage water. Fresh potable water can be used in cement concrete works without the need for testing.
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Table 14.2.4: Requirements of cement concrete aggregate gradation
Sieve size, mm
Gradation 1
37.5
25
19
12.5
9.5
4.75
2.36
1.18
0.60
0.30
0.150
0.075
100
95-100
25-60
.
0-10
0-5
..
..
Passing by weight %
Gradation 2
Gradation 3
..
100
.
.
20-55
0-10
0-5
..
.
..
..
100
95-100
80-100
50-85
25-60
5-30
0-10
Gradation 4
.
100
82-100
72-93
66-85
51-69
38-56
28-46
18-36
11-27
6-18
2-5
* Gradation (4) is used in producing compacted concrete.
Table 14.2.5: Quality requirements of water used in mixing & curing concrete
Composition type
Cl ions
ASTM D-512
S O 4 ions
Alkali ( N a 2O+0.658 K2O )
Total content of solid materials.
Compressive strength (1) at 7

days.
Setting time
Testing method
Primary
Secondary
ASTM D-516
AASHTO T-26
Specified values
Max. 1000 part of 1 million

Max. 3000 part of 1 million.
Max. 600 part of 1 million
Max. 50000 part of 1 million.
ASTM C-109
Min. 90% (2)
ASTM C-191
Difference not more than 60 min.

Difference not more than 90 min.
14.2.4 Admixtures & additives:
When special specifications stipulate the use of admixtures such as setting readers, water
reducers, workability improvers, and other cement concrete property improvers or additives such as fly
ash and silica dust, the additives shall be compatible with AASHTO M-295 specifications, however,
admixtures shall be compatible with AASHTO M- 194 or ASTM C-494 specification. In addition, they
shall achieve the requirements indicated in Table (14.2.6), and Contractor shall submit a certificate based
on laboratory tests ensuring the suitability of those materials for the local environment in which they
shall be used.
Materials shall be supplied from approved sources according to source guarantee certificate. These
materials shall be applied by the method and in the rate specified in the approved design job mix formula
and in accordance with the instructions of the manufacturer. When using more than one type of the
admixtures or additives in the same concrete mix their compliance shall be ensured on the condition that
none of them causes damage to the other. In all conditions, application of those materials shall not lead
to improving some properties of concrete and damage the others.
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14.2.5 Chemical curing compounds:
When special specifications state or necessity calls for using chemical curing compounds to cure
tender concrete, specially during cement concrete casting in hot weather, those materials shall be used
immediately after surface finishing to avoid evaporation of the mixing water from concrete surface.
It is possible to use chemical liquids that form the curing membrane which are compatible with the
requirements of specification (Liquid Membrane Forming compound, AASHTO M-148 Type 2).
The chemical liquid is sprayed with a rate ranging between 0.5 and 1.0 liter./m2. When temperature
exceeds 38 degrees the liquid shall be sprayed two consecutive times. The rate of spraying is determined for
each time according to the results of the experimental section, such that a complete cover is obtained for the
concrete surface that prevents evaporation of mixing water.
It is possible to use emulsified asphalt type SS-1h or CSS-1h compliant with the requirements indicated in
Table (7.2.4) or (7.2.5), of these general specifications, only in curing roller compacted concrete and with
spraying rate ranging between 0.5 and 1.5 liter./m2. The actual rate of spraying shall be determined on the
basis of experimental section results.
When prevailing environmental conditions require, the Engineer may ask the Contractor to saturate
concrete surface with water either by flooding or spraying method and to cover it with canvas or plastic
membrane for a period ranging between 24 & 72 hours, then covering it with chemical curing compounds as
indicated above.
Table 14.2.6: Classification of admixtures and performance improvement

requirements, compared with standard mixes which do not contain admixtures
Admixture type
Normal reducer of water
High reducer of waterHRWR
Setting retarded
Setting accelerator
Entrained air voids
Required properties
Lowest reduction of water quantity
Lowest compressive strength at age 28 days
Lowest reduction of water quantity
Lowest compressive strength at age 1 day
Increase at primary setting time
Increase at final setting time
Decrease in final setting time
Lowest compressive strength at age 1 day
Size of entrained air voids
A S T M C 494
requirem ents
5%
110%
12%
140%
115%
60-90 min.
Less than 210 min.
90%
Minimum 60 min.
120%
90%- 100%
3.5%-7%
75%
14.2.6 Reinforcement materials:
When special specification, drawings, or other contract documents indicate the use of reinforced
cement concrete or reinforced joints in carrying out the cement pavement layer, it is possible to use any of
the following reinforcing materials according to drawings:
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14.2.6.1 Steel Re-bars:

Re-bars shall be from deformed type and should be compliant with the requirements of
specification SASO2 or specifications ASTM A-615 or ASTM A-706 class (60 or 40), as specified in the
special specifications or shown on drawings.
When special specifications stipulate the use of re-bars painted with rust resistant epoxy material and they
shall be compliant with specifications ASTM A 775, and Contractor shall ensure the absence of scratches
or holes in epoxy exceeding the limits allowed in the special specifications.
14.2.6.2 Fabricated Bar mats:

Reinforcement fabricated bar mats shall achieve requirements of specifications ASTM A-184.
14.2.6.3 Steel wire fabric reinforcement:

The steel wire fabric reinforcement shall achieve specification SASO224 or specifications
ASTM A-185 or ASTM A-497 and according to ASTM A-884 for epoxy painted bar mats.
14.2.6.4 Tie bars:

Tie bars from deformed steel shall achieve compliance with specifications ASTM A615, class 60
or 40, as specified in special specifications and drawings. Except otherwise allowed in special
specifications, bars with diameters 14 mm shall be used for slabs of thickness 200 mm or less, and bars
diameter 16 mm shall be used for slabs with thickness more than that. It is possible, when necessary and
after obtaining written acceptance from the Engineer, to use 12 mm diameter bars in slabs with thickness
less than 200 mm.
14.2.6.5 Dowel bars:

Except otherwise allowed by the specifications, dowel bars shall be of circular cross section and
with level smooth surface that is free from nicks and deformations. They shall be made from steel that
achieves specifications ASTM A 615, class 60. Diameter 32mm bars shall be used for slabs with thickness
equal to or less than 200 mm or less and diameter 38mm bars for slabs with thickness that exceed 200
mm.
14.2.6.6 Reinforcement fibers:

When special specifications or other contract documents stipulate the use of reinforcement
fibers, or glass or plastic, these fibers shall be from the type specified in the special specifications or
other contract documents. The steel reinforcement fibers shall achieve specifications of ASTM A 820.
They shall be applied in the rate of at least 0.20% of concrete volume. The reinforcement fiber glass shall
achieve specifications ASTM C- 1116 Type I I , while plastic fibers shall achieve specifications ASTM C1116 Type I I I and they are applied in the rate of at least 1% of concrete weight, except otherwise
stipulate special specifications or other contract documents.
14.2.7Jointsfillmaterials:
Joints fill materials shall
be chosen by
using The American Asphalt method ACI-504R, except otherwise stipulate special specifications.
Maximum limits of requirements shall be applied for areas where the temperature of concrete exceeds 50
degrees.
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Joint fill materials shall be in compliance with the type specified in the special specifications or
other contract documents; and except otherwise special specifications stipulate for a specific type; it is
possible to fill joints by using prefabricated fills or joint fill materials which are cast at site from one of
the following types, providing that they are from proven and approved types in the kingdom. Contractor
shall submit the approved certificates which prove that and the Engineer's acceptance shall be obtained.
14.2.7.1 Prefabricated fills:
These include any of the following materials:

a- Expansion fills from asphalt (hard or elastic) for concrete pavement and structures according to
specifications ASTM D- 1751.
b- Fills from sponge rubber or cork for concrete pavement and structures according to specifications
ASTM D-1752.
c- Seals from polychloroprene elastomers compounds according to specifications ASTM D-2628.
14.2.7.2 O n site cast fills:
These include any of the following materials: Fills which are from elastic type and cast hot into
joints providing that they achieve specification ASTM D-1 190.
a.
b.
Fills which are cold cast into joint and achieve specification requirements of
ASTM D-1850.
Elastomer fills cast hot into joints and achieve specification requirements of ASTM D-3406.
It is possible to use any other suitable prefabricated or on-site cast joint fills providing that Contractor
shall submit an approved source guarantee certificate showing suitability of the proposed type and
method of using it in filling joints after obtaining the Engineer's acceptance for using it.
14.2.8 Plastic sheet:
They include the following types, except otherwise stipulate special specifications or other
contract documents:
a.
Bond breaker plastic sheets between cement pavement layer and bottom sub base.
b. Plastic sheets for retaining moistening water used for curing cement concrete. The plastic sheet
shall be from P.V.C. compliant with the requirements of specification (ASTM D-1593, type I I) , or from
polyethylene type compliant with the requirements of specification (ASTM D-2103, type II). The
nominal thickness for these sheets shall range between 0.15 mm and 0.20 mm.
14.3 Cement concrete:

14.3.1 Description:
The used cement concrete shall be of suitable resistance and high strength that provide effective
performance throughout its use period in light of what cement pavement layers are subjected to of stresses
due to the operational and environmental conditions. They shall meet the requirements of specifications
ASTM C 94, except otherwise this may contradict with special specifications or these general specifications
or contract other documents.
Except otherwise specify special specifications and other contract documents, choosing the cement
concrete type shall be done on the basis of prevalent environmental
364
conditions as to under ground water table, exposure level of concrete to chemically harmful environment
whether from soil or underground water, as shown in Table (14.3.1) and as specified in the special
specifications or drawings.
Table 14.3.1: Guide for choosing cement concrete type according to existing
environmental conditions
No.
Cement concrete type
Depth of underground
water level under the
cement pavement layer
Level of exposure to
chemically harmful
environment in soil or
underground water or
sewage water
More than 1.5 m

More than 1.5 m
Less than 1.5
None
None
Low
Concrete type (A).
Concrete type (B)
Resistant concrete type

(C).
Not specified
Low- medium
Resistant concrete type

(D)
Not specified
High
Roller compacted
concrete type M1
Not specified
None- Low
Roller compacted
resistant concrete type
M2
Not specified
Medium- High
14.3.2 General requirements:
Contractor shall, before one month from commencement of work, provide the Engineer with a
detailed work plan fore review and approval. Contractor has no right to commence supply and execution
before obtaining the Engineer's acceptance of the work plan.
The work plan shall include the following:
1- Detailed working schedule that contains concrete casting program, equipments, production rates,
methods of spreading, operating, and curing concrete, joint cutting and filling with fill and insulation
materials.
2- Concrete supply program and casting locations as shown on drawings, providing that concrete
supplying shall be from one plant any time, so that the supplied concrete from each source shall be
used for construction in a specified site. It is allowed to carry out construction works at one casting
site by using concrete from more than one source.
3- An undertaking from the manufacturer to adhere to the concrete supplying program to the casting
site at the time specified for that.
4- Weather condition provisions during casting and operating the concrete.
5- Traffic control measures and scheduling of road opening to vehicle traffic.
In addition, contractor shall consider the following during construction works:
1- Concrete pavement construction for the road by using cast forms with slip-form. It is possible to use fixed cast
forms at areas where cast equipments with slip-forms cannot reach. Ramps and non-uniform cast areas may
be executed by either using slip-form or fixed forms.
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2- To stake levels and mount grade wire according to regulatory lines and the levels required on the
drawings and delivering these to the Engineer before adequate time before casting for approval.
3- Abidance with concrete supply schedule from the mixer to work site and casting locations as shown on
drawings and according to the approved plan.
4- Completion of casting, compaction, leveling, grading and roughening of layer surface before concrete
initial setting with adequate time. That shall particularly be considered when executing works in hot
weather.
5- Taking the necessary measures to prevent cracks as a result of plastic shrinkage of the layer surface, the
most important of which is not surpassing water evaporation rate from concrete surface. (Maximum
value is 1 litr/m2/h) after which cracks occur.
6- Except otherwise that contradict with drawings and/or special specifications, cement pavement layers,
concrete shoulders, and vehicle side parking shall be cast at the same time and in one pass in the form of
a monolithic pass. Lateral joint locations in the cement pavement layers shall be compliant with the
road, concrete shoulders, and side parking.
7- When the width of the cement pavement layers under construction is less than the whole width of the
road, longitudinal joints shall be constructed which shall extend on the whole rout line or on the main
road edge.
8- Do not start construction of cement pavement works on an underlying layer with concrete with little
cement content or on cement treated base course or on cement treated sub grade before the elapse of the
approved curing time. Providing that it shall not be less than 7 days from the date of its construction.
9- Protection for the underlying layer due to cleaning operations with equipments and from casting wastes.
Any damage that may have inflicted the underlying layer shall be repaired immediately by the method
accepted from the Engineer, before commencing pavement works. It is not permissible to allow water
used in washing to collect in the form of ponds on road surface.
10- Concrete that drops or scatter on the existing pavement shall be removed before it hardens.
11- When necessity calls for cement concrete pavement layers with high rates which require production
capacity that can not be met from one concrete source, contractor can, after obtaining the Engineer's
acceptance, supply concrete from more than one source of qualified ready mix concrete plants. In such
case, it shall achieve requirements of specification ASTM C-94, considering the following:
To submit plant qualification certificate and its production capacity per hour and availability of
concrete transportation equipments to work site.
Submission of necessary technical report on design mix and job formula.
Submission of concrete supply program and casting locations as shown on drawings, providing that
concrete shall be supplied only from one plant at all times, such that supplied concrete from each
source is used for execution at a specified site. It is not permissible to execute at one casting site
using concrete from more than one source.
To chose the plant location that causes the least confusion for traffic movement
inside urban areas.
Submission of an undertaking from the plant stating adherence to concrete

supply schedule to casting site at the time specified for that.
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14.3.3
Concrete mix design:
Except otherwise stipulate special specifications or contract other documents, concrete mix shall
be designed by getting use from available suitable raw materials and, except otherwise stipulate special
specifications or other contract documents, cement concrete shall be produced by using technically
acceptable materials which achieve material requirements indicated in section 14.2. In addition, the
concrete shall achieve the qualitative requirements listed in Table (14.3.2) and meet the requirements of
strength and soundness as to its durability in the environment in which cement pavement layer works shall
be executed. In that environment consideration shall be given to type and salinity of soil, underground
water table, type of this water and the chemical environment in general.
Except otherwise stipulate special specifications, cement concrete from type A, B, C, D shall be
designed by applying ACI 211.1 method. However, roller compacted concrete from types (M1 and M2)
shall be designed by applying ACI 211.3- A3 method.
Table 14.3.2: Qualitative requirements of cement concrete used in constructing

cement pavement layers
Concrete
type (D)
Concrete
type
(M2)
Concrete
type (A)
Concrete
type (B)
Type of cement
according to
A S T M C 150
specifications
Type I or
IP or
I(PM)
Type I or
IP or
I(PM)
Type V
Type V
Cement quantity,
kg/m3 (minimum)
300
350
350
400
350
400
Aggregate maximum
size, mm AST M C-33
37.5
37.5
37.5
37.5
25
25
Water cement ratio

(Maximum)
0.55
0.45
0.45
0.38
0.50
0.40
Slump, mm, AASHTO

T-119
10-75
10-75
10-75
10-75
Zero
Zero
Air voids content,

percentage,
A A S H T O T-152, T196, or T-199
Less than
3
5-8
3-5
5-7
Compressive strength
(age 28 days),
minimum, M Pa.,
A A S H T O T-22
28
35
35
40
28
40
Flexural strength (age

28 days), M P a
minimum A A S H T O T97
3.5
4.5
4.5
3.5
5.0
Concrete
type (C )
Concrete
Type
(M1)
Requirement
No.
Type I or
IP or
I(PM)
Non
applicable
Type V
Non
applicable
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During concrete mix designing, the following standards shall be considered:

A-
Concrete workability:
Produced concrete shall achieve required workability of concrete transportation, unloading and
spreading, such that uniform pavement layers, which fulfill the required thickness, smoothness and density,
are constructed. Control on these is done through suitable values of water cement ratio, cement type and
quantity, aggregate maximum size and gradation, particles shape and texture and usage of suitable additives
and admixtures when needed.
B-
Concrete strength:
Produced concrete shall achieve the strength specified in the approved design job mix formula,
within the limits indicated in the special specifications and other contract documents. These are controlled
through setting limits for compressive strength, flexural strength, using suitable cement quantity, least
possible value of water cement ratio, aggregate maximum size, and using suitable curing method.
Focus shall be made on concrete flexural strength, since it is the main factor that controls cement
pavement layers capability to bear traffic loads and effects of change in temperature. Concrete flexural
strength value required for structural design of cement pavement layers shall be obtained with reliability of
not less than 95% for arterial urban roads, highways, and industrial area roads or in other pavement layers
which are subjected to heavy vehicle traffic, and with reliability of not less than 85% in other pavement
layers.
Compressive strength shall be used for the purpose of mix design, production follow-up and
quality control. In case there is contradiction between concrete flexural strength requirements and concrete
compressive strength, then concrete flexural strength is the decisive factor.
C-
Concrete durability:
Used concrete shall have high durability suitable for pavement layer work conditions and for
ambient environment. This can be controlled by choosing the lowest possible values for water cement ratio,
cement type and quantity, entrained air voids rate, and usage of metal additives, providing that does not
affect the required rates for entrained air voids by any means.
D-
R a n d o m cracks control:
Random cracks shall be controlled by choosing the lowest possible value of water cement ratio,
using cement types IP or I(PM) whenever possible, control on water evaporation rate from concrete surface,
and casting when temperature is lowering, whenever possible.
E-
Polishing resistance:
This can be controlled by using aggregate that enjoys high polishing resistance and suitable particles shape
and size.
Before starting construction of cement concrete pavement layer works by 30 days, Contractor shall
submit to the Engineer a complete technical report prepared by a specialized approved agency. The report
shall contain the design job mix formula. The
368
report shall be based on laboratory testing results by using representative samples of aggregate, cement,
water, admixtures or additives determined for use in work execution. The report shall at least include the
following information:
1- Cement, admixture, additive types and a source certificate for each.
2- Original of testing results, which proof compliance of cement with specification requirements signed and
stamped from the Contractor and the laboratory approved by the Ministry.
3- Source of water used in mixing and curing process plus original of all test results
which show that water is in compliance with the requirements of these general
specifications or special specifications, signed and stamped from the Contractor.
4- Source of coarse and fine aggregate, and original of all test results which show that
water is in compliance with the requirements of these general specifications or
special specifications, signed and stamped from the Contractor, plus results of the
following tests on aggregate, which are necessary for mix design process shown on
Table (14.2.3), in addition to the following:
a.Maximum aggregate size (Absolute & nominal)..
b.Fine aggregate smoothness factor.
c.Aggregate qualitative density and its water absorption rate, according to requirements of ASTM C
128 & ASTM C 127.
d.Coarse aggregate dry unit weight according to requirements of ASTM C 29.
5- Rates of materials involved in the composition of the mix and allowable tolerance limits for each
material.
6- Test results original which proof compliance of qualitative properties of the mix with the requirements
indicated in special specifications and contract documents or with the contractor's proposed type and
approved from the Engineer, which is compliant with one of the types listed in Table (14.3.1). Except
otherwise stipulate special specification and contract documents for a specific type, such as concrete
slump, density, compressive and flexural strength, elasticity index values at age 28 days or any other age
specified by the Engineer. The report shall be signed and stamped from contractor.
The report shall include the following information:

1.
Type & location of mixer that shall be used together with concrete testing results produced.
2.
Weather state conditions and execution provisions in hot weather.
3.
Proposed date for commencing cement concrete production.
Contractor shall provide the adequate materials involved in the composition of the design mix such
as aggregate, cement, water, admixtures, and additives to the Engineer for verifying testing results of the
design mixes and whether mixing formulae have achieved specification requirements. Also, he shall provide
an access for the ministry representatives to locations of material storing, sampling, testing, production and
execution plants at all times.
14.3.4.1 Acceptance procedures of job mix formula:

Contractor shall submit the proposed design job mix formula with all its appendices as indicated in
the previous item. The Ministry shall review the job mix formula according to the following steps:
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1.
Ensure that the report includes all the required information. In case a shortage was found in
the required information, the report is returned to the contractor within 7 days to take the
necessary action and re-submit it.
2.
I f the report was complete but does not comply with the specified requirements, it is
rejected and returned to the contractor within 14 days. In such case contractor shall prepare
and submit a new design mix formula, which complies with the specified requirements to
the ministry.
3.
Verification shall be made for the possibility of executing the mix based on first working
day production as to execution and compaction.
It is not allowed to change source, methods of breaking, screening, blending, storing (piling) of
materials. Also, it is not allowed to change methods of producing the cement mix from the methods
applied in producing materials used in the approved design job mix formula, since any change of this sort
requires a re-evaluation for the mix. Also, it is not allowed to make any changes in the approved design
job mix formula without re-testing and re-submitting the proposed job mix formula (the modified one)
according to the steps indicated in item (14.3.4).
14.3.5 Mixing:
Except otherwise stipulate special specifications, production of cement concrete mix shall be made
in central mixers with suitable capacity. It is possible to use batch mixing plant or continuous mixing
mixers. In both cases, the mixers used shall be capable of applying water and completing the mixing
process in the mixer by applying the design mixing formula. Also, they shall be capable of producing
uniform mix compatible with the requirements indicated in these general specifications or special
specifications.
Those mixers shall be calibrated and provided with all control devices which allow aggregate
feeding according to approved weight and gradation plus cement and water feeding within allowable
tolerance limits.
It is allowed, when necessary and after obtaining the Engineer's written acceptance, to perform
dry mixing whereas all components are mixed and water is applied in the mixing truck during its journey
to the site, providing that shall not lead to degrading concrete quality or an increase in its non-uniformity.
The Engineer has the right to increase number of samples or repetition of sampling to verify the soundness
of such concrete.
Except otherwise it contradicts with these general specifications or special specifications, the
batch mixing plants shall achieve requirements of specification ASTM C-94 that controls ready mix
concrete. Also, continuous mixers shall achieve specification requirements of ASTM C-685 that control
concrete produced by volumetric rating and continuous mixing.
Consideration shall be given to the high production capacity required by the execution of roller
compacted concrete works when choosing type of the mixer to be used. It is recommendable to use
continuous mixers due to their high capacity and their capability of mixing compacted concrete
components with more uniform way. The mixer location shall be as near as possible to the work site and
it is preferable to use mobile trailed mixers whenever it is possible.
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Contractor shall submit with his design mix formula type and location of the mixer intended for
use. Verification shall be made for the possibility of producing a mix that is compatible with specifications
based on first day production. And it not allowed for the contractor to commence production before the
Engineer's acceptance for the mixer intended for use. Production shall be stopped and the necessary measures
shall be taken for calibrating the mixer or modifying the design job formula i f it was found that the
produced mix does not achieve the specified requirements.
14.3.6 Transportation:
Contractor shall prepare a plan for transporting the concrete mix, according to a time schedule for
production and transportation in which the separating interval between applying water to the mixture of
aggregate and cement, spreading, and starting/finishing compaction more than the periods stipulated. It is
possible to transport cement concrete (normal) in tipcart trucks provided with a leak proof tipcart truck or in
mixing truck. Compacted cement concrete shall be transported in tipcart trucks. Trucks shall be cleaned
after each load and it shall be ensured that there are no stuck materials on surfaces or mixing alternators in
the mixing trucks. The mix shall be discharged from the mixer to the trucks and shall be transported in such
way that ensures no particle segregation shall occur. Tipcart trucks shall be covered during transportation to
prevent mixing water evaporation.
14.3.7 Concrete handling:
Concrete handling shall be performed during all operations (mixing, transportation, spreading,
finishing) with the method suitable for the type of pavement layer and its construction method. That shall
not lead to damage of surfaces on which the pavement layer shall be constructed. Concrete shall not be
discharged in a free way over reinforcement steel bars or from a height of more than 1 meter, since that may
lead to particle segregation. Also, the method of concrete handling shall not affect reinforcement materials
for joints or slabs or layers when using reinforced pavement layers.
14.3.8 Weather condition limitations:
Cement concrete works shall not be executed in unsuitable weather conditions, when temperature
is less than 5 degrees or expected to drop within 48 hours and when wind speed exceeds 25 km/h. Also,
during sand & dust storms and during rainfall. The following precautions shall be taken during the
execution of cement concrete works in hot weather:
1- Concrete temperature shall not exceed 38 degrees when supplied to site.
2- Using iced water or ice cubes in mixing concrete.
3- Cooling aggregate by keeping it in shaded areas and spraying it with water, providing that does not
lead to an increase in mixing water or tolerance rates in it.
4- Do not use cement directly supplied from the factory and allow some sufficient time to pass for it
to cool down after being stored in silos.
5- Using type of cement suitable for carrying out cement concrete works in hot
weather.
6- Pre-planning of cement mix transportation process from the mixing location to
casting site such that it is executed within the shortest time. Setting retarders
shall be used when transportation period exceeds 45 min.
7- Works shall be executed by night when temperature is dropping.
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8- Continuous moistening of concrete surface by using water dribbles.

9- Spraying reinforcement bars with water dribbles for cooling immediately before casting without
leading to excessive moistening of the later surface over which the cement pavement layer shall be
cast.
10-Recording measures which shall be taken during hot weather when submitting mixing formula and
obtaining advance Engineering acceptance.
11-Maintaining mixing water evaporation rate from concrete surface such that it does not exceed 1
kg/m2 per hour. Evaporation rate is determined with relative air moisture index, concrete
temperature and prevailing wind speed according to ACI 305-R-99 method.
14.4 O n site cast cement concrete:

14.4.1 Normal concrete:
This item includes requirements of materials and works required for the construction of surface
layer from on site cast normal cement concrete according to dimensions, levels, and sites shown on
drawings, special specifications, other contract documents or these general specifications. That includes
provision of required materials, equipments, manual tools and labor; also procedures for ensuring quality,
levels, slopes of underlying layer surfaces on which pavement layer shall be constructed, and concrete
mixing, supplying, casting, and finishing works. Also, execution of different joints, when used, including
dowels and tie bars installations, filling of joints with fill materials as shown on relevant drawings, general
specifications and special specifications. In addition, this item includes construction work evaluation
procedures for production control, quality control and work acceptance purposes.
14.4.1.2 Materials:
The materials used shall be in compliance with the requirements indicated in special specifications,
other contract documents, and approved design job mix formula. They shall, except otherwise stipulate
special specifications, achieve requirements of sections 14.2 and 14.3.
14.4.1.3 Equipments:
Contractor shall provide all types of equipment required for executing the surface layer in the
required way and with sufficient numbers, which ensure completion of works within the specified time
schedule. Also, contractor shall submit to the Engineer a list of equipments and machines before he
commences work and shall obtain the Engineer's acceptance for it. In addition, he shall service the
equipments and keep them in a good operational state throughout construction period.
The equipment list includes the following types:
1- Mixers: Mixers shall be compatible with item 14.3.5.
2- Concrete transportation equipments: Concrete transportation equipments shall be compatible with
item 14.3.6.
3- Formwork:
It is possible to cast normal concrete pavement layers by using slip-forms fixed on concrete
spreading machine or by using fixed casting forms. It shall be confirmed that the fixed forms bear the
passing of spreading machines over them.
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Contractor shall use straight steel form joints not less than 3 m. in length, except at horizontal turn
areas where turning radius is not less than 30 m., whereas curved steel forms or other suitable forms
accepted from the Engineer shall be used. It is possible to use mobile or fixed forms according to
equipments used in concrete casting.
Form joints shall be, according to construction requirements:

- Straight or curved, according to construction requirements, without any bends or crookedness or
deformations.
- Have a depth equal to the thickness of the layer to be cast.
- Fixable with suitable stakes which enable them to bear the construction process of the surface layer
without deviations or any change in their straightness or level, while their base shall be in contact with
the underlying layer surface along the form length without any spaces.
- Provided with bolt nuts, which keep joints in place without any displacements and bolt nuts for linking
joint ends without protrusions.
- Also, their internal surface shall be oiled with suitable mineral oil (petroleum) before use.
4-
Concrete casting and spreading equipments:
When casting cement concrete pavement layers, concrete casting, spreading and operation shall be
done with slip-form paver and, when necessary, concrete spreader machines, which move over steel forms,
may be used. It is also possible, after obtaining the written Engineer's acceptance to cast concrete, of
quantity not more than 10 cubic meters, manually using ready mix concrete pumps.
5-
Vibrators (concrete densification systems) :
Suitable mechanical vibrators shall be used to condense concrete to the required density. It is
possible to use internal or surface vibrators.
Sufficient numbers of internal vibrators shall be used (one vibrator approximately each 600 mm).
These are usually fixed at the rear of concrete casting equipment to reach the density required in the special
specifications. Contractor shall provide sufficient numbers of manual internal vibrators as a precautionary
measure to be used when casting equipment vibrators go out of order or to use them to obtain additional
densification for the concrete in construction joint areas.
6-
Leveling and finishing equipments:
Suitable leveling screeds and finishing floats shall be used to obtain a layer that has a smooth and
fine surface.
The Leveling and finishing equipments which are going to be used shall allow for densification of
concrete surface, removal of excessive quantities, and formation of the slopes required for the layer surface.
Mechanical finishing equipments shall be used and when necessary, it is possible to use manual equipments
which shall be available at site as standby.
Any of the following surface roughening equipments may be used:
a. Dragged mat composed of artificial grass length ranging between 16-25 mm and weigh about 1.9
kg/m2. It is of the whole width of the layer along 1.25 cm. It is mechanically dragged over the layer
surface to give the required roughness.
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7-
b.
Transverse metal tinning, its length equals at least casting rout width, mechanically dragged over
concrete surface. When necessary it is possible to use manual metal tinning that should be available
at site as standby.
c.
Mechanical cutter saws, used to make longitudinal grooves parallel to road center line at distances
of 25 mm, 3 mm wide and with 5 mm depth.
Cutter saws:
Single disc mechanical cutter saws shall be used in cutting shrinkage joints or multi disc to saw
grooves in concrete surface to roughen it. Cutting disc thickness shall range between 3-6 mm and its radius
shall not be less than 250 mm.
8-
Curing materials spraying equipments:
Water sprayers and chemical curing material spraying equipments shall be equipped with spraying
arms with suitable length that allow for spraying without the equipment using the constructed layer surface.
They shall be capable of spraying with the required rates for the whole constructed surface within a short
period that doesn't allow random cracks on the layer surface.
14.4.1.4 Qualitative requirem ents and mixes:
Except otherwise stipulate special specifications and other contract documents, the cement concrete
shall achieve the qualitative requirements indicated in sections (14.2 and 14.3) above.
14.4.1.5 Design job mix formula:
Procedure of design job mix formula submission and acceptance shall be according to item 14.3.4
of this division.
Cement pavement layer works shall be executed according to method ACI 325. 9R-97, except
otherwise that contradicts with these general specifications or special specifications or contract documents.
1- Surface preparation:
The underlying layer on which concrete pavement layers shall be constructed, shall be composed
of sub base or treated/untreated base which achieve requirements of section 6.4, or from cement
treated/untreated sub grade that achieves requirements of item 5.5.3, or from asphalt concrete surfaces
which achieve requirements of division 8 of these general specifications, special specification requirements
and contract documents.
Before commencing construction of the cement pavement layer, the surface on which this layer
shall be constructed, must be sound and in compliance with approved drawings and specifications, as to
levels, longitudinal/lateral slopes within allowable tolerance for that layer. It shall be free from loose
materials or any other surface deformations that may affect the new layer performance.
Contractor shall carry out survey for the whole underlying layer surface and shall obtain approval
for this from the Engineer. I f there is a non-allowable tolerance, contractor shall modify surface levels to
become compliant with the levels shown on the drawings or in the special specifications. That shall be made
in such a way that ensures
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obtaining a surface compliant with the specifications after getting the written acceptance from the Engineer
for the treatment method.
Before starting concrete casting, the underlying layer surface shall be moistened uniformly with
water, without that leading to formation of water collection areas or weak parts.
2- Cast forms:
Contractor shall prepare the cast forma according to the following steps:
To locate the required survey control points to adjust levels and alignments by the method accepted
from the Engineer.
To fix pilot ropes and adjust levels and straining these with the suitable strength.
To provide spreaders with automatic sensor units which enable the equipment to follow reference
lines automatically when using slip form.
When using fixed form, forms shall be installed according to the lines and levels specified on the
drawings in the way accepted from the Engineer, before spreading concrete with ample time.
The fixed form shall be from steel with approved section and with a base width not less than 100
mm and a depth equaling pavement layer thickness. The forms are fixed with side metal supports with
suitable length. Each form section shall have a stake hole at each end with joints at distances not more than
650 mm. The fixed form shall be supported regularly over the underlying layer, which should be adjusted
according to the required level and planning. The form shall be supported in such a way that prevents its
deviation by more than 4 mm from the correct level during pavement operations.
The fixed form shall be kept in place for one day after casting concrete and it shall be dismounted
in such a way that does not damage the cement pavement layer. It is absolutely not allowed to use steel
levers between the form and the constructed pavement layer for disengaging the form.
3- Casting & finishing:
Contractor, immediately before concrete casting, shall verify the correctness of grade wire level
which control cast equipments with slip form pavers and the fixed form height, such that the thickness of the
layer and the level of its surface are compatible with requirements of drawings and these general
specifications. Concrete casting shall be continuous between expansion joints or construction joints. Also,
concrete shall be cast by using methods which reduce particle segregation or non-uniformity.
Concrete shall be leveled, condensed, and finished with mechanical methods. It is possible to apply
manual methods for finishing the concrete slab surface where mechanical methods usage is impracticable
and when the width of concrete cast is less than 1.3 m. It is possible to stop casting only at an expansion
joint or construction joint.
Thickness of the cement concrete pavement layer shall not be less than the approved design
thickness when applying the one specimen method. The minimum acceptable thickness for determining
payment factor by the statistical method, is considered as the approved design thickness minus 1 cm or 10%
of the design thickness
whichever is less.
Casting can be performed by one of the following methods:
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a- Slip-form method:
When special specifications stipulate the using of the slip-form method, contractor shall use a
mobile casting equipment equipped with side forms which move with the equipment movement and
designed to provide side protection for concrete during casting and throughout the period required for
producing the layer according to the required section, in such way that the section remains unchanged after
the equipment leaves.
Contractor shall provide the equipment capable of spreading, grading, leveling, and finishing fresh
concrete all over the layer in one cycle and with the least possible amount of manual interference such that it
is possible to obtain a consistent and uniform pavement. The equipment shall be operated continuously
without stop throughout the work shift period. More labor and equipments shall be provided pavement
requires construction outside the side form limits after -arranging that in advance according to the approved
from the Engineer.
The equipment shall condense concrete on the whole width and depth of the layer. This condensing
process shall be made by internal vibrators which operate with frequency not less than 6000 vibration per
min. Concrete casting shall be stopped when vibrators stop working and standby vibrators shall be
immediately used to complete the process of condensing cast concrete. The equipment shall be operated in
the form of a continuous movement forward as far as possible so that all the mixing, transportation, and
spreading operations are executed in a coordinated way to achieve a regular work progress. I f it was found
(for any reason) that it is necessary to stop the pavement machine movement forward, then vibrators and
compaction units shall be stop automatically at the same time.
Slump and indentation at pavement edges which exceed 6 mm shall be corrected during work
execution, i f possible. I f that was not possible when the concrete is fresh, the excessive slump at the slab
side shall be removed by cutting with saw at least 130 mm from pavement layer edge and replacing the
removed part according to the Engineer's approved method. Contractor may remove the whole slab and
replace it instead of resorting to saw cutting process. Contractor is not paid any additional costs against
repairs.
When concrete is cast parallel to a previously executed pavement, it is permissible to establish

platforms to be able to cast and finish concrete, also chain equipments are allowed, from one side of the
pavement machine, to pass over the pavement on the condition that:
1- No less than 72 hours should have elapsed since the casting of pavement.
2- The pressure caused by the pavement machine on constructed pavement should not exceed 200 Kpa.
3- Casting equipment chains (spreader) shall be equipped with rubber or plastic protection pads, otherwise
existing pavement surface shall be protected against damage.
4- No part of the chain equipments shall be operated at a distance of 330 mm from the constructed
pavement layer.
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Any part of the constructed pavement layer that has been damaged during work due to contractor's
equipments, shall be repaired by the method accepted from the Engineer and on the Contractor's own
account.
Excluding mechanical saws used in constructing contraction joints, none of the contractor's
equipments is allowed to pass over the pavement layer except after 14 days from casting or when concrete
obtains 80% of its strength whichever is less, providing that depreciation of the pavement layer arising from
the passing of the equipments does not exceed 5% of its design life by any means.
b- Fixed form method:

When specifications indicate using the fixed form method, the necessary equipments for that shall
be provided. These are spreader, finisher and float. It is possible to use a single machine that performs two
or more of those operations i f it was found that it is capable of achieving acceptable results. The machines
shall be automatic and their wheels shall be equipped with rubber tires.
Concrete shall be spread regularly between both sides of the form immediately after being cast by
using a spreader. The spreader is followed by a finisher equipped with not less than two vibrating straight
edges. The spreader or finisher shall be provided with vibrating equipments for condensing the concrete all
over the width of pavement whereas the vibrators are mounted at the rear of the spreader or finisher.
Vibrators shall not lean on the new pavement layers or the side form, and they shall not be in
contact with any tie rods or dowels. The operation of the vibrators shall be controlled such that the
condensation process stops when the machine stops moving. The vibrators shall be operated at the rate of at
least 5000 vibration per minute.
The spreading of concrete shall be on the whole width of the pavement layer before leveling the
surface with the finisher machine. Concrete shall be leveled and compacted such that its surface becomes
compliant with the constructed surface level and the cross section shown on the project drawings while
leaving an adequate amount of the concrete mix for the float process. The spreader or finisher shall move
over the pavement (for a number of times) at the distances required for achieving integrated condensation.
After finishing and condensing the pavement layer, surface level shall be verified and adjusted.
After that it shall be surveyed with an approved longitudinal float. Contractor can use a longitudinal float
composed of one or more of the cutting and finishing floats suspended and directed from a solid frame
carried on at least four wheels.
In addition, it is possible that contractor will use a longitudinal float operated in a sawing motion
carried in a floating position parallel to the road's centerline during its regular passing from one side to the
other of the pavement sides. Front movements along the whole road's centerline shall be in the form of
consecutive front movements not more in length than half the length of the float. Instead of using any type
of the longitudinal floats mentioned above, it is possible to use one machine that shall be capable of carrying
out the compaction, leveling and floating works. This machine may be hauled at the spreader rear such that
the machine shall be capable of carrying out the leveling and floating works. Also, it shall be equipped with
leveling straight edges and
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vibrators as mentioned above. The floating process shall be executed by using a non-vibrating float carried
in a suspended way on the frame.
I f it was found that any of the spreading, leveling and finishing equipments used are not enough
to achieve the required results, those equipments shall be repaired or replaced with other suitable
equipments or adding more equipments.
4-
Manual methods:
It is possible, with the acceptance of the Engineer, to apply manual methods only at places where
mechanical equipments can not reach. When manual methods are allowed, concrete shall be cast, spread
and leveled such that surface level is compliant with the required lines and levels. The finishing plate shall
be moved forward in longitudinal and lateral motion with pressure so that the concrete surface level shall
not higher than the level of any of the side form ends. During the finishing process a small amount of
concrete shall be preserved in front of the cutting edge of the finishing plate at all times.
Concrete shall be vibrated and compacted by an internal vibrator which is operated at a minimum
limit equaling 50000 vibration per minute. It is allowable to use vibrators in driving the concrete mass; after
completion of condensation process concrete shall be leveled to the correct level and cross section of the
surface by using a condenser or finisher or by using a mechanical vibrator that extends over the whole
width between the two sides of the form. A small amount of concrete shall be left in front of the condenser
or vibrator. Condensation shall continue until the required cross section is obtained and the mortar driving a
little towards the surface. It is possible to apply other approved methods for concrete finishing.
During casting concrete in grades of more than 5%, a second surface finishing plate may be
required for passing it behind the compaction equipment or vibrator. It is used in the same way in which the
compaction equipment is used for removing any indentations arising from the concrete flow.
Regardless of the method used, it is important to ensure obtaining the required thickness of the
layer and smoothness of its surface within the allowable tolerance limits which are measured at two
perpendicular directions using a metal straight edge 3 m long.
5-
Surface texturing:
The layer surface shall be textured until the suitable friction factor is obtained for the layer
surface. Work shall start by texturing the surface in the fresh concrete after concrete casting and finishing
and before initial setting. Bleeding water from the surface shall be removed before starting the surface
texturing process which is done by moving the drawn mat longitudinally over the surface followed by
lateral motions by using steel tines. The texturing process shall lead to longitudinal and lateral grooves 2
mm wide and 3-5 mm deep at a distance of 20-25 mm from each other. Texturing with the drawn mat and
tinning shall be enhanced with by rotary mechanical beams. Those beams shall be equipped with automatic
detection and control units that move in the same pattern of operation of the slip form pavement. This
machine shall be used for final texturing only of the concrete slab surface. The drawn mat material shall not
be supported by the same rotary mechanical beam used in supporting the steel tines.
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Also, it is not allowable to support these operations manually except at places where the beams can not
reach.
After completing the texturing process work shall be commenced on both edges of expansion and
construction joints and edge corner curve to obtain a radius of 6 mm along the edge and to obtain a smooth
finishing for the edge corner and to compact mortar in it. Excessive mortar is not allowed at edges.
6- Concrete curing:
Concrete curing shall be performed immediately after completion of the texturing process and for a
period not less than 7 days. The Engineer may, when he notices that contractor has not maintained concrete
curing in the required way, halt concrete work execution at site, and contractor in such case shall bear full
responsibility. Work is allowed to commence after contractor deals with the defect and after the Engineer's
acceptance. In case concrete surface started to dry before completing the finishing process it shall be kept
moistened by being sprayed with water without causing any damage to the surface.
I f the need calls for that, it is possible to remove curing material (such as shrinkage joint cutting),
on the condition that it is returned to its previous state immediately after ending the cause.
Concrete is cured by one of the following methods:
a- Plastic membrane:
The surface of the whole layer and its sides shall be moistened with water dribbles and covered
with a plastic membrane with adequate thickness and free from cracks. The two ends of the membrane shall
overlap for a length of 500 mm. The membrane length shall surpass the layer side by not less two times its
thickness. It shall be ensured that the membrane remains in contact with the layer surface throughout the
curing period. It is possible to use suitable weights to prevent winds from blowing the membrane off.
b- Liquid Membrane compounds:

Liquid chemical membrane can be used by spraying it on the surface and sides to prevent mixing
water from evaporation and consequently continuity of concrete curing process. Contractor shall provide the
Engineer with source and used material compliance with specifications certificate. The liquid chemical
membrane shall be sprayed on the surface by the quantity that ensures its coverage completely, providing
that the spraying rate shall not be less than the manufacturer's recommended value. I f necessary, concrete
surface may be moistened with water after spraying the membrane for the period specified by the Engineer.
The liquid membrane compound shall be sprayed on the executed concrete surface within 15
minutes after completion of the surface texturing processes and before shrinkage due to dryness, or before
random hair cracks start to form. I f the surface starts to dry or cracks begin to occur, concrete shall be
immediately sprayed by water by using an atomizing nozzle. That shall continue till the curing chemical
compound is applied. The curing compound shall not be applied on a surface where water collects in a free
state. The liquid curing compound shall be sprayed uniformly with a rate ranging between one liter and one
and a half liter (1, 1.5) per square meter. The precise spraying
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rate is determined by the Engineer on the basis of experiments carried out by the contractor and what
ensures achieving a uniform covering without thin areas or flows or slumps or uncovered areas. The liquid
curing compound vessel shall be provided with an observation graded glass to verify the used quantities.
When ambient temperature is more than 30 degrees, contractor shall spray the concrete surface by
using fog water sprayer.
When need calls for fog spraying, the whole surface shall be left moistened by adding water with
an atomizing nozzle in such a way that avoids occurrence of erosion due to water sweep or concrete
washing. The concrete moistening process shall be continued for not less than 7 days together with
immediate repair of any damage that may be inflicted on the curing membrane compounds.
14.4.1.7 Joints:
Joints shall be constructed according to requirements of ACI 224-3R-95 and ACI 325.12R-02
without contradiction with these specifications or special specifications or any of the contract other
documents. Joints may be in layers of cement pavement pavements in the form of longitudinal joints or
lateral joints or construction joints. All faces of the joints shall constructed perpendicular with the cement
pavement layer.
1- Longitudinal joints:
Longitudinal joints in the road shall be shrinkage joints or construction joints. Longitudinal joints
shall be constructed between routs and between shoulders i f specifications stipulated execution of concrete
shoulders more than 1.65 m. wide by the sawing method whereas the surface of the layer is sawed with a
depth equaling third of the pavement layer. Joints shall be filled as immediately as possible with the suitable
fill materials according to specifications and traffic on the road shall be restricted before filling the joints.
For longitudinal joints in ramps or tapers, they shall be shrinkage joints or construction joints.
Locations of longitudinal joints in ramps and tapers shall be determined with the Engineer's acceptance.
Except otherwise shown on the drawings, tie bars shall be fixed at all longitudinal joints by
acceptable mechanical methods when concrete is still fresh (during construction). When the cement
pavement layer is cast parallel to an existing cement pavement, tie bars shall be fixed in the existing
concrete by drilling holes perpendicular to the pavement layer edge. The holes diameter shall be equal to the
diameter of the tie bars plus 6 mm. The hole length shall not be less than 310 mm, except otherwise indicate
special specifications. The diameter of the holes shall be checked and they shall be cleared from any
deleterious materials before fixing the bars on them. The holes shall be received by the engineer before
starting dowel bars fixing. Tie bars shall be fixed in the existing layers by using a suitable binder material
according to special specifications and in accordance with the details shown on the drawings. Acceptance of
the Engineer for the binder materials and tie bars installation method before commencing work shall be
obtained.
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The tie bars used shall meet requirements of item 14-2-6-4 and shall be placed in separating
distances not more than 760 mm according to drawings. Except otherwise indicate special specifications or
contract documents, the length of the bars shall be 600 mm. The tie bars shall be fixed within a distance that
does not differ from the slab thickness middle by more than 25 mm. The tie bars which are intended for
fixing in parallel slabs of different thicknesses, shall be fixed at the middle of the slab with the lesser
thickness.
2- Transverse Joints:
Transverse joints on the road shall be shrinkage joints or expansion joints or construction joints.
a-
Shrinkage joints:
Shrinkage joints shall be sawed as shown on the drawings. The sawed joints shall extend all over
the road width. The alignment of shrinkage joints and their continuity in adjacent routs shall be ensured,
since the sawing of the joints shall continue at the same phase. The sequence of distances between transverse
joints shall be in the range of 3.5-4 m in normal concrete slabs or 4.4 times the radius of relative stiffness of
the pavement layer according to requirements of ACI 325 12R-02 whichever is lesser, except otherwise
shown on the drawings. When using shoulders or pavements from cement concrete, the shrinkage joint in
the shoulder or pavement shall continue in its same alignment in the adjacent pavement layer. .
Transverse shrinkage joints in ramps and cross-roads shall be constructed perpendicular to the
ramp axis or cross-roads.
Transverse shrinkage joints shall be executed at 2 meters distance, minimum, from transverse
construction joints which are measured along any longitudinal joint between routs. The last joint that lies
before any construction joint shall be omitted at a distance less than the specified distances. The sequence of
separating distances between joints shall start after each construction joint.
The transverse shrinkage joints shall be reinforced by dowel bars compliant with requirements of
item 14.2.6.5. It shall be ensured that the bars are placed at the middle of the layer thickness, sites and
according to the dimensions shown on the drawings, providing that the separating distance between bars
shall not exceed 350 mm.
The dowel bars shall be installed in an alignment parallel to the rout axis on non-detectable seats
during concrete casting and condensing. The stakes assembly shall be fixed in place by steel stakes to
prevent displacement of bars from their places or change their alignment. Contractor, after the acceptance of
the engineer, may use dowel bars installation machine during concrete casting, providing that ensures their
placing in their locations within allowable tolerance limits, whereas the difference in level shall not exceed
6 mm from the middle of the layer's thickness and the difference in the separating distances shall not exceed
25 mm. In addition, the alignment ___________________________________________ shall not change by
more than 6 mm for each 300 mm of the dowel bar length.
b- Expansion joints: Expansion joints shall be executed according to the dimensions and locations shown
on the drawings. Transverse expansion joints shall be used as shown on the
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drawings according to specification requirements. Transverse expansion joints shall be constructed

perpendicularly with the road center line. When using expansion joints between slabs, the length or width of
the slab shall not exceed 4.4 times radius of relative stiffness of the pavement layers according to
requirements of ACI 3251 2R02, except otherwise indicate special specifications.
Except otherwise stipulate special specifications, transverse expansion joints shall be reinforced
with steel dowels with smooth surface and with a radius not less than 32 mm and achieve requirements of
item 14.2.6.5 in addition to the requirements shown above for dowel bars used in shrinkage joints (except
for the bars to be corrugated).
The bars are installed whereas one of its ends shall be fixed in the pavement layer slab and the
other end free moving in the adjacent slab. It shall be ensured that the free moving end is greased with
petroleum grease that prevents bonding of the dowel bar with surrounding concrete. The free moving end
shall be encased with a cylindrical cap fixed in the concrete with a clearance equal to 35 mm that allows free
expansion of the dowel bar inside. The length of the cap, except otherwise indicate special specifications,
shall be 85 mm so that it may cover 50 mm from the end of the dowel bar and its internal diameter shall
exceed the diameter of the dowel bar by 3 mm. The cap shall be filled with sufficient amount of grease that
prevents water leakage into it.
c- Construction joints:
Transverse construction joints shall be formed according to drawings and specification

requirements. Those joints shall be placed in their specified locations at the end of each working day or
when halting concrete casting for a period more than one hour. No excessive concrete shall be cast behind
any construction joint or expansion joint at the end of any working day. Transverse construction joints shall
be reinforced with dowel bars which fulfill the requirements mentioned above for dowel bars used in
shrinkage joints. The alignment of the transverse construction joints shall be perpendicular with the road
center line and the pavement layer side shall be supported at the joint with a form which ensures that the
side remains perpendicular with the layer surface till the concrete casting process is commenced. Any loose
materials shall be removed from the joint side after the form is removed and before re-commencing the
casting process.
3- Joints around structures:
Expansion joints shall be made between the surface layer and any structures on the road such as
lighting posts bases or traffic signals or any other structures such as bridges. The joints shall be executed
according to the type, dimensions and sites shown on the drawings. It is not permissible to use any
reinforcement bars binding between the surface layer and road structures. The joints shall be filled with the
suitable fill materials according to what is practiced with expansion joints.
14.4.1.8 Joint construction:

1- Cut joints:
Both longitudinal and transverse types of joints shall be sawed according to the dimensions shown
on the drawings. It is not allowed for the excess water from the sawing process to collect on any part of the
sub grade intended for pavement.
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Contractor shall apply acceptable methods for controlling water used in the sawing process such that does
not cause any damage to the sub grade.
Sawed joints shall be executed before the occurrence of any random cracks in the pavement layer
surface. The joints shall not be cut except after the concrete is hardened enough to prevent occurrence of
particle segregation or corrosion in the surface during the sawing process. Contractor shall determine the
suitable time for starting the sawing processes.
Contractor shall keep a standby concrete saw suitable for use in the project site at all times in
which joints are sawed so that it may be ready for use as a replacement for the original saw.
Any procedure applied in sawing joints from which premature uncontrolled cracks result shall be
reviewed and reconsidered immediately. Contractor shall repair areas inflicted with damage and random
cracks and this repair shall be according to specifications and engineer's instructions. Also, contractor shall
repair any broken or cracked concrete along the joints according to the method accepted from the engineer.
Contractor has no right to claim any additional costs for that.
In case the joints are sawed in stages, the initial cutting shall be with the saw to the minimum
specified depth and after that the sawing process is completed throughout the sawing depth shown on the
drawings.
The necessary measures shall be taken to ensure execution of the joints at the locations shown on
the drawings. When using dowel bars much care shall be taken to ensure that the joints are cut over the
middle length of the dowel bars properly.
Immediately before filling joints, they shall be cleared completely from all deleterious materials
and removal of the remains of the curing membrane compounds from the concrete surface at both sides of
the joint. So that the face of the joint appears clean with dry surface during applying the joint fill material
The fill material of the joints shall be applied according to the manufacturer's recommendations. All the
excessive fill material cast at site shall be removed from the pavement layer surface. The joints shall be
filled with the joints fill material within 10 days from concrete casting and before opening the pavement
layer to traffic.
2-
Construction joints:
Both types of longitudinal and transverse construction joints shall be formed according to details shown on
the drawings and according to the Engineer's instructions.
When the concrete is finished completely or its surface is not textured but protected with a
moistening material after one hour of being cast, the Engineer may instruct contractor to execute a transverse
construction joint by sawing at the position he specifies. All the concrete which is cast after the construction
joint shall be removed and disposed of by the contractor on his cost before continuing pavement construction
works.
3- Transverse Expansion joints: Transverse expansion joints shall be formed according to the details shown
on the drawings or according to instructions of the engineer.
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14.4.1.9 Remedial measures:
Contractor shall repair pavement areas in which protrusion exceeds 10 mm in each 10 m or less.
The raised areas can be removed from the pavement by the mechanical surface smoothing devices or by
multi saw machines accepted by the engineer.
After removal of protrusions, the longitudinal section shall be re-planned along 100 m from the
pavement section affected by this process. I f the original section index of the pavement layer is within the
specified range, the longitudinal section shall be re-planned only for that part of the pavement layer, which
included positional protrusions.
Evaluation processes of the low areas on the pavement layer surface shall be performed on the
presumed correction of the adjacent raised areas. When pavement layer works include locations, in which
depression exceeds 10 mm every 10 m or less, contractor shall corrode the adjacent pavement layer surface
according to the instructions of the engineer and re-plan the longitudinal section of pavement as indicated
above.
When it is found that, after repairing the raised and low locations, the pavement is not in
compliance with the specified requirements, further texturing of the pavement shall be done and the
longitudinal section measurements are taken according to the instructions of the engineer.
In addition to fulfilling the requirements of the surface section index, pavement surface shall be
tested by a straight edge 3 m long and the surface shall not vary in any direction by more than 3 mm, except
at longitudinal and transverse joint locations where the surface shall not vary across them by more than 6
mm. In such cases it is required to carry out the eroding and smoothing process to ensure the smoothness of
the surface across the joints.
The corroding and smoothing process shall be performed in such a way that maintains the original
coarseness of the pavement layer surface and in such a way avoids formation of smooth or polished surface.
All the repairs in the pavement layer section shall be executed before evaluation processes of the
pavement layer thickness. Also, the repair works required for correction of the excess in the roughness of
the pavement layer surface shall be carried out on the contractor's account.
Contractor shall take the necessary measures for maintaining and protecting traffic during
execution of the required repair works in the pavement layer section and carrying out the subsequent
measurements for the pavement layer section, according to the Engineer's instructions and on the
contractor's cost.
Cracks that exceed 0.25 mm shall be repaired. These repairs shall be to the whole depth of the
pavement layer or removal and replacement of the cracked part from the pavement layer, as specified in
these specifications, before opening the road to public traffic.
Within 28 days from the date of concrete casting and before work acceptance, the engineer shall
perform a survey for the pavement surface for cracks and contractor shall clear the surface before starting its
surveying for cracks.
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The engineer identifies visual cracks which need repairs, i.e. those wider than 0.25 mm, and
pavement layer slabs which need replacement by clear marks and contractor shall repair or replace these as
specified in the specifications on his own account.
Also, contractor shall repair cracks which appear after 28 days from the date of casting concrete up
to the end of the guarantee period, as specified in the special specifications on his own expense. Contractor
shall provide the engineer with detailed information about the methods and materials to be used in repairing
the cracks so that the engineer may approve them before commencement of the required repairs.
Random cracks shall be repaired when any of the following crack types occur throughout the
whole pavement depth:
Lateral cracks far from any point by more than 300 mm from the transverse joints.
Longitudinal cracks which at any point are within 300 mm distance from the longitudinal joints.
Longitudinal cracks which lie at a distance of more than 540 mm from the longitudinal joint.
Cracks which occur in the constructed pavement layer without dowel bars and longitudinal cracks
in the pavement executed by using dowel bars shall be repaired by cutting or by increasing the width of the
cracks to not less than 13 mm and with a depth of 25 mm, then filling them with suitable joints fill material
by the method accepted from the engineer. Before starting the cracks filling process, each crack shall be
cleared completely in such a way that all deleterious materials are removed so that the face of the crack
becomes clean and its surface dry when cracks are filled with the fill material.
When any part of a repaired crack is within a distance of 150 mm from a cut joint is not workable,
that cut joint shall be filled with epoxy by the method accepted from the engineer.
Lateral cracks, which occur in a pavement, which has been constructed by, using dowel bars, they
shall be repaired by deepening any adjacent non-cracking cuttings to 13 mm over the dowel bars level, then
the brown colored approved epoxy material is injected under pressure in the randomly formed crack. The
injection process by pressuring epoxy is performed only when ambient temperature is between 5 degrees
and 35 degrees.
Repair of the cracks shall start after 7 days from completion of survey process for cracks so that the
repair works are accomplished within 30 days from their start.
In case cracks exceed those indicated above the pavement layer shall be removed and replaced.
Cracked pavement layers shall be removed to the limits specified by the engineer. Generally, cracked
pavement requires removal of the slab on the whole width of the rout and for a length of at least 2 m.
Cracked pavement layers shall be removed in excess along it whole width according to the engineer's
instructions. Parts of the pavement layer intended for removal shall be cut through the whole depth of the
layer before commencing the removal process.
Contractor shall repair or replace the parts of the underlying layer which are damaged as a result of
removal of the pavement layer by the method accepted from the engineer.
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Contractor shall dispose of the removed pavement layer materials and underlying layer materials
by the method accepted from the engineer.
After removal of the cracked pavement layer, tie rods and dowel bars shall be replaced by digging and
injecting with cement to about the middle of the depth in the existing pavement layer. Reinforcement works
of the joints shall be according to requirements of item 14.4.1.7 of these specifications and casting of the
replacement cement pavement shall be performed according to requirements of item 14.4.1.
14.4.2 Reinforced concrete:

When special specifications or contract documents stipulate this, it is possible to use reinforced
concrete in carrying out cement pavement layer works.
This section includes requirements of materials and works for the construction of pavement layers
from cast on site reinforced cement concrete. That includes provision of the required materials, equipments,
manual tools and labor. Also, procedure for ensuring quality, levels, and slopes of the underlying layer on
which the pavement layer shall be constructed, and works of mixing, supplying, casting and finishing
concrete together with construction of various joints, when used, including installation of dowels, tie rods
and filling joints with fill materials according to relevant drawings, general specifications and special
specifications.
These specifications cover the following types of cement concrete layers from reinforced concrete:
a.
b.
Reinforced concrete slabs with reinforcement bars.

Slabs reinforced with reinforcement fibers.
c.
Continuous reinforcement slabs.
Pavement layers from reinforced concrete shall be constructed according to requirements of item
14.4.1, except otherwise indicated in the special specifications, contract documents or in the items of this
section.
14.4.2.2 Materials:
The used materials shall achieve the requirements of section 14.2, except otherwise indicate special
specifications and contract documents.
Contractor shall provide the equipments and machines capable of executing the works. Those
equipments and machines shall fulfill requirements of item 14.4.1.3
14.4.2.4 Cement concrete mixes:

The concrete mixes shall achieve requirements of section 14.3, except otherwise indicate special
Reinforced concrete works shall be constructed according to requirements of item 14.4.1.4, except
otherwise indicate special specifications and contract documents; also consideration shall be given to each
type as follows:
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1-
2-
Bars reinforced concrete slabs:
a.
Contractor shall install reinforcement bars according to drawings and special specifications.
b.
The level of steel bars in the slabs shall be achieved by using suitable metal or plastic seats and
according to requirements of special specifications. The ends of steel shall be stopped before 100
mm from the slab sides and steel bars shall not be connected in the same slab.
c.
Reinforcement bars shall be placed at the middle of the layer thickness, except otherwise indicate
special specifications, whereas it is possible to place the bars at two different levels as shown on
the drawings.
d.
It is possible to use reinforcement bar mats providing that they meet requirements of item 14.2.6.2
instead of single bars particularly in large casting works.
e.
Reinforcement steel shall be sprayed by water dribbles immediately before concrete casting to cool
it providing that this does not lead to water collection on the underlying layer surface.
Fiber reinforced concrete:
When the special specifications and other contract documents indicate using fiber reinforced
concrete the reinforcement fibers applied shall be compliant with requirements of item 14.2.6.7 to the
concrete according to the requirements of the previous item. Also, when concrete casting is required in hot
weather conditions whereas water evaporation from the concrete surface exceeds 1 liter per square meter per
hour as in item 14.3.7.1.
Shrinkage and construction joints shall not be used in fiber reinforced concrete.
The application of reinforcement fibers does not nullify the need for taking precautions against
particle segregation and fiber stacking in the concrete mix.
3 - Continuous reinforcement concrete:
When special specifications and contract documents stipulate using continuous reinforcement
concrete, contractor shall:
a. Ensure steel level in the continuous slabs by using metal or plastic seats according to the special
specifications. Reinforcement bar ends shall be stopped before 100 mm from the slab sides.
Except otherwise indicate special specifications, overlapping shall be achieved between
b. reinforcement bars at the joints with a length of not less than 30 times the reinforcement bar
diameter.
Connection of bars by approved tying tools, as shown on the drawings or special specifications.
c. Reinforcement bars shall continue through construction joints and their level shown on the
drawings shall be maintained. It is not permissible to use shrinkage joints in continuous
d. reinforcement slabs.
Using expansion joints at both ends of the slab when it approaches solid structures such as bridge
ends or ends of existing cement pavement layers.
e.
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14.4.3 Roller compacted concrete:

14.4.3.1 Introduction:
Compacted concrete pavement layers are constructed by using plastic consistency concrete with
slump of no more than zero. It is spread by using compacted concrete spreader similar to asphalt spreader
but equipped with rear compaction system of high capacity that enables it to compact concrete to 98% of its
maximum density. It is possible to use a modified asphalt spreader by adding compaction vibrator to spread
compact concrete with density not less than 80% of its maximum density.
After that concrete compaction is completed by using rollers, then curing it like normal cement
concrete.
Roller compacted concrete is characterized by the absence of reinforced joints and lack of using
expansion joints in it.
The pavement layer from roller compacted concrete shall be covered with asphalt surface layer
executed according to requirements of division eight of these general specifications, providing that the
asphalt concrete used and thickness of the layer are specified in the special specifications. This section
contains requirements of constructing pavement layer works from compacted concrete and includes
materials, concrete, equipments, construction methods and acceptance procedures.
Cement pavement layer works shall be executed by using compacted concrete according to
requirements of ACI 25. 15R, except otherwise stipulate special specifications and contract documents.
14.4.3.2 Materials:
The materials used in executing cement pavement works from compacted concrete include
materials involved in the production of concrete such as cement, aggregate, water, admixtures, additives,
curing compounds and plastic membranes. The materials used shall comply with the requirements of section
14.2 of these general specifications, special specifications and other contract documents. Also, this section
includes compacted concrete specifications including mix design, concrete mixing, spreading, handling,
compacting and finishing methods, whereas it shall meet requirements of item 14.3 of these general
specifications or special specifications.
Contractor shall provide the equipments required for carrying out roller compacted concrete
pavement layer works within the specified time and according to the approved work program.
Before commencing execution of compacted pavement layer works by a sufficient period,
contractor shall submit a list of all the required equipments. In this list, he shall describe their types,
numbers, and technical condition The engineer has the right to replace with what he deems more suitable.
The final list is approved before sufficient time from starting the execution of the works.
This list shall include the following equipments: 1- Fixed or mobile central mixers:
Production capacity of those mixers shall be enough to ensure continuous spreading of the
pavement layers without stopping or interruption. Continuous or batch mixers can be used. The mixers shall
be capable of dealing with the plastic consistency
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of the mix and completing the mixing operation with high efficiency that ensures uniformity of the mix
components such that no particle segregation occurs while ensuring full coverage of all the aggregate
surfaces with cement mortar.
Components of the mix shall be mixed by the weight method, mixing water shall be applied to
other components, and mixing all of them in the mixer, then discharged in the tipcarts.
Scales, timers, water, different admixtures systems used the mixers shall be susceptible to control
and calibration. Their operation shall be controllable by computer as far as possible to ensure the uniformity
of the mixes.
2-
Tipcarts:
Tipcart trucks shall be with the capacities and the numbers enough for transporting cement
concrete from the mixing site to the spreaders in a sequence that ensures no stopping of the spreader.
Contractor shall coordinate with the concerned authorities to organize movement of the tipcarts inside the
city and to choose the roads through which they shall pass so that public traffic shall not be interrupted.
The iron box shall be with sound sides, which tolerate concrete pressure, and the internal surfaces of the box
shall be smooth allowing full pouring of all the concrete amount without the sticking of some materials on
it.
Tipcarts shall be provided with tough covers which prevent exposure of the concrete to air and
dryness of its surface during transferring it from the mixer to the spreader.
Contractor shall abide with approved regulatory loads of the trucks and shall not increase their loads more
than allowable limit to ensure that the constructed surfaces shall not be subjected to excessive stresses.
3-
Spreaders:
The compacted concrete spreader may be used. It is similar to the asphalt spreader but equipped
with rear compaction system with high capacity that enables it to compact concrete to 98% of its maximum
density. The asphalt concrete spreaders can be used in spreading roller compacted concrete after modifying
them by adding a compaction vibrator with high efficiency such that it raises the surface layer density to
more than 80% of its maximum density immediately after spreading. The spreader shall be self propelled
and capable of dealing with plastic concrete such that the surface layer is spread regularly and with the
thickness required by the drawings. The spreader shall be capable of spreading concrete with a layer
thickness ranging between 100-250 mm after compaction. Also, it shall contain an accurate level control
system automatically controlled. The spreader shall contain automatic detectors for longitudinal, lateral and
slope control.
4-
Rollers:
Self propelled vibrating steel rollers and rubber rollers can be used in additional ___________________
compaction works after spreading the compacted concrete layer until the density required in the special
specification is obtained. The rollers shall be chosen according to requirements of item 8.5.4.3 and the rollers shall
be capable of compacting the layers after spreading and leveling to the required compaction levels.
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5-
Water spraying equipments and emulsified asphalt spraying equipments:
These shall be susceptible to calibration and of spraying materials with the percentages and rates
specified and capable of spraying regularly all over the rout width.
6-
Water atomizers:
Shall be mounted on water tank and capable of dribbling water in the air in a foggy way that does
not allow collection of water over the concrete surface.
7-
Mechanical cutting saw:
Contractor shall provide a mechanical cutting saw that includes circular cutting discs which can be
controlled to obtain the required cutting width and depth and it shall fulfill requirements indicated in item
14.4.1.3.
8-
Manual equipments:
The manual equipments required for completion of the works shall be provided and they shall
achieve requirements of item 8.5.4.5 of these general specifications.
14.4.3.4 Quality requirements and mixes:
The compacted concrete shall achieve the qualitative requirements described in

sections 14.2 and 14.3 above. Pavement layer works from roller compacted concrete
require special care during spreading, compaction processes and construction of joint
works. Also, they require obtaining binding of various layers during construction to
obtain a uniform pavement layer. To obtain that contractor shall do the following:
1. Planning and arrangement ahead with relevant authorities to ensure spreading and compacting the
compacted concrete during a period not more than 90 minutes from applying water or before 20
minutes from initial setting of the concrete whichever is lesser.
2.
Take hot weather precautionary measures as it is with on site cast concrete
3.
4.
whereas concrete temperature shall not exceed 35 degree when spread.

Concrete shall not be spread when ambient temperature is less than 5 degrees.
Cover tipcarts to prevent evaporation, and any shipment that contains dry
5.
concrete shall be rejected.

Discord of trucks in which particle segregation occurred and that may be noticed during unloading
tipcarts.
6.
Discord cargos witch contain concrete masses in tipcarts.
7.
Prevent movement of equipments on constructed layers for 7 days after end of concrete initial
setting time.
8.
Prevent traffic on constructed layers during the first 14 days from the compacted concrete surface
layer age.
9.
Do not allow emergency vehicles traffic before 3 days have elapsed after casting.
14.4.3.5 Job mix formula:
The type of cement concrete mix is chosen from one the two types M1 or M2 from Table (14.3.2)
according to prevailing environmental conditions. Before starting compacted concrete layer works by 30
days, contractor shall submit to the engineer a complete technical report prepared by an approved
specialized agency including the design job mix formula according to requirements of section 14.3 above.
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This section contains description for surface preparation, and concrete spreading and compacting
including the necessity for executing an experimental section before starting work execution and
construction of construction joints plus concrete curing.
Contractor shall submit to the engineer a comprehensive report before one week from starting
construction including:
a- Wok plan.
b- Detailed work plan including description of the following tasks:
1.
Concrete supply rate and sequence of tipcarts arrival and a proof that coordination has been
made with traffic authorities on allowing tipcart movement and arrival to work site without
interruptions.
2.
Plan of consecutive layers casting to ensure obtaining a strong binding between layers.
3.
Work plan of longitudinal and transverse construction joints.
4.
5.
c-
Program of cutting shrinkage joints.

Opening pavement layers for traffic.
Hot weather measures.
14.4.3.6.1 Surface preparation:

Before starting construction of roller compacted concrete pavement layer, all previous works
should have been completed, inspected and handed over. The surfaces, on which the compacted concrete
cement pavement layer shall be constructed, shall be level and free from all deleterious and loose materials.
The surface on which it is going to be executed shall be level, strong and sound enough to receive pavement
layer and passing of used work equipments without causing any deformations.
Contractor shall perform all the works and procedures required for repairing all defects and
deformations, i f any, in the surfaces which shall bear the cement pavement layer from compacted concrete,
including removal of deleterious and loose materials or modifying levels by removing extra materials or
introducing new materials not less in quality than the materials of the executed layer, spreading, leveling,
and compacting it according to the requirements of the specifications for that layer. The produced surface
shall fulfill thickness, compaction, smoothness, and slope requirements specified on the drawings or in the
special specifications according to the engineer's instructions. Contractor has no right to claim any
additional costs against that.
Contractor is not allowed to supply and spread compacted concrete pavement layer before he
obtains the engineer's written acceptance for that after inspection of the surface which shall bear the layer
and determining control surface level for using spreader until the required thickness of the surface layer is
obtained. Surface level is determined by adding the design thickness of the layer to the highest level on the
layer surface over which the compacted concrete pavement layer works shall be constructed.
Before starting spreading of the compacted concrete pavement layer, the surface of the layer which
shall receive it shall be moistened by water uniformly, without that leading to formation of water collection
areas or appearance of weak parts incapable of bearing spreaders due to excessive moistening rate and
compaction. Moistening rate shall be determined from the experimental section results.
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14.4.3.6.2 Experim ental section:

Contractor shall execute an experimental section before he starts execution of the works showing
through it the method he intends to apply in executing the pavement layer works from compacted concrete.
It is possible, except otherwise require the engineer, that the experimental section can be within work site
and contractor shall remove joints, which do not achieve specification requirements without claiming any
additional costs. The experimental section shall be executed with a width of 5 m and length 40 m, whereas
that is possible by constructing a longitudinal construction joint plus executing transverse construction and
shrinkage joints.
a.
Contractor shall clarify to the engineer or his representative the following:

Spreader driver skill in obtaining the layer longitudinal alignment, thickness, uniformity and
smoothness of its surface.
b.
Standard speed of the spreader to give continuous spreading to the layer for obtaining the required
thickness and the minimum limit of concrete density after spreading without stopping by using
available equipments, and production capacity of the mixers and traffic conditions between mixers
site and work site.
c.
d.
The ideal method for preserving moisture on the surface layer up to start curing.
The method that shall be applied by the contractor in executing longitudinal joints.
e.
The method, which will be applied by the contractor in executing transverse joints.
f.
Succession of layers to obtain the required thickness of the layer when the layer thickness exceeds
250 mm, to ensure the highest possible binding rate between layers to obtain a uniform pavement
layer.
g.
Method of compacting layers with rollers including number of required passes to obtain the
required final compaction.
h.
Method of concrete curing, including method of calibrating asphalt sprayer to obtain the required
spraying rate.
i.
Method of cutting shrinkage joints including determining the suitable time for starting the cutting
process according to prevailing climatic conditions.
j.
Calibration of the nuclear density gauge.
Results of the experimental section shall be approved by the engineer and used by the contractor as
a basis for work throughout construction period, except when a change is made in materials and/or mix
and/or execution method.
14.4.3.6.3 Concrete spreading and compaction:

Except otherwise indicate special specifications, method ACI 325.10 R shall be applied in
execution.
The roller compacted concrete surface layer, of thickness not more than 250 mm after compaction,
at one time continuously without stopping. That requires at least one tipcart full with concrete waiting
throughout the spreading process. When the spreading process stops for a period of more than one hour, a
transverse construction joint shall be made.
Any truck load that arrives to work site without the possibility of spreading it before 30 minutes
from concrete initial setting shall be rejected. Separating time can be increased by using initial setting
retarders.
When the design thickness of the compacted concrete pavement layer exceeds 250 mm, contractor
shall spread the pavement layer in layers of no more than 250 mm thickness each. He shall ensure that
minimum binding between layers has been achieved
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during construction whereas tensile strength at binding level between two layers shall not be less than 50%
of concrete tensile strength. One of the following methods can achieve that:
a.
Spreading the upper layer within a period not more than one hour from start of spreading bottom
layer with continuous moistening of the bottom layer surface. When using more than two layers,
spreading and compaction of upper layer shall be completed before 20 minutes from concrete
initial setting.
b.
Spreading the upper layer after 7 days from starting the spreading of the bottom layer, providing
that the bottom layer surface shall be coated with cement slurry or mortar of which the maximum
sand grain size is not more than 0.6 mm. The coating process shall be done immediately before
spreading the upper layer. Contents of cement slurry and its thickness are determined according to
experimental section results.
When it is necessary and after engineer's acceptance, it is possible to spread the second layer before
the end of the 7 days interval, providing that consideration shall be given that the layer/layers shall not be
stressed, as a result of equipment traffic over it by more than 5%.
It is possible to spread two neighboring routs within a period not more than one hour or before
initial setting of any of the two routs by 20 minutes, whichever lesser, without taking any additional
procedures for making construction joints except leaving a width ranging between 3 0-40 cm from the first
rout without compaction to be compacted with the next layer. The non-compacted concrete surface shall be
used later by the spreader to identify the thickness of the second rout. When the separating period between
spreading the neighboring routs exceeds concrete initial setting time, the first rout slab end shall be cut such
that the surface resulting from cutting shall be vertical and free from loose materials. The materials resulting
from the cutting shall be removed and disposed of outside work limits. The resulting cutting face shall be
moistened by water immediately before spreading the concrete of the second rout. The second rout shall be
spread overlapping with the first rout by 10 cm.
Contractor shall maintain longitudinal alignment of the rout within tolerance limits not more than
15 mm from the road centerline. Also, leveling of slab surface shall be maintained, whereas it is determined
by using a metal straight edge 4 m long, providing that space between the edge bottom and the slab surface
shall not exceed 9 mm in any of the longitudinal or lateral directions of the slab. Level of the slab surface
shall be adjusted when the spreader driver applies standard speed determined from experimental section
results and by strict following of direction lines such that the slab surface level shall not vary from the
specified level by more than 6 mm. Each constructed layer thickness shall be measured after verifying
compaction. This verification is done by taking 5 core random samples from each constructed layer
separately. The acceptable thickness to determine payment factor shall not be less than the approved
thickness.
Additional compaction of the layer surface immediately after spreading it by two passes is done by
using steel rollers while stopping vibrator. Compaction then continues by using rollers together with operating
the vibrator until a compaction level of not less than 100% is obtained of the concrete ultimate density. The
number of passes is determined from the experimental section results. That is followed by layer compaction
by a number of passes using rubber rollers to finish the surface of the layer. Final
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leveling of the layer surface is made by using the steel roller without vibrator until the rubber wheel traces
are removed. Contractor shall moist layer surface by using water atomizers throughout compaction period
considering to avoid any excessive moistening that may cause sticking of concrete on the cylinders of the
steel rollers or tires of the rubber rollers.
Compaction level for each constructed layer is determined by taking timely random samples
immediately after compaction, by applying sand cone method according to (ASHTO T-191) test, or nuclear
gauge method for field density (AASHTO T-3 10) or any other approved non-destructive method.
Compaction level is calculated by dividing the field density percentage over the maximum concrete density,
which is determined according to (ASTM D-1557).
Three readings shall be taken in different directions at each site when using the nuclear gauge method or any
approved non-destructive method. The average of the three readings is considered as site density. The
minimum acceptable limit of compaction level to determine payment factor by the statistical method is
considered as 98% of the maximum dry density.
Thickness of the pavement layer from roller compacted concrete shall not be less than the approved
design thickness when using the one sample method. The minimum acceptable thickness limit for
determining payment factor by the statistical method is considered to be the approved design thickness
minus 1 cm or 10% of the design thickness whichever is lesser.
14.4.3.6.4 Curing of compacted concrete:
Contractor shall moisten layer surface immediately after concrete spreading with water dribbles
until the compaction process is completed.
When constructing pavement on one layer, the moist layer shall be sprayed emulsified asphalt
membrane immediately after completing compaction according to requirements of item 14.2.5. The rate of
spraying is determined from the results of the experimental section. The layer surface shall be moistened by
water spraying starting from the second day and for a period of 7 days.
When constructing pavement on more than one layer, the emulsified asphalt is used only in curing
the upper layer. The layer surface shall be kept moistened for 7 days by spraying with effect from the
second day of spreading the layer and covering with a plastic membrane. Curing of the bottom layer
surfaces is made, immediately after compaction, by covering with water soaked jute and the jute is covered
with plastic membrane to prevent water evaporation. The jute is sprayed continuously with water for many
times daily for a period of 7 days or until subsequent layer is spread.
14.4.3.7 Joints:
Contractor shall execute joints according to drawings and/or special specifications and/or these
general specifications. Contractor shall give more attention in executing joint works. Joints in pavement
layers from compacted concrete are not reinforced, and they divided into two types:
1- Construction joints:
These are divided into longitudinal and transverse joints. Longitudinal construction joints are made
between routs and they shall be minimized by spreading concrete on the whole width of the road as far as
possible. When the separating period between construction of two neighboring layers exceeds the initial
setting time of the concrete, a longitudinal joint shall be constructed as indicated in item 14.4.3.6 above.
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Contractor shall make longitudinal construction joints, providing that is done by cutting both sides
of the pavement layer horizontally and removal of loose materials before executing pavement and curb
works to ensure obtaining proper and water proof construction joints.
Transverse construction joints are constructed when casting stops and initial setting occurs for the
executed concrete for any reason. In such case between 3 0-40 cm from the end of the layer are left without
compaction. Contractor shall remove the end of the non-compacted section from the layer on the whole
width of spreading rout and through the whole thickness of the layer, providing that the layer side shall be
vertical. Spreading shall be re-commenced with an overlapping of 10 cm with the end of the compacted
layer. The spreader driver shall re-commence the spreading process with the care necessary for obtaining the
required concrete density at the joint.
3- Shrinkage joints:
When casting pavement layer on one layer transverse shrinkage joints shall be executed by cutting
the layer surface after completion of the compaction process and within a period not more than concrete
final setting time. Timing of cutting is chosen such that no looseness occurs to the materials at the joint area.
The joint is cut with a width ranging between 3-6 mm and with a depth equal to third of the layer thickness
when casting layers successively.
When casting pavement layer on two layers or more, it is cast in long time intervals. Shrinkage
joints shall be cut in each layer separately and with a depth equal to third of the layer thickness after
completion of layer compaction and within a period not more than concrete final setting time. Cutting
locations shall match in different layers within a variation that does not exceed 5 cm.
Shrinkage joints are cut in distances ranging between 8-14 m as indicated in the special specifications or
drawings.
14.5 Pavement layers from pre-cast concrete:
14.5.1 Pre-cast concrete slabs:
When special specifications require that, it is possible to construct cement pavement layers by
using pre-cast concrete slabs from normal or reinforced concrete or pre-stressed concrete. The slabs are
produced at the factory, transported, and installed at site.
This section includes description of material requirements and work execution for the construction
of the surface layer from pre-cast concrete slabs. That includes provision of required materials, equipments,
manual tools and labor. Also, include procedures for quality control, levels and slopes of surfaces on which
will be constructed the pavement layer, execution of different joints when used including fixing dowels and
filling with fill materials as shown on the drawings and according to relevant general and special
specifications.
1451.2 Materials:
Except otherwise indicate special specifications and contract documents, used materials shall
achieve the requirements indicated in sections 14.2 and 14.3 above.
395
Contractor shall provide all the equipments required for executing the surface layer as required
and in the numbers sufficient enough for completion of works within the specified time schedule. Those
include special trucks for transporting the slabs and winches used in lifting slabs from the trucks and fixing
them in their places on the road. Contractor shall service the equipments and keeps them in a proper
operational condition throughout the construction period. The engineer shall approve the list of equipments
and the plan of transporting the slabs to the work site before starting execution of a sufficient period.
14.5.1.4 Qualitative requirements:

Contractor shall provide the qualified staff for executing work with the accuracy required in the
special specifications and to install slabs at their locations as shown on the drawings. Contractor shall,
before 30 days from commencing construction work, submit a technical report including the following:
1.
A statement showing the manufacturer's capability for producing the slabs with the required
dimensions and quality.
2.
Production capacity that achieve work completion within contract period and time schedule that
ensures achieving that.
3.
Mixers type, production, curing and transportation methods plus slabs storing area in the proper
way up to the time of their installation according to the time schedule prepared for that.
4.
Necessary documents, which prove fulfillment of the requirements of sections 14.2 and 14.3 of
these specifications.
5.
Slabs transportation program from the factory to the work site approved from the concerned
authorities.
6.
The engineer shall review the report within two weeks from the date of its submission after which
it is approved or returned to the contractor for amendment.
14.5.1.5 Manufacturing:
Slabs shall be made from concrete type (B) or (C) or (D) according to the required dimensions.
They shall be cured with water moistening until they obtain the required strength, then their storing in
storing yards in such a way that ensures they shall not be subjected to extra stresses, which may harm their
performance in the road.
Verification shall be made to fulfillment of compressive strength and flexural strength by testing
samples cast from the same mix used in slab production. The engineer has the right to take core samples
from the slab to check achievement of specification requirements. The engineer also has the right to make
surprise visits to the factory during production to verify implementation of manufacturing steps with the
technique indicated in the technical report according to requirements of item 14.4.3.4.
The dimensions and thickness of each produced slab shall be verified within variation limits not
more than 3 mm and verification of slab surface smoothness by using a metal straight edge whereas the
space between the edge bottom and slab surface shall not exceed 6 mm. Slabs shall be identified with
numbers showing their installation location later.
396
14.5.1.6.1 Surface preparation:
Before commencing installation of the slabs, contractor shall construct the sub grade according to
the requirements indicated in item 5.4.5 or section 6.3 of these general specifications. After the engineer
acceptance of the sub grade as to smoothness and compaction level, contractor shall construct an aggregate
bedding layer according to specifications indicated in item 4.2.2 from aggregate gradation No. (4) with a
thickness of 10 cm. It shall be leveled and compacted by the method that achieves the required alignment
and slope so that it may form a stable foundation on which the slabs shall be placed. Movement of any
equipment or vehicle on the aggregate bedding layer shall be prohibited after being handed over to the
engineer.
14.5.1.6.2 Installation:
After the engineer's acceptance of the aggregate bedding layer as to alignment and compaction
level, contractor shall install slabs over the aggregate bedding layer directly using the suitable lifts in such a
way that ensures obtaining the longitudinal alignment of slabs within a variation that does not exceed 6 mm
from the road centerline and the width required for joints as shown on the drawings. The lifts can use
constructed slabs when sufficient space is not available for the movement of the equipments after the
engineer's acceptance. Consideration shall be given to slabs installation sequence according to their
numbers.
Slab surfaces shall not differ from the levels shown on the drawings or determined by the engineer
by more than 5 mm and the level between any two adjacent slabs shall not exceed by 3 mm. The surfaces of
the slabs shall be level and provide smooth touch. Initially surfaces are measured by metal straight edge
according to requirements of item 8.5.8.2 providing that final handing over of the surfaces shall be
completed by using devices for calculating the international roughness index according to requirements of
8.5.8.2 of these specifications.
14.5.1.7 Joints:
There is only one type of joints, which is construction joints that also play the role of expansion
joints. Joints shall be constructed according to the dimensions shown on the drawings. Joints shall be filled
with the fill materials required in the drawings after clearing the joints from deleterious materials by using
compressed air. Joints are filled during one working day from slabs installation.
14.5.2 Pavement layers from overlapping concrete bricks:
Pavement layers can be constructed from overlapping concrete bricks at the locations specified on
the contract drawings, such as cross-roads, pedestrian walkways, and vehicle parking areas on both sides of
the roadway, acceleration & slow areas and internal streets between houses. This work includes surface
preparation and supply of overlapping concrete bricks for the construction of pavement layers and finishing
them according to the dimensions, levels and slopes shown on the drawings, special specifications and these
general specifications or determined by the engineer within approved tolerance limits. Works of overlapping
concrete pavement layers shall be executed according to requirements of item 15.2.2.2 of these
specifications, except otherwise indicated in this section.
397
14.5.2.1 Manufacturing:
Overlapping concrete bricks shall be manufactured according to requirements of item 15.2.2.2.1

of these general specifications, except the brick thickness that shall not be less than 10 cm, and not more
than 15 cm. The suitable Portland cement only shall be chosen according to Table (14.2.1) of these
specifications.
14.5.2.2 Installation:
Before he commences bricks installation, contractor shall construct Subgrade according to

requirements indicated in item 5.4.5 or section 6.3 of these general specifications. After the engineer
accepts, the Subgrade as to smoothness and compaction level, a sand-bedding layer shall be constructed and
it shall achieve gradation requirements shown in Table (15.2) and then installation of the overlapping bricks.
Installation, filling space between bricks, and sweeping of extra fill sand shall be performed according to
requirements of item 15.2.2.2 of these general specifications. During installation consideration shall be
given to leave spaces of 2-5 mm between adjacent bricks to be filled later with fill sand.
After brick installation and compaction is completed, extra sand shall be removed by light
sweeping, without this leading to removal of fill sand. Tiled surfaces shall be finished according to
dimensions, levels and slopes shown on the drawings and indicated in the specifications. Those surfaces
shall be absolutely compatible with curbs. They shall be higher than drainage utility manhole surfaces by
3.6 mm. Finished surfaces shall be inspected by a 3 m long straight edge. The space between the bottom of
the edge and brick surface shall not exceed 6 mm.
An experimental area shall be constructed with dimensions not less than 2x2 m for verifying the
possibility of construction according to approved shapes and the possibility of filling, compaction and
finishing surfaces in accordance with special specifications, drawings and approval of color distribution.
14.6 W o r k Acceptance:
Contractor shall quality control cement pavement layer works of all types by carrying out all the
procedures required for ensuring that the materials and methods used and the executed works achieve
quality requirements stipulated in these general specifications and contract documents.
The Ministry shall ensure the quality of the product by verifying that contractor has conducted
quality control procedures independently on representative samples and in adequate numbers to judge
construction standard and decide on the acceptance or rejection of the executed work, on the basis detailed
in division 17 of these general specifications, except otherwise indicate special specifications and contract
documents.
1- Quality control:
Contractor shall control the quality of the materials and executed works, monitor and analyze
results, draw quality data of critical properties. Also, he shall perform all the tests and measurements shown
on Table (14.6.1).
Contractor shall provide the engineer with copies of all tests immediately and shall apply all the
steps indicated in item 17.1.1 of these general specifications.
398
Table 14.6.1: Quality control procedures for cement pavement layer works
Work
Cement
Testing
Method
Source
guarantee
certificate from
Aggregate
gradation
manufacturer
AASHTO
T-(27,1 1)
Properties
Aggregate quality
requirements
Raw
materials
`
Water
All
requirements
indicated in
Table 14.2.3
All
requirements
Sampling
site
Re-Sampling
At commencement of supply and

whenever the source is changed
materials
Joint fill materials
Materials
and mixes
during
use
design job mix formula are

approved, or source change, or
noticing a change in executed
work properties
At source
Guarantee
certificate from
manufacturer
All
requirements
indicated in
Table 14.2.3
slump
14 2 6
14.5.2.2
3 tests at starting production &
one test for each 1000 cubic meter
3 tests at beginning of production,
and one test for each 5000 cubic
In mixer
All
requirements
indicated in
Table 14.3.2
ASTM C1078
(1992)
ASTM C 107992
AASHTO T119
Mix temperature
Air voids content
14.2.5
At beginning of supply and
14.2.7
Aggregate quality
requirements
Water cement ratio
14 2 3
14.2.4
AASHTO
T-(27,1 1)
AASHTO
(27,11)
Cement quantity
14-2-2
At starting supply and whenever

source is changed
indicated in
table 14.2.5
Bedding sand and

fill gradation
Aggregate
gradation
Cement concrete
mix
14-2-1
3 tests on different samples from

each source, when source and
Admixtures and
additives
Curing compounds
Reinforcement
Requirements
AASHTO T152, or T-196,
meter of produced mix or when

noticing change in executed work
properties
3 tests at beginning of production
and one test when noticing change
in mix properties, while
considering preparation and
storage according to ASTM 19290
14.2.2
Table
(14.2.3)
Table
(13.3.2)
When engineer requires

At site
directly
behind
spreader and
before
starting
condensation
process

One test each 50 cubic meters and
when engineer requires
14.3
One test each 100 cubic meter
or T-199
Compressive
strength (1)
Flexural strength
(1)
Field density
(compacted
concrete)
AASHTO T-22
AASHTO T-97
AASHTO T181
At site
directly
behind
spreader and
before
condensation
process
One test (at any age required by

the Engineer) for each 100 m3 w/
preparation of samples and
maintaining them according to
ASTM C 31-91 & C 617-94, and
At site
directly
One test at any age required by

engineer for each 100 m3 w/
behind
spreader &
preparation of samples and

keeping them according to ASTM
C31-91
before
condensation
process
14.3
when necessary it is possible to

prepare samples according to
ASTM C3 1-91
One test each 100m3
14.3
14.3
399
Compressive
strength
(overlapping tiles)
Thickness
(overlapping
bricks)
Mixers calibration
AASHTO T-22
At start of supply, then 5 samples
At site
for each 1000 tile
14 5 2
AASHTO T-24
ACTM C94
At mixer
When preparing design job mix

formula and before starting work
14.3
and periodically per week

Work
during
execution
Alignment, levels,
and thickness of
cast slabs
Slab reinforcement
bars.
Sites, levels, and
diameter of joint
reinforcement bars
Compressive
strength
Flexural strength
Slump
Cement quantity
Field density
(compacted
concrete)
Executed
works
Survey
measurements
Survey
measurements
ASTM C 108492
AASHTO T 119 or
AASHTO T310 or any
approved nondestructive
method.
Thickness
Core samples
Levels &
dimensions
Surface smoothness
At site
AASHTO T 119
Skid resistance
engineer
Survey
measurements
engineer
One test each 1000 m2 or one
working day whichever lesser, w/
preparation of samples according
to ASTM C 617-94
working day whichever lesser, w/
preparation of samples according
to ASTM C 42-90
14 4 2 5
14.4
14.5.1
One test each 500 m2 immediately

after compaction
On handing over from engineer

working day whichever lesser
5 measurements each 1000 m2 or
one working day whichever lesser
Cross sections each 25 m, or 5
cross sections each 1000 m2
whichever is more
5 measurements each 1000 m2 or
measurement between each 2
Straight edge
International
index for
measuring road
roughness
14 4 1 7
One test from each load
approved cross sections whichever

more
Road surface
roughness
14.4.1.6
During handing over from

At site
AASHTO T-22
AASHTO T-97
When handed over from engineer

During handing over from
At site
Survey
measurements
Contract
drawings and
documents
ASTM E 30283
Joint sites & sizes
At site
14.4
14.5
During preparation of periodic

payment certificates
(1) 3 samples shall be prepared from each tested mix, for measuring compressive and flexural strength. The average of the
three samples results is considered as the strength approved for evaluation.
2- Quality assurance procedures:
The Ministry has the right at any time to ensure the quality
of executed works and materials by carrying out or by requiring the carrying out under its direct supervision
testing of cement pavement layer materials and inspection of the executed work or some of the items of quality
control indicated in item 1 of this paragraph.
400
Also, the Ministry has the right to review contractor's records of quality control and to compare
those records statistically with the results it obtains by the method determined by it for quality assurance, as
specified in division 17 of these general specifications. Also, it can inspect contractor's laboratory,
equipments, technical staff, testing methods, sites & methods of production and execution applied by the
contractor to ensure the efficiency of his technical staff, equipments, and to compliance of the applied
methods of testing, execution, and inspection with the approved methods.
14.7 Measuring:
Pavement layers from normal concrete or cast on site reinforced or compacted concrete or pre-cast
concrete, are measured by cubic meters or according to special specifications. However, pavement layers
from overlapping concrete tiles are measured in square meters. Measuring the actually executed and
technically acceptable works are measured technically after being laid by the specified thickness and within
the dimensions and levels shown on the drawings or according to engineer's instructions. It is not allowed to
perform any measuring for the purpose of payment for materials placed outside the work boundaries shown
on the drawings or special specifications or determined by the engineer.
14.8 Payment:
Payment shall be for actually executed and technically accepted works within the approved limits
and dimensions according to contract rates or reduced prices due to quality assurance works, when contract
documents stipulate that.
The paid amounts are considered full compensation for extraction, supply, mixing, transportation,
spreading, moistening, condensation and/or compaction of materials and work finishing and execution all
types of joints including materials required for their filling, all according to these specifications, special
specifications and contract documents. Also, for operation, provision, and operation of machines,
equipments, labor, testing, measuring and all requirements for executing the works according to drawings,
special specifications, general specifications, benefits, revenues, and third party payments. Payment shall be
according to the item shown on Table (14.7.1), providing that does not contradict with contract documents.
Table 14.7.1: Concrete pavement layer work items

Item
Work item
Measuring unit
14.1
Surface preparation (when contract documents stipulate

paying it separately)
M2
14.2
Reinforcement steel (when contract documents stipulate

paying it separately)
Tons
14.4.1
14.4.2
14.4.3
14.5.1
14.5.2
Normal cement concrete

Reinforced concrete
Roller compacted concrete
Pre-cast concrete
Overlapping concrete tiles
M3
M3
M3
M3
M2
14.5.3
Sand bedding for overlapping concrete tiles (when

contract documents stipulate paying it separately)
M2
401
DIVISION 15
15.1
15.2
15.3
15.4
15.5
15.6
15.7
SIDEW ALKS, CURBS AND M EDIAN ISLANDS
405
Scope
Sidewalk
405
405
15.2.1 Surface preparation

15.2.2 Pre-cast Concrete (Tiles)
15.2.2.1 Sidewalks Concrete Tiles
15.2.2.2 Interlocking brick
15.2.2.3 Uncurbed sidewalks
15.2.3 Cast in site Cement Concrete Sidewalks
15.2.3.1 Materials
15.2.4 Asphalt Sidewalks
15.2.4.1 Materials
405
405
405
407
409
409
410
410
411
411
411
C em ent C oncrete C urbs and Gutters
411
15.3.1 Materials
15.3.2 Construction
15.3.3 Curb paint
412
412
413
Island and Medians

W ork acceptance
M easu rem ent
Paym ent
413
414
415
415
Division 15- Sidewalks, Curbs and Median Islands
DIVISION 15
SIDEWALKS, CURBS AND MEDIAN ISLANDS
15.1 Scope:
This division consists of construction works for sidewalks, curbs, median and
regulatory islands on roads and streets according to limits, dimensions, levels and slopes
shown on the drawings and contract documents.
15.2 Sidewalk:
This work includes surfaces preparation, materials provision and construction of
sidewalks at locations specified according to dimensions, levels and slopes shown on the
drawings, contract documents and these general specifications. Prior starting of sidewalk's
construction Contractor shall, finish curb and utilities works within the sidewalks and
handing over to the engineer or utility authority.
15.2.1 Surface preparation:
Before starting sidewalk's works all previous works in construction area shall be
completed, tested and handed over. The bedding layers of sidewalks shall be investigated
and Contractor shall repair all defects, remove deleterious and loose materials, check the
compaction degree and correct levels and slopes to conform to drawings. Contractor has
no right to claim any additional costs for this work.
15.2.2 Pre-cast Concrete (Tiles):
This work includes production, supply, and installation of the pre-cast concrete
tiles on the prepared surfaces, in accordance with dimensions, colors and shapes, and at
the locations specified in drawings, special specifications or specifications approved by
the Engineer.
The pre-cast concrete tiles are classified into following two types:
- Pre-cast concrete tiles.
- Interlocking bricks.
The special specifications and contract documents shall indicate the type which shall be
used.
15.2.2.1 Sidewalks Concrete Tiles:

The concrete tiles used in sidewalks shall comply with the shapes, colors,
dimensions, materials, durability, abrasion resistance and saturation degree and the
requirements indicated in the drawings, special specifications, contract documents and
1.
Fabrication:
The concrete tiles shall be fabricated using sand and cement mixture in the rate
of 1 cement to 3 sand for the bottom layer of the tile and in the rate of 1 cement to 1 ________
sand for the upper layer of the tile. Unless otherwise indicate special specifications, the
thickness of the upper layer shall not be less than 1/4 of the total tile's thickness and it
405
shall be fabricated using crushed sand or clean natural sand. The total thickness of tile
shall not be less than 1/10 of the maximum horizontal dimension of tiles. Dimensions of
square tile shall be 40 x 40 cm or other dimensions indicated in the special specification
and they shall be edge trimmed by 7 mm or as specified in the special specification. The
tile shall be fabricated in shapes and colors indicated in special specifications or other
contract documents or according to the Engineer's instructions. Casting shall be done
using steel molds of suitable angles and shape under pressure not less than 15 Mpa and
tile shall be submerged in water after 48 hours from its casting for a period of one week
then water sprinkling shall continue for two weeks. It is not allowed to supply and install
tiles before 28 days from casting.
The suitable mineral oxides shall be used in producing colored tile providing that
they shall not cause any reduction in tile's properties and durability and the final colors
shall be uniform and stable.
Contractor shall submit to the Engineer tile's samples for testing and approval. The
supplied tiles shall achieve shape, color, size and forms requirements and requirements
indicated in Table (15.2.1) below, unless otherwise indicated in the special specification.
Table 15.2.1: Tile requirements
Ser. No.
Test
Flexural strength
1
Abrasion resistance
2
Degree of Saturation
3
Test method
ASTM C-78
ASTM C-241
ASTM C-140
Requirements (minimum)
40 kg/cm2
12 mm
5 % of weight
2. Installation:
Contractor, prior Tile's installation, shall construct Subgrade according to
requirements indicated in section 5.4 of these general specifications, and compact it to a
compaction degree of not less than 95 % of the maximum dry density, at a moisture
content not differ by more than 2 % from optimum moisture content, determined by
moisture/density relationship test according to AASHTO T-1 80 method.
After the Engineer's approval of Subgrade smoothness and compaction degree,
Contractor shall construct aggregate Subbase layer, according to requirements of section 6.2
of these general specifications or better or according to special specifications and
drawings. The thickness of Subbase layer shall not be less than 10 cm. Subbase shall be
leveled and compacted to a compaction degree not less than 95 % of the maximum dry
density at moisture content not differ by more than 2 % from the optimum moisture
content determined by moisture/density relationship test according to AASHTO T- 180
method. The compaction processes shall be performed by the method which achieves the
required smoothness and slope to forms a stable foundation on which the sidewalks may
be laid.
When Subbase is finished and accepted by the Engineer, Contractor shall wet its
surface and construct not less than 8 cm thick cement concrete layer having cement
content 200 kg/m3 and 15 Mpa strength after 28 days according to ASTM C-39 method,
before installing the tiles. Contractor shall cure cement concrete layer using water and it
shall be covered when necessary, to prevent evaporation for a period not less than 3
406
days before constructing the subsequent layers. The produced surface of cement concrete
layer shall be leveled to allow the installation of tiles and the constructed side walks shall
gave a surface conforming to approved longitudinal and cross slopes and compatible with
the upper surface of the curbs as approved in the drawings or specifications or according
to the Engineer's instructions.
At the end of concrete Base curing period, sidewalks tiles shall be installed on
cement mortar layer having a thickness not more than 5 cm, composed of sand and
cement mixture of proportional 1cement, 2 sand (1:2), on seats of brick pieces, to achieve
the required levels and slopes. Joints between the bricks for full depth shall be filled with
same cement mortar used in installation and a groove shall be formed at the top of the
mortar material to form the joint.
The constructed sidewalk surface shall conform to slopes shown on the drawings
and all tiles shall be embedded and fully stuck on cement mortar.
Level tiles shall be used at crossing areas and ramps designated for handicapped wheel
chairs traffic at locations and according to dimensions and slopes shown on the drawings,
special specifications or according to the Engineer's instructions.
Contractor shall preserve, maintain and sprinkle with water the tile surfaces until
final setting of cement mortar.
After not less than 48 hours, Contractor shall sweep sidewalk surface with the method
accepted by the engineer and construct a layer from water, cement and sand mortar while
applying the approved colored dyeing materials as required.
15.2.2.2 Interlocking brick:

This work includes surface preparation and supply of interlocking brick to
construct and finish the sidewalks according to levels and slopes shown on the drawings,
special specifications and these general specifications or as specified by the Engineer
within the approved tolerance limits.
1. Fabrication:
The interlocking brick shall conform to dimensions, shapes and colors shown on
drawings, special specifications, requirements of specification ASTM C-936, or SASO
1246 specification. And interlocking brick shall chose conform to SASO 1247.
Bricks thickness shall not be less than 6 cm and not more than 10 cm, and it shall
achieve the following basic requirements:
- Cement content in the mix shall not be less than 450 kg /m3.
- Average compressive strength for many samples shall not be less than 55 Map, and
the strength of any sample shall not be less than 50 Map as determined by
AASHTO T-22 method.
- Average percent of absorption for a number of samples according to test ASTM
C-140 method shall not be less than 5 % and the result of any test shall not exceed
7 %.
- When freeze and thaw test is required it shall be executed according to method ASTM
C-67 and freeze and thaw brick resistance shall not be less than 50 cycle.
407
Brick thickness shall be verified by measuring at different 3 points and the average
size at any 3 points shall not vary from the specified thickness by more than 2 mm.
- Friction abrasion resistance shall not exceed 3 mm when tested according to ASTM
C-418.
2. Bedding and Filling Sand:

The sand used shall be from natural sources or crushed sand and it shall be clean
and free from plastic, or organic and deleterious materials and it shall achieve the
gradations indicated in Table (15.2.2) of this division. It is permissible to use other
gradations indicated in the special specifications and other contract documents or any
suitable gradations recommended by the manufacturer.
Table 15.2.2: Bedding Layer Gradations
Sieve size (mm)

9.5
4.75
2.36
1.18
0.6
0.3
0.15
0.075
Bedding sand
100
95-100
85-100
50-85
25-60
10-30
2-10
Percent
Filling sand gradation
natural sand (1)
Crushed sand (2)
100
95-100
70-100
40-75
10-35
2-15
0
100
95-100
70-100
40-100
20-40
10-25
0-10
3. installation:
Prior starting of bricks works, Subgrade layer shall be constructed according to
Division five requirements and aggregate base shall be constructed accordance to
requirements indicated in section 6.4 of these general specifications, unless otherwise
indicated in special specifications.
The aggregate base thickness shall not be less than 10 cm and it shall be spread,
wetted and compacted to a compaction degree not less than 95 % at a moisture content not
varies by more than 2 % from the optimum moisture content determined by AASHTO T180 test. Contractor shall use the compaction equipments which achieve the required
compaction degrees without causing damage to curbs and utilities existing within the
work area. Contractor is responsible for any damage caused from works constructions.
Aggregate base Surface shall be finished according to dimensions, slopes and
levels shown on the drawings, special specifications and these general specifications. The
smoothness of the aggregate base surface shall be measured by straight edge 3 meters
long and the clearance between bottom of straight edge and surface shall not exceed 1 cm
at any point.
An experimental section shall be constructed with dimensions not less than 2 x 2
meters for color distribution approval and verification of construction regarding shapes,
joint, compaction and finishing the surfaces. Before starting brick installation, the sand
408
bedding shall be spread according to gradation indicated in Table 15.2.2 drawings and
special specifications. Spaces between two adjacent bricks shall vary between 2 to 5 mm.
After approval of installation and color distribution methods, brick installation
shall be commenced by spreading and leveling of the bedding sand layer in a compacted
thickness not less than 3 cm and not more than 5 cm and it is not allowed to use the
bedding sand in filling depressions in the base layer surface.
Edge spaces which do not accommodate a full brick shall be filled by pieces of
brick or special elements and the brick shall be cut when required by using special
equipments which give the proper shapes that compatible with the space.
Bricks joint shall be filled using filling sand according to gradation indicated in
table (15.2.2) and Contractor when approved by the Engineer may use bedding sand for
filling. Compaction shall be performed by light vibratory equipment not less than 220 kg
weight, having vibration frequency between 75-100 Hz, or any other equipment accepted
by the Engineer and achieves the required compaction. The filling and compaction
operation shall continue until the joints are completely filled, providing that number of
passes shall not be less than three.
Compaction shall not be performed within 1 meter of the unconfined brick areas
and joints works and compaction of the constructed brick surface shall be completed at
the end of each working day up to 1 meter from the end of brick works. Parts constructed
over night shall be covered if the ends lie within unconfined areas.
When brick construction and compaction were finished, surplus sand shall lightly
swept out without removing filling sand.
The bricked surfaces shall be finished according to dimensions, levels and slopes
shown on drawings and specifications. Surfaces shall be compatible with the curb surfaces
and higher than manhole surfaces by about 3 to 6 mm. The finished surfaces shall be
inspected using 3 meters straight edge, and the clearance between straight edge and brick
sidewalk's surface shall not exceed 10 mm.
15.2.2.3 Uncurbed sidewalks:
When sidewalks edges are in free areas without buildings or other structures
limited it, these edges, executed from concrete tiles or interlocking bricks, shall protect
from breaking and crumbling by using concrete curbs.
Curbs shall conform to special specifications and contract documents, curbs
thickness shall not be less than 15cm, and its height 3 0cm.
Concrete curbs shall be able to support and protect sidewalk edges, its level shall
conform to sidewalk tiles and higher than nearest ground by 5cm. Concrete curbs shall be
executed by using materials and methods as in
15.2.3 Cast in site Cement Concrete Sidewalks:
This work includes surface preparation, supply, mixing and material spreading,
compaction, leveling and finishing according to the dimensions, levels and slopes
409
shown on the drawings, special specifications and these general specifications or as

specified by the Engineer within the approved tolerance limits.
15.2.3.1 Materials:
Materials used to produce cement concrete for sidewalks construction shall
achieve requirements indicated in division 14 regarding materials, mix design, quality
requirements and construction while considering the following:
Cement content used in casting in place sidewalks shall not be less than 350 kg/m3 and
compressive strength after 28 days shall not be less than 25 Map according to AASHTO
T-22 and slump shall not exceed 75 mm according to AASHTO T-1 19 test method.
Casting in place concrete sidewalk shall be started before the construction of
untreated Subgrade, compacted, finished and handed over according to approved slopes,
levels and dimensions indicated in section 5.5 of these general specifications. and
construction of aggregate Subbase shall be done using materials and construction
methods, conforming to requirements indicated in section 6.3 of these general
specifications or better or according to special specifications and drawings. The thickness
of Subbase layer shall not be less than 10 cm and it shall be leveled and compacted using
method that achieves the required smoothness and slopes to forms a stable foundation for
sidewalks.
Contractor shall cast concrete into prepared wooden or steel forms having level,
cleaned and smooth surfaces and it shall be fixed firmly without movement with required
dimensions and thickness. Contractor shall wet the surface on which the concrete shall be
constructed immediately before casting.
Concrete sidewalks casting shall be in one batch for the full thickness and compacted by
approved equipments to form a relatively smooth layer of sand and cement on surface.
The produced surface shall conform to longitudinal and cross slopes. Cross slopes shall
comply with road slopes and shall not be less than 2 %, unless otherwise indicated
contract documents.
Contraction joints shall be constructed by grooving the cast concrete to a width of
3 mm and a depth of 1/4 of lift thickness in regular distances each 3 meters or according to
drawings and special specifications. Expansion joints shall be constructed in regular
distance not more than 18 meters and construction joints shall be formed around manholes
and utilities lying within the work zone according to the method specified in the special
specifications or according to the Engineer's instructions. Joints shall be filled using
filling materials conform to standard specification AASHTO M - 213, unless otherwise
indicated in special specifications or drawings.
The sidewalk concrete shall be protected from any damage caused by machines,
equipments and individuals. Machines shall not allowed to pass over sidewalks before 7
F
orms shall not be disassembled before cast concrete reached a strength not less
than 5 Mpa, providing that the period from casting shall not be less than 24 hours. It shall
be sprinkled with water continuously and kept wet until it fully hardened and
410
reaches a strength not less than 80 % of the design strength providing that the curing
period shall not be less than 7 days.
15.2.4 Asphalt Sidewalks:
This work includes surface preparation, material supply and mixing spreading,
compaction, leveling and finishing of asphalt concrete used in sidewalk, according to the
dimensions, levels and slopes shown on the drawings, special specifications and these
general specifications or those specified by the Engineer within the approved tolerance
limits.
15.2.4.1 Materials:
The asphalt, aggregate materials and other additives used in asphalt sidewalks
construction shall achieve all asphalt concrete surface layer requirements indicated in
division 7 and 8 of these general specifications and the gradation used in sidewalks shall
conform to one of gradations (a) or (b) or (c) of the asphalt surface layer as indicated in
Table 7.3.4, and aggregate shall conform to table (7.3.1) type (1, 2, 3) of these general
specifications.
Prior construction of asphalt concrete sidewalks an aggregate base and prime coat
shall be constructed in compliance with all requirements of these layers indicated in
division 6 and 8 of these general specifications and according to special specifications and
drawings.
Asphalt sidewalk shall be constructed in normal conditions according to
construction requirements indicated in division 8 of these general specifications.
It is possible, if necessary, to use manual spreading of asphalt concrete used in
sidewalks at small irregular sections in a way that fulfills the required conformity, slopes,
smoothness and without particle segregation, and Contractor shall use the suitable
equipments approved by the Engineer to compact such sections using method that
achieves the required compaction degree.
All sidewalk surface finishes shall conform ,in dimension and levels, to drawings
and special specifications.
Surface leveling shall verify by using straight strap with 3m length, and the space
between strap bottom and tile surface shall not be more than 10mm, and no more than
6mm for curbs.
The curbs, gutters and manholes walls adjacent to asphalt sidewalk shall be
sprayed with prime coat before the sidewalk layer is laid and compacted.
15.3 Cement Concrete Curbs and Gutters:
This work consists of constructing curbs and gutters, composed of pre-cast
concrete or cast in place concrete curbs and gutters, which separate road shoulders
sidewalks and driveway islands works consists of, surface preparation, supply, installation
and finishing of curbs and gutters at the specified sites according to levels shown on the
drawings, special specifications and these genera specifications. The curbs
411
used in these works shall be from pre-cast or on cast in place cement concrete, unless
otherwise indicate special specifications.
15.3.1 M aterials:
The cement concrete used in curb and gutters works shall be composed of Portland
cement, aggregate and water. The cement concrete used in Curbs and Gutters works shall
contain cement rate not less than 350 kg /m3, a compressive strength not less than 35 Mpa,
and slump not exceed 75 mm, unless otherwise indicated in special specifications and
contract documents. The type and properties of the steel shall be specified in special
specifications when reinforcement is required.
Sampling and testing method required for aggregate, water, steel and mix design
of the cement concrete mixture used in curbs and gutters shall be performed according to
methods indicated in division 14 providing that concrete class shall not be less than
category B as indicated in Table (14.3.2) of these general specifications.
The surface shall be prepared by excavating the layer, on which curbs and gutters
shall be constructed to a depth sufficient for curbs or gutter laying and aggregate materials
layer conforming to requirements of Subbases or Base layers shall be constructed for a
full width of curb with the required extra width in both sides.
The installed or cast in place curbs and gutters shall conform to lines and levels
shown on the drawings, special specifications or specified by the Engineer and achieve
the required height of 15 cm above the asphalt surface layer or as indicated in the drawing
and special specifications. However, when constructing curbs or gutters separating
pavement and non-paved areas the curb level shall be higher than earth surface by not less
than 5 centimeters and the upper surface of the curb or gutter shall conform to surfaces of
adjacent sidewalk.
Pre-cast curbs and gutters shall not contain any defects or cracks. All surfaces
shall be smooth, level and conforming to dimensions shown on the drawings and special
specifications.
Installation of pre-cast curbs and gutters shall be done on a layer of cement mortar
composed of cement, water and sand mixture in the rate of 1cement to 2 sand (1:2) and
the layer on which the mortar shall be laid shall be wetted by water immediately before
spreading the mortar. The curbs or gutters shall be fixed from both internal and external
sides using the same installation mortar providing that the support thickness shall not be
less than 8 cm from each side.
Joints between adjacent curbs or gutters shall be completely filled with cement
mortar and grooved to give joints the proper shape.
Contractorshallprotectinstalledcurbsorguttersfromanydamageandwetthejoints with water for aperiod not less than 72 hours.
Construction of in place cast curbs shall be performed using normal metho special
casting machines such as self propelled machine or spreaders equipped with casting
machine or other methods accepted by the Engineer for confined areas and small sections.
412
Contractor, prior starting normal casting works shall, fix forms according to the
dimensions and lines shown on the drawings, special specifications or specified by the
Engineers. Forms shall be steel or wooden and fixed firmly to prevent any movement
during casting and their faces shall be smooth and with the required shape, smoothness
and surfaces conforming to drawings and special specifications.
Contractor when constructing curbs and gutters using special casting machine,
shall prove that machine is capable of constructing these works in required shapes and
dimensions and approved lines. The engineer has the right to reject the use of machine
and to require from the Contractor to construct the curbs by other methods or to use
pre-cast curbs if it is not possible to construct them by the machine.
Contractor shall construct expansion and contraction joints between in place cast
curbs or gutters according to following requirements, unless otherwise indicated in the
drawings and/or special specifications:
1. Expansion joints shall be constructed at all cement concrete pavement joints.
2. Expansion joints 20 mm wide shall be constructed at distances not more than 9
meters.
3. Contraction joints shall be constructed with conformity of concrete pavement joints,
providing that the distance between contraction joints shall not exceed 3 meters with a
depth of 5 cm and a width of 3 mm, using suitable elements such as metal pieces
during casting.
4. All joints shall be filled with asphalt filler materials comply with AASHTO M-213
standard specification, unless otherwise indicate special specifications.
15.3.3 Curb paint:
Contractor shall, when the special specifications specify, Paint all curb face, after
all finishing.
Except otherwise specify special specifications, Paint color and type shall conform
to item 16.4.2 requirements in these general specifications.
All curb faces shall be clean before painting, and painting shall prevent in cases of rainfall
or sand storms.
15.4 Island and Medians:
This work consists of construction of median and traffic driveways and regulatory
islands at intersections, and it includes surface preparation, material supply, spreading and
installation according to the limits, dimensions, levels and slopes shown on the drawings,
special specifications or specified by the Engineer.
The paved median or regulatory islands shall be constructed using in place cast
concrete or pre-cast tiles and they shall be separated from traffic lanes by curbs and
gutters.
All surface preparation works, concrete works, tiles, curbs and gutters works on
medians and islands shall be constructed according to the requirements of sidewalks,
curbs and gutters indicated in this division, unless otherwise indicated in special
413
Planting works on median islands and sidewalks shall be according to types of

plants, trees, soil and filter layers proposed and specified in the special specifications,
drawings and other contract documents. Curbs around trees and plants or planted median,
islands, between pavement and sidewalks and between sidewalks and adjacent areas shall
be constructed from solid concrete and higher than soil surface by not less than 5 cm.
15.5 Work acceptance:
Contractor shall control the quality of tiles, curbs, gutters and median or islands
through performing all the required arrangements to insure that materials, methods and
completed works meet the quality requirements specified in these specifications and other
contract documents.
The Ministry shall insure quality of constructed works by verifying contractor's
quality control procedures either, through direct supervision of quality control activities,
or performing quality assurance procedures neutrally, on a sufficient number of
representative samples, to determine level of construction and to accept or reject the
constructed work, on basis detailed in division 17 of this specifications except otherwise
indicated in the special specifications and other contract documents
15.5.1 Quality control:
Contractor shall apply a quality control to the constructed works in his own
laboratories or in independent laboratories approved by the Ministry and monitor, record
and analyze results and draw quality charts for critical properties. Contractor shall prepare
quality control program for the works and submit it to the Engineer for approval and he
shall follow that work program after approval. When the Ministry perform quality
assurance program, Contractor shall enable the Engineer to reach production, storing and
construction sites, take samples and perform tests at any time during works constructions.
Contractor shall carry out quality control procedures for the materials at source
and during their using at site by testing samples of the materials and constructed works as
indicated in Table (15.5.1) of this division.
Quality control procedures shall be performed on materials and Subgrade,
Subbase or aggregate Base, according to requirements indicated in related sections or
divisions five and six of these general specifications.
15.5.2 Quality Assurance:
The Ministry has the right to insure the quality of the materials and completed
works of tiles, curbs, gutters and median or regulatory islands through carrying out or
ordering others under its direct supervision to carry out the necessary tests and
measurements, and checking the completed work for each or some of quality control
items specified in Table (15.5.1).
compare these records statistically with the results obtained by quality assurance
procedure as specified in division 17 of these specifications, and inspect contractors
equipments, technical staff, and measurement and construction methods, to determine the
degree of compliance of measurements and constructed methods with the approved
requirements.
414
Works shall be accepted with the prices specified in the contract or with lower prices or
might be rejected according to the quality levels by applying the statistical method
specified in division 17 of these specifications except otherwise specified by the special
specifications.
15.6 Measurement:
Quantities of sidewalks, median or islands shall be measured in square meters.
However, curb and gutters works shall be measured in linear meters for actually and
technically accepted constructed works. Measurements shall not perform for the purpose
of payment for works constructed outside the boundaries shown on the drawings, contract
documents or specified by the Engineer.
15.7 Payment:
within the approved limits, dimensions and according to contract prices or reduced prices
results from quality assurance procedures when indicated in contract documents.
The amounts paid are considered full compensation for provision of materials,
labor, equipments, machines, testing, finishing, painting works, benefits, surface
preparations, excavation, construction of aggregate layers, cement concrete bases or sand
bedding and filling layers, joint filling, curing and any other works for completing
construction items indicated in special specifications, other contract documents or special
specifications.
Payment shall be according to one or more of the items indicated in Table (15.5.2)
of this division or according to contract documents and special specifications.
415
Table 15.5.1: Quality Control for Sidewalks, Curbs, Gutters and Medians
Item
Work
Pre-cast tiles for

cement concrete
sidewalks
Interlocking
brick sidewalks
Materials in
Source
Properties
Location
of
Sample
Test
method
Flexural
resistance
Abrasion
resistance
ASTM C78
ASTM C241
Tiles
Fabrication
requirements
SASO
1246
Bedding
and Filling
Sand
Gradation
AASHTO
T-27
Compressive
resistance
Thickness
SASO
1247
SASO
1247
on site
5 samples
each 1000
tiles
Certification of
supply or source
change
Certification of
supply or source
change
on site
5 samples
each 1000
tiles
Curbs
Fabrication
requirements
SASO1248
SASO1249
Certification of
supply or source
change
cast in site
C em ent concrete
Curbs and
gutters
Works
Requirements
In item
15.3.1
Testing
methods in
table
14.6.1
In mixer
or site
Cast in place
cement concrete
sidew alks
Materials
and works
AS in table 14.6.1
Asphalt concrete
sidewalks
Materials
and works
AS in table 8.5.6
Pre cast Cement

concrete C urbs
and gutters
Requirements
Certification of compliance at start of supply or source change
Used
materials
Works
Sampling
frequency
AS in
table
14.6.1
Item 15.2.21
Item 15.2.2.2
Table 15.2.2
Item 15.2.2.2
Item 15.3.1
Item 15.3.1
Table 15.5.2: Measurement and Payment

Item No.
Type of work
Unit
15.2..1
Pre-cast concrete tiles sidewalk
m2
15.2.2
Interlocking brick sidewalk
m2
15.2.3
Cast in place sidewalks
m2
15.2.4
Asphalt concrete sidewalk
m2
15.3.1
Cement concrete curbs and gutters
Linear meter
15.3.2
Curbs paint
Linear meter
15.4.1
Median and Island
As in quantity bill
416
DIVISION 16
TRAFFIC SIGNALS, TRAFFIC SIGNS, ROAD

MARKING, FENCES, GUARDRAILS AND
CONCRETE BARRIERS WORKS
16.1 General Description 16.2

Traffic Signals
16.2.1 Description
16.2.2 Materials
16.2.2.1 General
16.2.2.2 Concrete Footings and Reinforcing 16.2.2.3
Steel Products
16.2.2.4 Aluminum Products
16.2.2.5 Cables and Ducts
16.2.2.6 Controllers
16.2.2.7 Traffic Signal Head
16.2.2.8 Pedestrian Signal Head
16.2.2.9 Traffic signal poles
16.2.2.10 Suspended Traffic Signal
16.2.2.11 Vehicle Detectors
16.2.2.12 Pedestrian Detectors
16.2.3 Construction 16.2.3.1 General
16.2.3.2 Controllers 16.2.3.3
Traffic Signal
16.2.3.4 Suspended Traffic Signal
16.2.3.5 Vehicle Detectors
16.2.3.6 Pedestrian Detectors
16.2.4 Work acceptance
16.2.5 Measurement 16.2.6
Payment
16.3 Traffic Signs
419
419
419
419
419
419
420
420
420
421
421
422
424
424
424
425
425
425
425
425
425
427
428
428
428
429
429
430
16.3.1 Description
16.3.2 Materials
16.3.2.1
16.3.2.2
16.3.2.3
16.3.2.4
Concrete
Steel Products
Aluminum Products
Galvanizing
16.3.2.5 Structural Paint

16.3.2.6 Reflective Sheeting
16.3.2.7 Backing Materials for Reflective Sheeting 16.3.2.8
Honeycomb Sections
16.3.2.9 Performance Requirements
16.3.3 Construction
16.3.3.1 General
16.3.3.2 Signs
16.3.3.3 Storage and Shipment of Signs
16.3.3.4 Placement and Orientation
16.3.3.5 Footings for Sign Supports
16.3.3.6 Porcelain Coatings
430
431
431
431
431
431
431
432
433
433
435
437
437
437
437
437
438
439
16.3.3.7 Letters, Numbers, Arrows, Symbols

16.3.3.8 Aluminum Sign Sections
16.3.4 Work acceptance
16.3.5 Measurement
16.3.6 Payment
16.4 Traffic Paint and Road Marking

16.4.1 Description
16.4.2 Materials
16.4.2.1 Reflective Traffic Lines
16.4.2.2 Reflective Thermoplastic Traffic Lines 16.4.2.3
Reflective Road Markers 16.4.2.4 Delineators
16.4.3 Construction
16.4.3.1 General
16.4.3.2 Reflective Traffic Lines
16.4.3.3 Reflective Cateyes
16.4.3.4 Plain Prismatic and Ceramic Markers 16.4.3.5
Delineators
16.4.3.6 Adhesive
16.4.3.7 Paint
16.4.3.8 Traffic Lines and Markings Equipment 16.4.4
Acceptance
16.4.5 Measurement
16.4.6 Payment
16.5 Fences, G uardrails and Concrete B arriers
439
439
439
440
440
442
442
442
442
442
444
446
446
446
447
447
447
448
448
448
449
449
450
450
16.5.1 Description
16.5.2 Materials
16.5.3 Construction
452
16.5.3.1 Fences
16.5.3.2 Guardrails
16.5.3.3 Cable Barriers
16.5.3.4 New Jersey Concrete Barriers 16.5.4
Work Acceptance
453
453
16.5.5 Measurement
16.5.6 Payment
452
452
453
453
455
457
457
457
Division 16-Traffic Signals, Traffic signs, Road Marking,

Fences, Guardrails, And Concrete Barriers Works
DIVISION 16
TRAFFIC SIGNALS, TRAFFIC SIGNS, ROAD MARKING, FENCES,

GUARDRAILS AND CONCRETE BARRIERS WORKS
16.1 General Description:

This section includes the specifications and construction methods of traffic control works,
presented in Traffic Signals, Traffic Signs, Road Marking and Safety Barriers.
The Contractor must finish all works according to these General Specification using
materials and equipment that have been described in this section, and the standard specifications
used in the Kingdom of Saudi Arabia to fill the local traffic department's requirements.
This section Contents:
- Traffic Signals.
- Traffic Signs.
- Road Marking.
- Fences, Guardrails and Concrete Barriers.
The meanings of the terms will be used in these General Specifications are detailed in
BS892:1967 Glossary of Highway Engineering Terms and BS6100, Highway Engineering
Section.
16.2 Traffic Signals:
16.2.1 Description:
This section contains traffic signal specifications including description of works, materials,
installation and operation for Traffic Signals Head Assembly, Posts, Footings, Traffic Signal
Control Units and Detectors, also it includes traffic signals complete with lamps, cable connections
and provision of all the services required for installation and construction all in accordance with
traffic requirements and in compliance with the requirements of the local traffic authorities in the
Kingdom of Saudi Arabia.
The control system and signal poles must be installed on stable concrete foundations or
bases which must be submitted by the Contractor according to the specifications indicated in this
section. The signal poles and control unit box must be placed at the suitable locations according to
special specifications which comply with traffic department requirements to avoid collision of
errant vehicles.
16.2.2 Materials:
16.2.2.1 General:
Materials used must be of the best types of their respective kinds and the labor must be of
high skills. Material must be selected or treated to serve perfectly during their lifetime of the
installation.
419

Electronic equipment must be used in accordance with the BS 9000 and NEMA (National
Electrical Manufacturers Association) specifications.
The equipment must be designed to operate on two hundred twenty A.C. 220 volts single
phase, sixty (60) Hz. and it must function properly i f the voltage increased by fifteen percent
(+15%) or decreased by twenty percent (-20%), and the frequency vary within plus or minus
four percent (4%).
All equipment must operate properly at one hundred percent (100%) relative humidity
with temperatures reaching eighty five degrees Celsius (85C) under direct sunlight with a high
ultra violet content and in different weather conditions.
A l l wiring must be securely fixed in their positions and wiring. Loop detector wire,
must be in high temperature PVC insulated cables, and must be capable of tolerating high
temperatures with characteristic color to facilitate their recognition.
16.2.2.2 Concrete Footings and Reinforcing:
Concrete for footings must be according to section (14.3), "Concrete Works" in these
Reinforcing steel must be according to item (14.2.6), "Reinforcing Steel" in these General
Specifications.
Prestressing steel must be according to item (14.2.6.2) "Prestressing Steel" in these General
Specifications.
16.2.2.3 Steel Products:
Steel products must be according to the following:
1- Structural Steel Tubing must be according to ASTM A 501 or ASTM A 595, Grade
A.
2- Steel Castings must be according to ASTM A 27, Grade U-60-30.
3- Low Carbon Bolts, Nuts, and Washers must be according to ASTM A 307.
4- High-Strength Bolts, Nuts, and Washers must be according to ASTM A 325.
5- Stainless Steel Bolts, Screws, and Washers must be according to ASTM A 193, A
194.
6- High Tension Wire must be according to the requirements of AASHTO M 30, TypeII,
Class A, with a minimum breaking strength of nineteen thousand four hundred (19,400)
kilograms, and elastic modulus equal to eight thousand three hundred (8300) kilogram
per squire millimeter.
7- Galvanizing must be according to ASTM A 123 or ASTM A 153
16.2.2.4 Aluminum Products:
1- Aluminum tubing:
Aluminum tubing must be according to ASTM B108, B209, B211 or B221, as required.
Aluminum alloys must have a minimum tensile strength of two thousand five
420

hundred (2,500) kilograms per square centimeter, and minimum yield strength of two thousand
(2,000) kilograms per square centimeter.
2- Non-structural Aluminum castings:

Non-structural Aluminum castings must be according to ASTM B 108.
16.2.2.5 Cables and Ducts:

1- Conductor Cable, High Voltage:
Voltage rating of the conductor cable supplying primary electrical power must be five
(5) KV for primary voltages less than five (5) KV, and fifteen (15) KV for voltages of five (5)
KV or more.
2- Conductor Cable:
Conductor cable must be six hundred (600) volt cable, single conductor, thermoplastic
insulated. The conductor cable must be plainly marked on the outside with the manufacturer's
name and identification.
3- Duct:
Ducts must be of polyvinyl chloride (PVC) plastic pipe according to ASTM F 512, Type
DB-120, or ABS plastic pipe according to ASTM D 2750, Type II.
16.2.2.6 Controllers:
1- General:
Traffic signals control equipments must be of high quality types, durable and capable of
operating in complete efficiency in all climatic conditions and high and low temperatures. The
manufacturer must program each control system to work properly as specified in the Special
Specifications. Al l input data incoming from logical circuits must tolerate passing currents and
electric noise arising from normal usage without being subjected to any damage to the circuits.
Timing of the control system must be fully programmable by using units from switch panels at
the front panel of each control system with a suitable display screen. Memory storage must be
non-volatile EPROM under a main power-off condition for at least thirty (30) days.
The control system box must have a manual operation switch with traffic police, and this
switch must be capable of controlling all time intervals except the time interval of changing to the
yellow and red lights which must be timed by the control system according to the program
prepared for that.
Controllers must be designed for operation at a nominal power input of two hundred
twenty (220) volt, single phase, sixty (60) Hz. The controller and all associated electrical
equipment must operate properly at any voltage between one hundred eighty (180) and two
hundred forty five (245) volts, within a power mains frequency range of sixty (60) Hz plus or
minus three (3) Hz, and each system must have a diagnostic unit showing the operation plan,
phase sequence, timing intervals, standby battery existing condition and disorder warning.
The control systems must be solid state type such as transistors, dual valves, resistors and
capacitors and must operate with miniature digital treatment units.
The pre-timed control systems must be able to control the required phases and of operating
according to the requirements of various traffic departments.
421

The control systems which are operated by the activity of traffic movement must be
completely dependent on traffic volume and must be capable of working as a pre-timed partial
control system the program of which can be programmed partially so that it operates at all times in
complete uniformity within the traffic signal system. Each system must have a diagnostic unit
showing the operation plan, the phase being diagnosed, phase sequence, time intervals, vehicle
lights and pedestrian conditions i f any. Present condition of standby battery and failure warning.
Controllers must not operate with any timing parameters shorter than the following: - Yellow
Clearance two (2) seconds.
- Minimum green five (5) seconds.
All components and accessories must be able to operate properly for at least five (5) years with
routine maintenance only.
A heavy duty master switch and fuse must be provided to isolate all equipment in the controller
from the mains supply.
2- Controller Cabinet:
Each controller must be housed in a strong weatherproof metal cabinet designed to be fixed
to a concrete base.
The Cabinet is fixed on a concrete base as indicated in execution item (16.2.3.2) "Controller
Cabinet" in these General Specifications.
The cabinet must be of functional design and appearance and large enough to provide
space for housing all devices which including monitor detector amplifiers, load switches, circuit
breakers, and fuses.
The box must be composed of a number of suitable racks for installing parts. The box
must be with a front door or its entire front must be a door on which, from the internal side, is
placed a guide for the box components. It is possible to have a rear door similar to the front one in
case that was required in the special specifications .
16.2.2.7 Traffic Signal Head:
1- General:
Traffic Signal Head is composed of a metal box containing an assembly of optical units
which illuminate in red, yellow and green colors respectively from up downward. The signal light
must be regular and suitable to different environmental conditions. The maximum illumination
rate to the minimum rate must not exceed five (5) to one (1). Each of the optical units must be
automatically illuminated in a suitable and independent way.
The optical units must be designed such that transparency rate must not be less than the minimum
rates shown in table (16.2.1) in these General Specifications.
The signal head dismountable and susceptible to being installed with screws and tightly
fixed to protect its components from vibrations and wind motion, and with non-shining black
color.
Suitable protectors from sun light must be installed over each lens according to drawings
with a length of not less than two hundred forty (240) millimeters for lenses size three hundred
(300) millimeters and a length of not less than one hundred seventy five (175) millimeters for
lenses size two hundred (200) millimeters.
422

2-Optical Unit Lenses:

The optical unit lenses of the traffic signal must be made of glass or plastic that tolerate
ultra violet rays and the lens must endure all the fluctuating weather conditions and high and low
temperatures without change in their properties. The lens must be with one color from all sides and
free from all manufacturing deformations and air bubbles. The lens must provide the suitable
distribution of light and with a transparency that complies with requirements of the ASTM E 308
shown in table (16.2.1).
Table 16.2.1: Minimum relative luminous transmittance of traffic signal lenses
Co lor
Red
Yellow
Green
Minimum relative luminous

transmittance of traffic signal lenses
Ten percent (10%)
Forty four percent (44%)
Nineteen percent (19%).
The following information must be pressed on the flange of each lens:

- The word "TOP" at the proper point to indicate the correct orientation of the lens. - The
manufacturer's trademark.
- Maximum wattage of the lamp which may be used with the lens.
Lenses size two hundred (200) millimeters and three hundred (300) millimeters must be
provided and both types must be susceptible to direct tight installation in their designated site with
sealing ring.
3- Arrow and Symbol Lenses:
The arrow lenses must be size three hundred (300) millimeter and they may be prismatic
or similar lenses for light distribution. The color of the arrow lens must be according to the
required specifications with a transparency for the transparent part similar to the limits indicated
in table (16.2.1) of these General Specifications.
The color of the arrow lens must be compliant with what is specified in the Special Specifications.
A l l lenses, except for the arrow or symbol, must be covered by an opaque black or dark
grey material. Alternatively, the lens may be a composite of glass, colored plastic and filter, with
the symbol on an internal surface of the lens.
The opaque material must be high resistant to weather changes and to the high
temperature emitted from the lamp. The shape of the arrow or symbol and their dimensions must
be compliant with the drawings and light distribution on the arrow or symbol must be regular and
uniform.
The shapes of symbols and arrows must be compatible with the requirements of MUTCD
(Manual Uniform for Traffic Control Devices) of the Ministry of Communications in Kingdom of
Saudi Arabia.
4- Optical Unit Reflectors:
The reflectors may be composed of silvered glass or specular-finished Aluminum and
must be designed such that it provides the required reflection of the light emitted by the signal light.
The minimum limit for the reflector illumination values through green and red lenses for normal
roads is four hundred (400) candela at lens axes.
423

The glass reflectors must be made of the best types of clear temperature and weather
elements resistant glass without the addition of any other material between the glass and silver
which is tightly stuck with glass.
Aluminum reflector thickness must not be less than six tenths (0.6) millimeters with
reinforcing edges. The thickness of the reflecting layer of the Aluminum layer must not be less
than twenty five of ten thousand 0.0025 of a millimeter, and the reflecting surface must be free
from any scratches or deformations.
Except otherwise specified, a device for decreasing illumination output must be provided by night
such that illumination output is reduced in a rate varying between thirty percent (30%) and fifty
percent (50%).
5- Traffic Signal Lamps:
Traffic signal lamps must be of the standard type with a design life not less than six
thousand (6000) hours and their illumination power not less than six hundred (600) lumens and
they must be of tungsten or halogen tungsten.
Lenses size two hundred (200) millimeter must be used with lamps of illumination power
up to one thousand seven hundred and fifty (1750) lumen, and for lamps of higher illumination
power lenses size three hundred (300) millimeters must be used. The signal lamp must be
low-voltage type which takes its power from a transformer. The lamp power must be fifty (50)
watts for use at normal roads intersections, but i f there was a highway at the intersection with an
average speed more than eighty (80) kilometers per hour, the lamp power must be one hundred
(100) watts.
16.2.2.8 Pedestrian Signal Head:
Pedestrian signal lenses must be of three hundred (300) millimeters size. The luminance of
the signal head along the directed axis must be three thousand five hundred (3500) candelas per
square meter.
All the physical characteristics and material specifications for pedestrian traffic signal
head must be compliant with the characteristics of vehicles traffic signal head.
A complete pedestrian signal face must consist of two (2) signal sections, the upper
section must have the red "standing man" symbol. The lower section must have the green "walking
man" symbol. Pedestrian indications must be sufficiently bright and legible to be effective under
all normal atmospheric conditions.
16.2.2.9 Traffic signal poles:
The dimensions of the pole must be as shown on the drawings, and in each pole there should
be an opening with a cover plate not less than two hundred (200) millimeters height, and not less
than fifty (50) millimeters width. The cover plate must extend by not less than ten (10) millimeters
beyond the opening on all sides, and must be installed with screws. The opening height must not be
less than fifty (50) centimeters from the ground surface level.
Poles must install as in the special specifications and the distance between pore and
sidewalk edge shall not be less than 1.5 m.
16.2.2.10 Suspended Traffic Signal:
The suspended traffic signal poles must be compatible with specifications of the signal poles
mentioned in item (16.2.2.9) "Traffic Signal Poles" of these General
424

Specifications, and their dimensions must be according to drawings, and they must be made of
steel complying with the specifications mentioned in item (16.2.2.3) "Steel products" in these
Suspended traffic signal head must be compatible with the requirements of item (16.2.2.7)
"Traffic Signal Head" of these General Specifications.
The Suspension wire must be of nineteen (19) millimeters, according to the requirements
of item (16.2.2.3) "High Tension Wire" in these General Specifications.
16.2.2.11 Vehicle Detectors:
Vehicle detectors must be composed from copper braids extended beneath the road and
connected with a control system containing an amplifying unit that detects traffic to coordinate
traffic signal timings.
The detector amplifiers in the control system must be self operated type and capable of
automatic adjustment to suit usual environmental changes or electric failures. Detectors amplifiers
must be able to function properly with a ring conduction of between twenty (20) micro Henry to
two (2000) thousand micro Henry.
The detector loop wire must be formed from stranded copper wire with diameter (2.5) mm
(12 AWG).
16.2.2.12 Pedestrian Detectors:
Pedestrian detector must be composed from a button that is manually operated and it is
usually open, and can be pressed by pedestrians. The detector must be designed such that it can be
fixed on wooden or metal poles.
The detector must be composed of a metal box with only one button. The detector must
operate on alternate current of twelve (AC 12) volts and must be electrically insulated under all
natural circumstances. A suitable symbol must be placed on the detector's front side according to
Special Specifications.
The unit must be a cast Aluminum or galvanized steel box with glass or plastic display the
detector state (off/on). The detector must be mounted near pedestrian crossing points.
16.2.3.1 General:
Contractor must supply and install all the work parts indicated on the Special
Specifications in addition to the concrete bases, poles, fixtures, screws and all requirements used in
the works, and that include protective painting works and all other complementary works.
16.2.3.2 Controllers:
The control cabinet must be bolted to a concrete base not less than seventy five (75)
centimeters thick, of which ten (10) centimeters is above the ground level. The concrete base must
extend at least (10) centimeters beyond the control cabinet on all sides, fiber or plastic duct must
be placed in the concrete base, and it must be enough and suitable for all electrical connections
according to the Special Specifications.
16.2.3.3 Traffic Signal: 1- General:
Traffic signals must be directed towards vehicles to be visible in the road centerline by at least fifty
(50) meters for roads with maximum operational speed less
425

than or equal to ninety (90) Kilometers per hour, and by not less than two hundred (200) meters for
highways of operational speed more than ninety (90) Kilometers per hour.
A miniature signal head of the traffic signals must be fixed on the signal pole at a site
parallel to the signal front at height of one (1) meter. The miniature signal head must satisfy all
requirements of item (16.2.2.7) "Traffic Signal Head" in these General Specifications, considering
the size of the used lenses to be one hundred (100) millimeters.
The signal head must be fixed at the designated site on the stand pole carrying tightly so
that no swinging or shaking exist, by screw tightened steel clips. Electric connections must be
inserted inside the pole through an opening in the pole behind the signal head such that it is
invisible from the signal front.
The different parts must not be in an electric contact with each other, so insulating rubber
or plastic spacers must be used.
The upper openings of the poles must be closed with plastic plugs to prevent water leakage inside
the pole.
2- Foundation Preparation:
Contractor must carry out excavation for pole bases according to section (5.3)
"Excavations" in these General Specification, whereas pole bases are excavated to the required
depths according to drawings.
Contractor must undertake complete testing for soil and ensure its suitability or treat it i f
necessary such that it achieves the minimum acceptable limit for the bases tolerance and in
accordance with soil compaction works specified in section (5.5) "Base layer" in these General
Specifications.
Embankments must be compacted such that their density must not be less than ninety
percent (95%) of the maximum density calculated by the density testing according to section (5.4)
"Embankment" in these General Specification. It is not allowed to increase the height of the upper
surface of the base over ground surface level.
3- Concrete Works:
Casting:
Concrete must be cast after fixing reinforcement steel in the required dimensions inside the
tightly fixed cast forms which. The rate of concrete mix setting must not exceed 75 mm according
to AASHTO T119 test method, and the minimum cement content must not be less than three
hundred fifty (350) Kilogram per cubic meter. The reinforcement steel used in any type of
concrete bases must comply with the requirements of specification AASHTO M254.
The cement concrete must achieve material requirements and Job Mix Formula indicated
in section (14.3) "Concrete Works" in these General Specifications. When using Ready-mix
concrete, it must comply with the requirements of specification ASTM C94.
Before commencing the concrete base casting, all the necessary works for supporting it or on which
it must be cast must be completed, the surfaces of the
426
Division 16-Traffic Signals, Traffic signs, Road Marking, Fences,

Guardrails, And Concrete Barriers Works
executed bases must be smooth and uniform and in compliance with the vertical and horizontal
dimensions shown on drawings or according to the Engineer's recommendations, and they must be
free from clods.
The compressive strength of concrete must not be less than (21) Mpa when testing at age
of twenty eight (28) days according to the AASHTO T22 test. The captive air must not exceed
seven and a half percent (7.5%) and not less than four and a half percent (4.5%) of the total
volume of the unit.
Curing:
Compressive strength shall not be less than (21) Mpa after twenty eight (28) days
according to AASHTO T22.The units must be cured in accordance with the requirements of
section (14.3) "Curing" in these general Specifications, and also special specifications.
Removal of Forms:
The forms must not removed until the compressive strength reaches seven (7) Mpa
minimum, otherwise twenty eight (28) days.
Precast concrete foundations:

Completion of all the previous works must be confirmed at the construction area before
starting the pre-cast concrete bases execution, testing and handing over according to the approved
compaction degree, also the surface on which those bases must be constructed must be prepared
such that a smooth surface is provided. After completing installation of those bases, the excavated
part around them must be backfilled with materials having specifications not less than the
specifications of sub base indicated section (6.2) "Sub-base materials" in these General
Specifications.
The pre-cast concrete bases may be prefabricated by casting them in clean smooth
surfaced steel forms so that they may give a smooth surface free from voids and cavities of area
more than two (2) centimeters squire in area. The strength of the unit must not be less than (21)
Mpa when testing at age of twenty eight (28) days according to the AASHTO T22 test. The
captive air must not exceed seven and a half percent (7.5%) and not less than four and a half
percent (4.5%) of the total volume of the unit. The pre-cast concrete base units must be cured
according to AASHTO M170.
Transportation of precast units must only be allowed at a minimum of (24) Mpa strength.
4- Poles:
Traffic signal poles must be fixed at the locations shown on the drawings of the Special
Specifications on concrete bases tightly fixed with not less than 4 bolts. The bolts must be tied to a steel
plate welded to the pole base according to the Special Specifications. The steel plate used must be
compliant with item (16.2.2.3) "Steel Products" in these General Specifications.
The foundation for the post must be of sufficient size to resist an overturning moment of six (6)
Kn.m.
The distance between the pole and the road edge must not be less than one and a half (1.5) meters.
16.2.3.4 Suspended Traffic Signal:

The suspended traffic signal must be composed of two vertical poles, carrier cables and
signal head. The poles are fixed in the same execution method indicated in item (16.2.3.3) of this
specification. The height of the suspended traffic signal head
427

must not be less than five and a half (5.5) meters and not more than seven and a half (7.5) meters.
The pole distance from the road edge must not exceed 180 cm All the electric connections
must be passed inside the poles through the openings down to the pole base. Cables must be fixed
according to special specifications, and the signal head must be fixed by two (2) cables at least to
prevent vibrations.
16.2.3.5 Vehicle Detectors:
Traffic detectors are composed of copper braids extended beneath the road and connected
with a control system containing an amplifier.
Traffic detectors must have a multi cycle ring from a cable placed under the road at a depth
of not less than 50 mm according to drawings.
The detector ring must be formed from braided copper cable of a cross section width of
not less than three (3) millimeters (1 2AWG). The cable must be polyethylene insulated, and it is
placed inside a protective PVC pipe with wall thickness of not less than one and six tenths (1.6)
millimeters.
The detectors are placed at the locations shown on the drawings at a distance from the
intersection which may reach one hundred fifty (150) meters in the case of detectors for high
speeds that exceed ninety (90) Kilometer per hour. Strips must be excavated for the detector over
the whole width of the road with the depth indicated in the specifications and according to the
manufacturer's recommendations. The width of the strip must be equal to the detector pipe external
diameter.
A l l the wastes resulting from the excavation process must be removed before installation
of the detector. The detector must be installed at the bottom of the strip then covered with suitable
rubber material according to manufacturer's recommendations up to the coated pipe level, after
that the strip is filled with asphalt up to pavement surface level and the asphalt used must be
according to paragraph (7.2) "Asphalt" in these General Specifications.
16.2.3.6 Pedestrian Detectors:
The detector (pedestrian push button unit) must be tightly fixed with screws on its pole
such that no vibrations exist in it. The used detector must satisfy the requirements of item
(16.2.2.12) "pedestrian detectors" in these General Specifications. The detector takes its power
from a transformer through electric connections extended inside the pole from the rear side such
that they must not be visible from the detector front. The detector must be fixed at a height suitable
16.2.4 Work acceptance:
1- Quality Control:
Quality control procedures for the materials and executed works must be done
for pedestrians according to drawings and Special Specifications.
Quality control for executed works and used materials is the responsibility of the Contractor
and he must submit the quality control plan which he will apply during contract period, and
Contractor must incur all the costs related to quality control. Contractor has no right to start any
work before he obtains a written acceptance from
428

the Engineer indicating the acceptance of the Engineer for the quality control plan submitted by
the Contractor.
The Engineer must be provided with lists of materials, poles shop drawings, control
systems, electric connections drawings, tools and supplies for acceptance within sixty (60) days
from contract signing date. It is not permissible to submit partial shop drawings or lists for this
purpose.
The documents to be submitted must be complete and clear and in four (4) original copies
but material lists must include cut samples from catalogues or data brochures. Unacceptable
submittal must be returned back for the required corrections. Any changes intended for
incorporation in the approved materials and equipments lists must be made according to written
request and in case such changes were requested by the Engineer, Contractor must submit samples
for the alternative item(s) for inspection and acceptance without any additional costs arising from
this on the Ministry.
The Engineer must be provided with the guarantee certifications from the manufacturers of
the equipments and parts used in the work, and he must receive all the brochures, guide manuals,
spare-parts listings of equipments and parts used in the work. Standby units in the rate of not less
than ten percent (10%) of all used units must be provided providing that not less than one (1) unit
of each type. The manufacturer of guardrails and fences must be approved to a Quality Assurance
system complying with ISO 9002.
All the equipments and systems used in the work must be from the production of one
manufacturer except otherwise agrees the Ministry in writing. Table (16.2.2) shows quality control
requirements according to section (16.2) "Materials" in these General Specifications.
2- Quality Assurance:
Quality Assurance procedures for the materials and executed works must be done
according to item (17.1.2) "Quality Assurance" in these General Specifications. The Ministry is
responsible of Quality Assurance procedure by any standard testing that the Ministry prefer, to
insure that all works done by the Contractor are satisfying the requirements of these General
Specifications.
16.2.5 Measurement:
Accepted Traffic Signal Controllers, Traffic Signal Heads, Traffic Signal Head Supports,
Pedestrian Traffic Signal Heads, Pedestrian Signal Head Push Buttons, and Traffic Loop Detectors
must be measured by number of units.
High tension wire may be measured in meter length or may be included in the Suspended
Traffic Signal installation.
16.2.6 Payment:
The completed and accepted quantities, measured as shown in item (16.2.5), will be paid at the
contract unit price for the items listed in table (16. 2.3).
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Division 16-Traffic Signals, Traffic signs, Road Marking, Fences, Guardrails,

And Concrete Barriers Works
Table 16.2.2: Quality Assurance

Item
Electrical
Devices and
Equipment
Light
distribution
for lens
High
Tension
Wire
Property
Test
Sampling
Requirements
All properties
mentioned in the
BS 9000,
NEMA,
and Source
Certificate
According to
Manufacturer's
instructions
Item(16.2.2.6)
"Controllers" in these
According to
Manufacturer's
instructions and the
According to
Manufacturer's
Table (16.2.1)
in these General
Specifications
Item (16.2.2.5) "High
Tension Wire" in
these General
Specifications
Relative luminous
transmittance
All properties
mentioned in the
ASTM E308
AASHTO M 30,
Type I I
Three (3) tests at the

beginning of the
production and when
changing materials
sources or mix.
Properties.
Item (14.3) "Concrete

Works" in these
Concrete
Works
All properties
mentioned in the
According to
division 17 in these
general
specifications
Steel
Products
All properties
mentioned in the
ASTM A27 Grade

U-60-30, A307,
A325, A193, A194
According to
Manufacturer's
Item (14.2.-6) "Steel

Properties" in these
Aluminum
Products
All properties
mentioned in the
ASTM B108, B209,

B21 1 or B221
According to
Manufacturer's
Item (16.2.2.4)
"Aluminum Products"
in these General
Specifications
Table 16.2.3: Quantity

Item No.
16.2.3.1
16.2.3.2
16.2.3.3
16.2.3.4
16.2.3.5
16.2.3.6
16.2.3.7
16.2.3 8
16.2.3.9
Item
Traffic Signal Controller Type (.)
Pedestrian Traffic Signal Controller Type (.)
Traffic Signal Head, Type (.)
Pedestrian Traffic Signal Head, Type (.)
Traffic Signal Support, Type (.)
Suspended Traffic Signal Support
Suspended Traffic Signal Cable
Traffic Loop Detectors
Pedestrian Traffic Signal Push Button
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Meter
Unit
Unit
16.3 Traffic Signs:

16.3.1 Description:
This work must consist of constructing and installing of Traffic Signs and Kilometer-posts according
to the requirements of the Special Specification and these General Specifications in including materials and
specific works related to the signs _______________________________________________________ parts to
be used on urban roads.
The work also include the construction, erection and relocation of all temporary signing
works required before construction and during construction and before opening the road to the
traffic.
430

A l l sign faces and lettering must be in accordance with the Manual on Uniform Traffic
Control Devices (M.U.T.C.D.) of the Saudi Ministry of Communication.
16.3.2 Materials:
A l l materials used to finish this work must satisfy the following requirements:
16.3.2.1 Concrete:
Concrete for footings must be according to section (14.3), "Concrete Works" in these
16.3.2.2 Steel Products:
1- Reinforcing Steel:
Reinforcing steel must be according to Paragraph (14.2.6), "Reinforcing Steel" in these
2- Steel Plates:
Steel plate must be according to ASTM A525, with thickness not less than two (2)
millimeters.
3- Steel Posts:
Steel Posts must be fabricated according to Schedule 40 ASTM A120. Steel
pipe and I.P.E. sign supports must have a slip base breakaway support.
4- Stainless Steel Bolts, Washers and Nuts must be according to ASTM A 276, with
minimum yield of (200) Mpa.
16.3.2.3 Aluminum Products:
1- Aluminum Panels and sheeting:
Aluminum Panels and sheeting must be according to ASTM B 209 or B 211, alloy 606
1-T6. All Aluminum alloys must have a minimum tensile strength of (250) Mpa and minimum
yield strength (200) Mpa.
2- Extruded Aluminum Panels:
Extruded Aluminum Panels must be fabricated from Aluminum Alloy 6063-T6
according to the requirements of ASTM B221 Panels and must have a minimum thickness of two
(2) millimeters for sizes up to 762x762 millimeters. Larger panels must have a minimum
thickness of three (3) millimeters.
3- Aluminum Posts:
Aluminum posts must be according to ASTM B22 1, and must have a minimum thickness
of three (3) millimeters.
.
16.3.2.4 Galvanizing:
Steel parts must be according to ASTM A123. Nuts, bolts and similar parts must be galvanized
according to ASTM A153.
16.3.2.5 Structural Paint:
All steel surfaces (except galvanized surfaces) must be painted by a special paint which
must be according to AASHTO M300 Type I I requirements.
431

The color of the paint must be determined by the Special Specifications, and it must be
applicable in for hot weather and unstable climates.
Paint type, color, mixing instructions, Storage requirements a Trade Mark and date of
manufacture must be written on the paint container.
The paint must satisfy the following:
1- Does not show excessive settling in opened can within 48 hours.
2- Has a homogenous density and distribution.
3- Brushes on easily.
4- Shows no running when applied to smooth vertical steel surfaces.
5- Dries to a smooth uniform surface.
6- Shows no streaking or separation when flowed on clean and smooth surfaces.
16.3.2.6 Reflective Sheeting:

Reflective Sheeting must consist of white or colored sheeting having a smooth outer
surface, and have the reflective property for its entire surface. Reflective sheeting is classified into
nine types according to ASTM D 4956-Ola as follows:
Type I : Medium-intensity reflective sheeting with glass spheres lens, having a Coefficient of
Reflection according to table (16.3.1) and luminance factor compatible with Table (16.3.10). This
type is of the lowest known reflectivity as to road signs.
Type I : Medium-intensity reflective sheeting with glass spheres lens, having a Coefficient of
Reflection according to table (16.3.2) and luminance factor complying with Table (16.3.10) and it
is a poor reflective type.
T y p e I : High-intensity reflective sheeting with encapsulated glass spheres, having a

Coefficient of Reflection according to table (16.3.3) and Luminance Factor according to table
(16.3.10).
Type IV: High-intensity reflective sheeting composed of micro-prismatic non-metallic coated

elements, having a Coefficient of Reflection according to table (16.3.4) and Luminance Factor
according to table (16.3.12).
Type V : Super-high-intensity reflective sheeting with un-metallized micro-prismatic elements,
having a Coefficient of Reflection according to table (16.3.5) and Luminance Factor according to
table (16.3.11) These are used in temporary signs and non-adhesive signs such as re-foldable signs.
They are not used in making direction or warning signs. Type VI: High-intensity reflective
non-adhesive sheeting with micro-prismatic elements of phenyl. Having a Coefficient of Reflection
according to table (16.3.6), luminance factor complying with Table (16.3.10). They are used in
non-adhesive signs and temporary signs such as re-foldable signs and they are not used in making
permanent signs or aluminum pasted signs.
Type VI: Highly reflective specially on long distances which are determined at an observation
angle of (0.1 degree) & (0.2 degrees). They are composed of sheeting that include non-prismatic
non-metalized micro elements. With reflection factor complying with Table (16.3.7) and day
luminance factor according to Table (16.3.12).
432

Type IX: Highly intensive reflection sheeting particularly at long distances and they are similar
to type V I I with luminance factor a little less (at far angles and colors). Reflection factor is in
compliance with Table (16.3.8) and day luminance factor in compliance with Table (16.3.12).
Type IX: Super intensive reflection sheeting especially at short distances and it is characterized
by being the best of the 9 types as to reflection inside cities regardless of the driver's age or type
and height of his driven vehicle. It is the only type which has a high reflectivity on observation
angles which exceed (0.5 degrees), whereas reflection factor is defined on 1 degree. This
represents high vehicles such as 4 wheel drive cars, buses, trucks etc. of medium and heavy
transportation vehicles. Also, type IX is of characteristic performance and reflectivity on turns
whereas entrance angles are large. Reflection factor is compatible with Table (16.3.9) and day
luminance factor compatible with Table (16.3.12).
16.3.2.7 Backing Materials for Reflective Sheeting:
The backing required for reflective sheeting is classified into the following five classes:
Class 1 - Pressure-sensitive backing, require no heat, solvent or other preparation for adhesion to
smooth and clean surfaces.
Class 2 - Backing activated by applying heat and pressure to the material. The temperature
necessary to form a durable permanent bond must be sixty-six degrees Celsius (66oC) and at a
degree less than 38 degrees, it is suscecetible to re-pasting.
Class 3 Pressure-sensitive backing, required no heat, solvent or other preparations for adhesion to
smooth and clean surface, and its advantage on class 1 is that it may be reused at a temperature
reaches thirty eight degrees Celsius (38 oC).
Class 4 - Low-temperature pressure-sensitive backing that permits sheeting applications at
temperatures down to minus seven degrees Celsius (-7oC) without the aid of solvent or other
preparation for adhesion to smooth, dry and clean surfaces.
Class 5 Non-Adhesive backing and it is normally used with self-supported products such as
traffic cones and temporary signs.
16.3.2.8 Honeycomb Sections:
The front sheet of each sign must be fabricated in one piece of minimum thickness one and
sixth tenths (1.6) millimeter Aluminum alloy according to item (16.3.2. 3),"Aluminum Products"
The surface must be treated with amorphous chromate conversion coating according to the
requirements of ASTM B 449, Class 2.
Core material must be phenolic impregnated cellulose honeycomb, and it must be resistant
to fungus.
The back sheet of each panel must be fabricated in one piece of minimum thickness one
(1) millimeter Aluminum alloy according to (16.3.2.3),"Aluminum Products" in these General
Specifications.
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The adhesive material must be of thermoplastic neoprene and must be water and oil
resistant, and must have flexible cohesion strength. Solid materials content must be suitable for use
by automatic spraying or painting provides dry paint not less than fifty (50) grams per square
meter.
A thin uniform layer of the adhesive must be applied on each surface and this layer must
be dryable at temperature not less than eighty two (82) degrees and by using adequate pressure that
ensures tight cohesion between surfaces.
The tensile strength of the honeycomb unit must have a minimum of one and a half (1.5)
kilograms per square centimeter when tested according to ASTM C 297, Cycle C 481.
16.3.2.9 Performance Requirements:
Tables (16-3-1) to (16-3-9) present the performance requirements of the reflective sheets
types according to ASTM E810, E97.
Table 16.3.1: Minimum Coefficient of Reflection (RA) (Candelas/lux/m 2) for Medium

Intensity Ty pe I Sheetin
g
Observation Entrance
White Red Orange
Yellow Green Blue
Angle
Angle
Brown
0.2 o
-4.0o
70
14
25
2
50
9
4
o
o
0.2
+30
30
6
7
1
22
3.5
1.7
0.5 o
-4.0o
30
7.5
13.5
1
25
4.5
2
o
o
0.5
+30
15
3
4
5
13
2.2
0.8
Where:
Observation angle must mean the angle at the reflective between the observer's line of sight and
the axis of the incident light beam.
must mean the angle at the reflective between the direction of light incident on it and the
direction of the reflective axis.
Table 16.3.2: Minimum Coefficient of Reflection (RA) (Candelas/lux/m 2)

Medium-Hi gh Intensity Ty pe II Sheetin
White Yellow Orange Green Red Blue Brown
Angle
Angle
0.2 o
-4.0o
140
100
60
30
30
10
5
o
o
0.2
+30
60
36
22
10
12
4
2
0.5 o
-4.0o
50
33
20
9
10
3
2
0.5 o
+30o
28
20
12
6
6
2
1
Table 16.3.3: Minimum Coefficient of Reflection (RA) (Candelas/lux/m 2) HighIntensity Ty pe III Sheetin
g
White Yellow Orange
Red
Blue
Brown
Angle
Angle
Green
0.2 o
-4.0o
250
170
100
45
45
20
12
o
o
0.2
+30
150
100
60
25
25
11
8.5
0.5 o
-4.0o
95
62
30
15
15
7.5
5.0
o
o
0.5
+30
65
45
25
10
10
5
3.5
434

Table 16.3.4: Minimum Coefficient of Reflection (RA) (Candelas/lux/m 2 ) High

Intensity Ty p e IV Sheetin
White Yellow Orange Green Red Blue Brown
Angle
Angle
o
-4.0
250
170
100
35
35
20
7
0.2 o
o
+30
80
54
34
9
9
5
2
0.2 o
o
-4.0
135
100
64
17
17
10
4
0.5 o
o
o
+30
55
37
22
6.5
6.5
3.5
1.4
0.5
Table 16.3.5: Minimum Coefficient of Reflection (RA) (Candelas/lux/m 2 )
Super-Hi g h-Intensity Ty p e V Sheetin
White Yellow Orange Green
Red
Blue
Angle
Angle
o
-4.0
700
470
280
120
120
56
0.2 o
o
o
+30
400
270
160
72
72
32
0.2
o
-4.0
160
110
64
28
28
13
0.5 o
o
o
+30
75
51
30
13
13
6
0.5
Table 16.3.6: Minimum Coefficient of Reflection (RA) (Candelas/lux/m 2 )
High-Intensity Ty p e VI Sheetin
White Yellow Orange Green
Red
Blue
Angle
Angle
o
-4.0
250
170
70
30
35
20
0.2 o
o
o
+30
95
64
26
11
13
7.6
0.2
o
o
-4.0
200
136
56
24
28
18
0.5
o
+30
60
40
17
7.2
8.4
4.8
0.5 o
Table 16.3.7: Minimum Reflection Coefficient (Candela/lux/m2) of Highly
Intensive Reflection Sheetin g - Ty p e 7
Orange Yellow Green
White
Red
Blue
Angle
Angle
-4.0
750
150
280
560
75
34
0.2
+30
430
88
180
320
43
20
0.2
-4.0
240
48
90
180
24
11
0.5
+30
135
27
50
100
14
6
0.5
-4.0
10
2
4
8
1
1
1.0
+30
10
1
1
4
2
1
1.0
Table No. (16-3-8) Minimum reflection coefficient (candela/lucas/m2) of super
reflection sheetin g - ty p e 8
Orange Yellow Green
White
Red
Blue
Angle
Angle
-4.0
700
105
265
525
70
42
0.2
+30
325
49
120
245
33
20
0.2
-4.0
250
38
94
190
25
15
0.5
+30
115
17
43
88
12
7
0.5
-4.0
30
4
8
24
1
1
1.0
+30
10
2
4
6
1
1
1.0
435

Table 16.3.9: Minimum reflection coefficient (candela/lucas/m2) of over intensive

sheetin g- Ty pe 9
Orange Yellow
White
Red
Green
Blue
Angle
Angle
0.2
-4.0
380
76
145
285
38
17
0.2
+30
215
43
82
162
22
10
0.5
-4.0
240
48
90
180
24
11
0.5
+30
135
27
50
100
14
6
1.0
4.0
80
16
30
60
8
3.6
1.0
+30
45
9
17
34
4.5
2.0
Table 16.3.10: Luminance Factor (Y %) (Daytime)- Sheetin g Ty pes I, II, III & VI
Color
Minimum %
Maximum %
White
27
Yellow
15
45
Orange
14
30
Green
3
9
Red
2.5
12
Blue
1
10
Brown
4
9
Table 16.3.11: Luminance Factor (Y%) (Daytime)- Sheeting Type V

Color
Minimum %
Maximum %
White
15
Yellow
12
30
Orange
7
25
Green
2.5
11
Red
2.5
11
Blue
1
10
Brown
1
9
Table 16.3.12: Luminance Factor of IV, VII, VIII, & IX types- daytime
Color
Minimum %
Maximum %
White
40
Yellow
24
45
Orange
12
30
Green
3
12
Red
3
15
Blue
1
10
Brown
1
6
The materials must conform the following requirements: a. Artificial Weathering:
The reflective sheeting must be weather resistant and show no visible cracking, edge lifting,
or more than eight-tenths (0.8) millimeter shrinkage when tested according to ASTM G 123, Type
EK, as it is presented in table (16.3.13).
436

Table 16.3.13: Artificial W eatherin g Photometric Re quirements

Type
Hours
Minimum (RA*)
I
1000
50%
II
2200
65%
III
2200
80%
IV
2200
80%
*RA: Coefficient of Reflection
b. Specular Gloss:
The reflective sheeting must have at least eighty five (85) grad specular gloss when tested
in accordance with ASTM D 523.
c. Color Processing:
Reflective sheeting must be able for color processing with compatible transparent and
opaque process inks in accordance with manufacturer's recommendation at temperatures of fifteen
degrees Celsius (15C) to forty degrees Celsius (40C) and relative humidity of twenty (20) to
eighty (80) percent.
d. Shrinkage:
Shrinkage must not exceed allowed limit by testing reflective plates with an area of twenty
three (23) centimeter square at a temperature of two degrees Celsius (22oC) and relative humidity
fifty percent (50%) then shrinkage is measured. Shrinkage should not exceed eight tenths (0.8)
millimeter in all directions after twenty four (24) hours.
16.3.3.1 General:
Contractor must supply and install all required works shown on the drawings and special
specifications in addition to concrete bases, poles, fixtures, screws and all supplies used in the
works, also construction includes protective painting works according to requirements.
16.3.3.2 Signs:
1- Design:
A l l signs must be of the type, color and design shown on drawings and they must be in
compliance with contract specifications. Al l figures and symbols must be compatible with
MUTCD specifications.
2- Shop Drawings:
Contractor must submit drawings for all sign fronts for approval whereas he states all the
necessary dimensions, specifications and information.
16.3.3.3 Storage and Shipment of Signs:
Signs used must be stored in a place higher than ground level and covered in a way
approved by the Engineer. Each sign must wrapped by thick cloth or paper and must be bound
with each other to avoid their dropping during transportation.
16.3.3.4 Placement and Orientation:
Urban road signs must be installed according to special specification drawings
providing that the distance of the sign from the pavement edge must be between one and a half
(1.5) meter and two (2) meters according to the maximum speed of the road.
437

Contractor must be responsible for adjusting heights, modifications and levels for all signs being
installed by him and their compliance with the drawings in the special specifications.
A l l signs must be installed such that they must be fully vertical and the poles must be
straight. Poles made from iron pipes IPE for road signs must be with breakaway bases.
16.3.3.5 Footings for Sign Supports:
Contractor must carry out excavation for pole bases according to section (5.3)
"Excavations" in these General Specification, whereas pole bases are excavated to the required
depths according to drawings.
Contractor must undertake complete testing for soil and ensure its suitability or treat it i f
necessary such that it achieves the minimum acceptable limit for the bases tolerance and in
accordance with soil compaction works specified in section (5.5) "Base layer" in these General
Specifications.
Embankments must be compacted such that their density must not be less than ninety five
percent (95%) of the maximum density calculated by the density testing according to section 5.4
"Embankment" in these General Specification. It is not allowed to increase the height of the upper
surface of the base over ground surface level.
2- Concrete Works:
Casting:
Concrete must be cast after fixing reinforcement steel in the required dimensions inside the
tightly fixed cast forms which. The Slump of the concrete mix must not exceed seventy five (75)
millimeters according to AASHTO T119 test method, and the minimum cement content must not
be less than three hundred fifty (350) Kilograms per cubic meter. The reinforcement steel used in
any type of concrete bases must comply with the requirements of specification AASHTO M254.
The cement concrete must achieve material requirements and Job Mix Formula indicated
in section 14.3 "Concrete Works" in these General Specifications. When using Ready-mix
concrete, it must comply with the requirements of specification ASTM C94.
Before commencing the concrete base casting, all the necessary works for supporting it or
on which it must be cast must be completed, the surfaces of the executed bases must be smooth
and uniform and in compliance with the vertical and horizontal dimensions shown on drawings or
according to the Engineer's recommendations, and they must be free from clods.
Curing:
The compressive strength of concrete must not be less than (21) Mpa when testing after
twenty eight (28) days of curing according to the AASHTO T22 test. The units must be cured in
accordance with the requirements of Paragraph (14-3) "Curing" in these General Specifications
unless otherwise specified.
Precast Concrete Footing:
The pre-cast concrete bases may be prefabricated by casting them in clean smooth
surfaced forms so that they may give a smooth surface free from voids and cavities of area more
than two (2) millimeters squire in area. The strength of the unit must not be less than (21) Mpa
centimeter when testing at age of twenty eight (28) days
according to the AASHTO T22 test. The captive air must not exceed seven and a half percent
(7.5%) and not less than four and a half percent (4.5%) of the total volume of the unit.
16.3.3.6 Porcelain Coatings:
Porcelain coatings for sign faces must be a minimum of four hundredths (0.04) millimeter
thickness. The coating must be applied by automatic spray equipment.
The coating must have a gloss reading of fifty (50) to seventy (70) units at an angle of fifty (50)
438

grads when measured in accordance with ASTM C 346.

16.3.3.7 Letters, Numbers, Arrows, Symbols:
Letters, numbers, arrows and symbols must be with colors and sizes compliant with
drawings and writing must be in Arabic and English unless otherwise specified. Distribution of
holes for screws, rivets, bolts, which appear on the sign surface, must consider the distribution of
letters and their shapes such that they do not affect the shape of writing or symbol, also symbols
and figures must be compatible with MUTCD specification.
16.3.3.8 Aluminum Sign Sections:
The parts must be duly in compliance specifications and drawings. Each part must be
surrounded by a frame with hold path for bolts at each end whereas the bolts fix the sign plate on the
stand pole, but the vertical sides must be of the grooved type. The horizontal and vertical ends must
be extruded channel. An additional slot must be milled in the top and bottom frame for later field
insertion of post clip posts, the perimeter frame must be assembled by means of stainless steel
screws. A sealant must be used at the corner to prevent moisture penetration.
Cast Aluminum sign parts must be connected by rivet screws or bolts or any other fixing
requirements level with the front surface as shown on the drawings, they must be tightly fixed and
enforced against storms.
Multi pieces signs conjunction lines must be emptied by about eight tenth (0.8) millimeters and
not more than one and a half (1.5) millimeter. All the sharp edges which may be representing
danger must be smoothed.
Self closing-three (3) millimeters diameter bolts must be used at each corner, and the
color of the rivet screws apparent on the side of the sign front must be compliant with the sign
color.
16.3.4 Work acceptance:
1- Quality Control:
Quality control procedures for the materials and executed works must be done according
to item 17.1.1 "Quality Control" in these General Specifications.
Contractor must incur all the costs related to quality control.
Contractor has no right to start any work before he obtains a written acceptance from the
Engineer indicating the acceptance of the Engineer for the quality control plan submitted by the
Contractor.
The Engineer must be provided with lists of materials, parts, shop drawings of signs and
sign supports, quantities and tasks for acceptance within sixty (60) days from contract signing date.
It is not permissible to submit partial shop drawings or lists for this purpose.
but material lists must include cut samples from catalogues or data brochures.
Unacceptable submittal must be returned back for the required corrections. Any changes
intended for incorporation in the approved materials and equipments lists must be made according
to written request and in case such changes were requested by the Engineer, Contractor must
submit samples for the alternative item(s) for inspection and acceptance without any additional
costs arising from this on the Ministry.
The manufacturer must present certifications to insure the quality of used part complying
with ISO 9002 or equivalent standard accepted in the country of manufacturing.
The Engineer must be provided with all the brochures, guide manuals, spare-parts listings
439

of equipments and parts used in the work. Standby units in the rate of not less than ten percent
(10%) of all used units must be provided providing that not less than one (1) unit of each type.
Table (16.3.10) shows quality control requirements according to section 16.3 in these
according to item 17.1.2 "Quality Assurance" in these General Specifications.
The Ministry is responsible of Quality Assurance procedure by any standard testing that
the Ministry prefer, to insure that all works done by the Contractor are satisfying the requirements
of these General Specifications and the Special Specifications.
16.3.5 Measurement:
Ground-mounted and overhead highway signs must be measured by the face area to the
nearest one-hundredth (1/100) square meter for each highway sign and to the nearest one-tenth
(1/10) square meter for the total of each type of sign, as specified in the Bi l l of Quantities.
Dismount sign supports must be measured in Kilograms for supports with I section, and
pipe supports must be measured in number of units, that include required joint, bolts, screws and
all similar fasteners.
Overhead sign supports must be measured by the metric ton, and that include all related
parts. Kilometer posts must be measured by the number of units.
Measurements must be done in the presence of the Engineer, using accurate balances.
Sign support work must include all complementary work presented in excavation and backfill,
concrete and reinforcement.
16.3.6 Payment:
Items measured according to the item 16.3.5 "Method of Measurement" must be paid for at
the contract unit price for each type, including costs of all materials, labor, equipment, tools,
supplies, and all other items necessary for the proper completion of the Work. Payment must be
according to the quantity table (16.3.12) in these General Specifications.
440

Table 16.3.11: Quality Assurance Requirements

Item
Property
Test
Reflection
ASTM E 810
Luminance
ASTM E 97
Specular
Gloss
ASTM D 523
Shrinkage
Paragraph
(1 6-3-2-7-d)
In these General
Specifications
Reflective
Sheeting
Porcelain
Coatings
Visible Test
ASTM C 346
Concrete
Works
All properties
mentioned in
the Special
Specifications
Division14
"Concrete Works"
Unless specify in
special specifications
Steel
Products
All properties
mentioned in
the Special
Specifications
ASTM A27 Grade

U-60-30, A307,
A325, A193,
A194,A501,A595
Grade A
Source certified
Aluminum
Products
All properties
mentioned in
the Special
Specifications
ASTM B108, B209,

B21 1 or B221
Honeycomb
Panel
Tensile Test
ASTM C279,
ASTM C481 Cycle
A
Sampling
According to
Manufacturer's
According to
Manufacturer's
According to
Manufacturer's
According to
Manufacturer's
According to
Manufacturer's
beginning of the
production and when
changing materials
sources or mix.
Properties.
Requirements
Table (16-3-1) to
(16-3-6) in these General
Specifications
Table (16-3-7) to
(16-3-9) in these General
Specifications
Paragraph (16-3-2-9-b)
in these General
Specifications
Paragraph (1 6-3-2-9-d)
in these General
Specifications
Paragraph (16-3-3-6)
"Porcelain Coatings"
in these General
Specifications
Section (14-3) "
Concrete Works"
in these General
Specifications
According to
Manufacturer's
Item (14-2-6)
"Steel Properties"
in these General
Specifications
According to
Manufacturer's
According to
Manufacturer's
"Aluminum Products"
in these General
Specifications
"Honeycomb Sections"
in these General
Specifications
Table 16.3.10: Quantities

Item No.
16-3-12-1
16-3-12-2
16-3-12-3
16-3-12-4
16-3-12-5
16-3-12-6
16-3-12-7
16-3-12-8
Item
Highway Signs, Ground-mounted Type (.)
Highway Signs, Overhead Type (.)
Sign Support, (Breakaway) I.P.E.
Sign Support, (Breakaway)Tubular
Sign Support-Overhead
Sign Support-Cantilever
Kilometer Post
Structural Paint
Unit
Square Meter
Square Meter
Kilogram
Unit
Ton
Ton
Unit
Square Meter
441

16.4 Traffic Paint and Road Marking:

16.4.1 Description:
This work contains description and construction of white and yellow traffic lines, and
white and yellow thermoplastic traffic lines of Epoxy, and raised road markers of Ceramic,
prismatic, Cat eye (large, small and solar) and Delineators according to these General
Specifications and according to the Special Specifications to be use in urban roads.
16.4.2 Materials:
16.4.2.1 Reflective Traffic Lines:
The paint is composed of a ready mix of an adhesive material and a white or yellow
pigment and filler for using and sticking it on the finally paved surface. The paint can be made
reflective by adding small reflective glass spheres which are sprayed on the paint before drying or
by pressing them over the paint film. The lines must be compliant with specification AASHTO
248 Type F and the glass spheres must be compliant with specification AASHTO M47 Type I.
16.4.2.2 Reflective Thermoplastic Traffic Lines:
Thermoplastic traffic lines are thermoplastic paint, composed of a ready made adhesive
material, white or yellow pigment and filler in addition to other materials such as light colored
silica or quartz. Table (16.4.1) shows composition of thermoplastic paint according to specification
AASHTO M 249.
Table 16.4.1: Traffic Paint Components
Material
Binder
Glass beads
Titanium dioxide
Calcium carbonate
Yellow pigment
White
18 % minimum
30-40 %
10 % maximum
42 %
According to
manufacturer
Yellow
18 % minimum
30-40 %
According to
manufacturer
According to
manufacturer
1- Surface Glass Spheres:

Surface application glass spheres must be according to the requirements of AASHTO M
247, Type I, and the gradation must be according to table (16.4.2).
Table 16.4.2: Surface application glass spheres Surface application glass spheres
Sieve Size
1.70 mm (No.12)
0.600 mm (No.30)
0.425 mm (No.40)
0.300 mm (No.50)
0.180 mm (No.80)
0.150 mm (No.100)
Percent Passing by Weight

100
85-100
45-100
10-45
0-20
0-5
442

Pre-mix glass spheres must be according to the following requirements:

1-a- Crushing Resistance:
Crushing resistance of the glass spheres must be performed by determining the refraction
factor value after submerging the spheres in soda lime. The Refractive Index must not be less than
one and a half (1.5) for the tested glass spheres by "Soda lime glass test" according to British
Standards BS 6088-1981.
1-b- Roundness:
A minimum of seventy-five percent (75%) must be true proper spheres when tested in
accordance with ASTM D 1155. Spheres must be free from all defects including scratches,
cohesion and lack or poorness of transparency.
1-c- Refraction Index:
The Refraction Index for the glass spheres must not be less than one and a half (1.5) when
tested by "Liquid immersion method" at twenty-five degrees Celsius (25C), calculating the
Refraction Index.
1-d- Chemical Resistance:
Glass spheres must not be corroded, darkened or have scratches when submerged in water
or acids, and they must not be noticeably disintegrated when exposed to phosphates.
Testing can be performed by taking three samples of about 4 grams each to be submerged
in one glass pot containing distilled water, a second containing euphoric acid and a third containing
a solution composed of fifty percent (50%) sodium sulphate, forty eight percent (48%) distilled
water and two percent (2%) aerosol or any moistening material. The submersion must continue for
one hour after which the granules are investigated by the microscope to determine the extent of their
resistance to chemical reactions.
2-
Epoxy Thermoplastic Materials:

Epoxy thermoplastic reflective traffic lines are composed of two (2) types of epoxy resins,
liquid type and solid type. It is composed of Calcium Carbonate, filler packing, and glass spheres
together with titanium oxide dye for the white setup or silica coated lead chromate pigment for the
yellow formulation.
3Epoxy Resins:
The liquid and solid resins must be condensation products of bisphenol having the properties listed
in Table (16.4.3).
Table 16.4.3: Epoxy Resins requirements
Liquid Epoxy Resin
Average
Average
Difference*
Solid Epoxy Resin

Average
Average
Difference*
Viscosity (cps) 48 degrees
680-810
10
1300-2600
75
Epoxide Equiv. Wt.(gm./equiv.)
180-196
10
1600-2300
50
Material
*Between two replicates
443

3-a- Titanium Dioxide:

The titanium dioxide must be according to ASTM D 476. The oil absorption must be
between thirteen (13) and thirty (30) grams per one hundred (100) grams of the materials with
deviation not more than one (1) gram.
3-b- Calcium Carbonate:
The calcium carbonate must be according to ASTM D 1199, Type GC, Grade I, with a dry
brightness no less than ninety-one percent (9 1%). The oil absorption must be between nine (9) and
twenty-one (21) grams per one hundred (100) grams of the materials with deviation not more than
one (1) gram.
3-c- Lead Chromate:
The lead chromate must be silica encapsulated, and with no additive surface treatment.
The pH of the Lead Chromate is determined by ASTM D1028 test. Specific gravity of the Lead
Chromate is determined by ASTM D153. The Lead Chromate content is determined by ASTM D
444. Lead Chromate must satisfy the requirements shown in table (16.4.4) in these General
Specifications.
Table 16.4.4: Acce pted limits of tests results for Lead Chromate sam ple.
Property
PH
Specific gravity
Lead, percent by weight
Chromate (CrO4), percent by weight
Chromium (Cr), percent by weight
Minimum
Maximum
Maximum
Deviation
Between
Replicates
7.0
3.8
44
17
7.6
9.0
4.5
55
27
12.1
0.2
0.01
0.5
0.6
0.5
16.4.2.3 Reflective Road Markers:

Road markers are separate raised metallic or plastic or ceramic units fixed on the road surface for
the purpose of directing traffic according to the required lane.
Types and specifications of the road markers are as follows:
1- Large Cat eye Road Studs:
Large Cat eye Markers are units cast from Aluminum with dimensions approximately one
hundred fifty (150) millimeters by one hundred fifty (150) millimeters and twenty three (23)
millimeters high. stud anchor must be aluminum, approximately six (6) centimeters long and two
and a half (2.5) centimeters in diameter deformed or grooved to resist extraction or torsion. The
markers must withstand a tensile stress of two hundred seventy five (275) N/mm2. Each cat eye
unit must have one or two reflective faces according to the road type. Each reflective face must
contain 3 or four (4) fifteen (15) millimeter diameter discs of seven (7) bi-convex lenses or of one
prismatic face. Each reflective face must satisfy requirements table of table (16.4.5).
444
Where:

Observation angle must mean the angle at the reflective between the observer's line of
sight and the axis of the incident light beam.
Entrance angle must mean the angle at the reflective between the direction of light
incident on it and the direction of the reflective axis.
2- Small Cat eye Road Studs:

Small Cat eye Markers are units cast from Aluminum with dimensions approximately one
hundred fifteen (115) millimeters by one hundred fifteen (115) millimeters and high stud anchor
must be aluminum, approximately six (6) centimeters long and two and a half (2.5) centimeters in
diameter deformed or grooved to resist extraction or torsion. The markers must withstand a tensile
stress of two hundred seventy five (275) N/mm2. Each cat eye unit must have one or two reflective
faces according to the road type. Each reflective face must contain three (3) or four (4), fifteen (15)
millimeter diameter discs of seven (7) bi-convex lenses or of one prismatic face. Each reflective
face must satisfy requirements table of table (16.4.5).
3- Solar Cat eye Road Studs:

Solar Cat eye Markers are cast Aluminum units one hundred fifteen (115) millimeters by
one hundred fifteen (115) millimeters or one hundred fifty (150) millimeters by one hundred fifty
(150) millimeters and twenty three (23) millimeters high, with a stud anchor of deformed or
grooved aluminum to resist extraction or torsion and approximately six (6) centimeters long and
two and a half (2.5) centimeters in diameter, tensile markers must withstand a tensile stress of two
hundred seventy five (275) Mpa.
Solar marker must have a solar unit, conductor, storage unit and lighting unit. The unit
produce continuous or plus lighting working on electrical power of not more than half (0.5) watt.
Lighting pulses must be between one hundred eighty (180) and two hundred forty (240) pulses per
minute. Solar Cat eye unit must function perfectly with in temperature range between minus thirty
degrees Celsius (-30C) and ninety five(95) degrees Celsius. The design age of Solar Cat eye units
must not be less than five (5) years.
4- Plain Prismatic Reflective Marker:
Prismatic markers must consist of a methacrylate or other suitable material shell filled
with a mixture of a thermosetting compound and filler material approximately ten (10) centimeters
by ten (10) centimeters. The exterior surface of the shell must be smooth and designed to ensure
mechanical welding between the shell and the filler material.
The shell must contain one or two reflective faces of methacrylate methyl and the
reflective lenses must be free from voids and the rear of the lens must be coated with metallic
coating. The base of the reflector must be rough and cohesive when stuck with adhesives materials.
The direct vertical tensile strength of the reflector _______________________ must
not
be
less than one thousand (1000) kilograms.
Prismatic reflectors must meet the minimum limits of requirements indicated in table
(16.4.5).
445

5- Ceramic Pavement Markers:

Ceramic markers are heat treated, polished, glazed surface in white or yellow color and
ceramic base resulting from treating a mixture of argil, clay, talc, flint and mixed feldspar or any
similar inorganic material.
The marker must be of ten (10) millimeters radius disc. The upper surface of the marker
must be convex of curvature radius between nine (9) and fifteen (15) centimeters. The polished
reflector surface must be free of scratches, holes, or air voids. The reflector base must be coarse and
unpolished with raised protrusions in the shape of parallel lines.
The reflector direct vertical tensile strength must not be less than 680 kg. The adhesive
material of the ceramic reflectors must bituminous or epoxy resin to suit the high temperature
climate and not to be affected with climatic conditions, and to bear temperatures of 220 degrees
Celsius.
The Epoxy adhesive must be compliant with AASHTO M 237 Class I specification. The
compound must be tested and used according to manufacturer recommendations.
16.4.2.4 Delineators:
Delineators must consist of reflective unit fixed on Aluminum body, to be mounted on
side barriers. The propose of using the Delineators is to improve the vision on curved lanes at
night or at other natural conditions that reduce the vision level. The reflective unit must be either
of Acrylic plastic lenses or of reflective sheeting.
The reflective coefficient of the plastic lenses must not be less than the values shown in
table (16.4.6) in these General Specifications.
Table 16.4.6: Minimum values of Reflection Coefficient RA (Candela/lux)
Entrance
Angle
0.1
0.1
Observation
Angle
0
20
White
Yellow
Red
10.7
4.2
6.5
2.3
2.8
1.1
The type of the Reflective sheeting must be according to the paragraph (16.3.2.6)
"Reflective Sheeting", and it must satisfy the requirements of paragraph (16.3.2.9) "Performance
Requirements" in these General Specifications.
Aluminum part must be made of Alloy 6061 T6 according to ASTM B209, with a plate
thickness of one and six tenth (1.6) millimeters, satisfying the requirements of paragraph (16.3.2.3)
"Aluminum Products" of these General Specifications.
Dimensions and shapes of Delineators must be according to the Manual Uniform Traffic
Control Devices (MUTCD).
16.4.3 Construction: 16.4.3.1 General:
The surface on which the lines or reflectors must be installed should be clean and free from old
markers or lines, and the surface must be dry and free from any oils or lubricants.
After ensuring the cleanliness of the surface and its suitability for placing lines or markers,
consistence of the surface must be reviewed such that it must not be
446

disintegrated or with large cracks or any other defects which may minimize stability of the lines or
reflectors installed on it. Contractor must supply and install all the work parts shown on the
drawings of the special specifications with the dimensions, machines and tools required for
completing the works according to requirements.
16.4.3.2 Reflective Traffic Lines:
The paint used is a ready mix of an adhesive material, white or yellow pigment, and filler,
constructed in a special way for use and sticking on the finalized paved area. The paint must be
made reflective by adding small glass spheres sprayed on the paint before it dries or by pressing
them on the paint film. The paint must be applied by special equipments as indicated in paragraph
(16.4.3.6) and by the method indicated in paragraph (16.4.3.7) in these General Specifications.
As to thermoplastic traffic lines paint must be applied in its soluble state using mechanical
devices while placing the glass spheres on the surface and when the paint cools to the normal
pavement temperature a reflective cohesive paint line results with specified thickness capable of
resisting the deformation arising from traffic and the plasticity percentage must not be less than
ninety two percent (92%).
16.4.3.3 Reflective Cat eyes:
Road Markers (Cat eye type: large, small and thermoplastic):
The markers must be fixed at the locations specified on the drawings such that the distance
between markers must not be less than half (0.5) meter and not more than six (6) meters. For fixing
units, holes are first must be made on the asphalt after cleaning the whole surface, by a driller, the
diameter of the hole must be more than the reflector's stud diameter by about two (2) to four (4)
millimeters, and with a depth of more than the length of the reflector stud by about two (2) to four
(4) millimeters, after that the hole is cleaned and filled with the adhesive used according to
manufacturer's recommendation.
The reflectors are fixed by inserting the fixing shaft to a depth of six (6) centimeters on
the asphalt surface. The fixing stud must be deformed or grooved to resist extraction.
16.4.3.4 Plain Prismatic and Ceramic Markers:
The base of the prismatic reflector must be coarse with adequate consistence at being glued
with adhesive materials, whereas the reflectors are fixed after cleaning the surface at the locations
shown on the drawings such that the distance between the reflectors must not be less than half
(0.5) meter and does not exceed six (6) meters. Markers are fixed by the special adhesive material
according to the manufacturer's recommendation.
Ceramic markers must be of ten (10) millimeters radius disc, and the upper surface of the
marker must be convex of curvature radius between nine (9) and fifteen (15) centimeters.
The reflector base must be coarse and unpolished with raised projections in the shape of parallel
lines. The reflectors are fixed after cleaning the surface at the locations shown on the drawings such that the
distance between reflectors must not be less than half (0.5) meter and does not exceed six (6) meters. The
units must be fixed by the adhesive material that meets requirements of paragraph (16.4.3.5) ''Adhesive" in
447

16.4.3.5 Delineators:
The Delineators must be mounted on road side according to the manufacturer's
recommendations. The spacing between Delineators must be according to table (16.4.7) in these
I f there is no side barriers to support the delineators, then the delineators must be fixed on
steel supports raised to the determined elevation by the Special Specifications, the steel supports
must satisfy the requirements of paragraph (16.3.2.2) "Steel Posts" in these General Specifications,
and the delineators must be fixed according to the paragraph (16.3.3.5) "Posts Foundation" in these
General Specifications. Delineators must be fixed properly on the top of the support according to
manufacturer's recommendations.
Table 16.4.7: S pacin g between Delineators on horizontal curves
Curve Radius (meters) Delineators Spacing (meters)
15
6
35
8
55
11
75
13
95
15
125
18
155
20
185
22
215
24
245
26
275
27
305
29
Delineators must be mounted on suitable supports so that the height of top side of the
Delineators must be one hundred twenty (120) centimeters above pavement surface, and at six
tenths (0.6) to two and a half (2.5) meters far from the road shoulders edge.
16.4.3.6 Adhesive:
The markers are fixed by an adhesive material composed of bituminous compound or
epoxy resin manually mixed.
The bituminous adhesive must not contain rubber polymer, since the high temperature at
cohesion may lead to the adhesive disintegration. The compound must be tested and used according
to the manufacturer's recommendation.
Adhesive must be suitable for application in temperatures range between zero (0C) to
fifty eight (85C) degrees Celsius.
16.4.3.7 Paint:
Paint must be applied according to the manufacturer's recommendations and according to
the indicated specifications in the Special Specifications after the Engineer's acceptance. After the
Engineer ensures that the materials and equipments comply with the specifications, the required
paint is applied with the thickness and dimensions shown on the drawings providing that the
climatic conditions are suitable, whereas the Engineer does not grant his acceptance for the
commencement of the works at the following conditions:
448

- When there is moisture on the pavement or when air is saturated with water. - When
temperature is less than ten (10C) degrees Celsius.
- When there are air currents or storms which may cause dust accumulation on the pavement
surface after being cleaned and before paint application.
- When there is any other condition which the Engineer surmises unsuitable.
Contractor must execute experimental paint to ensure soundness of the materials and width
and thickness of the lines.
In case the road is opened for traffic during paint application, paint must be applied only
during day hours and in ample time for its dryness before sunset. For continuous traffic lines, the
rate of paint must be forty (40) liter per kilometer as minimum i f the surface was smooth, but i f it
were coarse the paint rate must not be less than fifty (50) liter per kilometer.
For discontinues traffic lines, the rate of paint must not be less than fourteen and a half
(14.5) liter per kilometer as minimum, painting six (6) meters every twelve (12) meters spacing,
also these limits must be changed to proportionate with the changes in line length or width.
Directly after lying the paint, a layer of glass spheres must be spread by a rate of six tenths (0.6) to
seven tenths (0.7) kilogram per liter of paint.
16.4.3.8 Traffic Lines and Markings Equipment:

Equipments installing markers and lines must either be units mounted on trucks or motor
equipped units that the worker rides or manually driven equipments according to the type of the
markers or lines required.
Motorized units which are rode by the worker must be capable of working in a speed not
less than eight (8) Kilometer per hour, but the manual equipments must be capable of maneuvering
in such a way enough for making the axes lines, lane lines, and side lines, and drawing triangular
pieces, turning lines, pedestrian lines, parking lines, arrows, symbols and terms. All shapes and
lines must be in compliance with the MUTCD specifications.
Painting equipments must be protected from shocks by shock absorbers installed in them.
Spraying equipments must be capable of spraying paint properly for direct spraying over pavement
providing that the machine must be provided with a mechanical distributor that operates
automatically at the spraying nozzle. Each spraying nozzle must be equipped with suitable pilots.
The machine must be equipped with frontal cleaning unit to remove dust and wastes from
the pavement surface. Each machine must be suitable to the type of markers or lines according to
the manufacturer's specifications and after the Engineer's acceptance.
16.4.4 Acceptance:
1- Quality Control
to item (17.1.1) "Quality Control" in these General Specifications.
Contractor must incur all the costs related to quality control. Contractor has no right to start any
work before he obtains a written acceptance from the Engineer indicating the acceptance of the
Engineer for the quality control plan submitted by the Contractor.
449

The Engineer must be provided with lists of materials, parts, shop drawings of traffic lines
and road markings, quantities and tasks for acceptance within sixty (60) days from contract signing
date. It is not permissible to submit partial shop drawings or lists for this purpose.
but material lists must include cut samples from catalogues or data brochures.
Unacceptable submittal must be returned back for the required corrections. Any changes
intended for incorporation in the approved materials and equipments lists must be made according
to written request and in case such changes were requested by the Engineer, Contractor must
submit samples for the alternative item(s) for inspection and acceptance without any additional
costs arising from this on the Ministry.
The manufacturer must present certifications to insure the quality of used part complying
with ISO-9002 or equivalent standard accepted in the country of manufacturing.
The Engineer must be provided with all the brochures, guide manuals, spare-parts listings
of equipments and parts used in the work. Standby units in the rate of not less than ten percent
(10%) of all used units must be provided providing that not less than one (1) unit of each type.
Table (16.4. 8) shows quality control requirements according to section (16-3) in these
according to item (17.1.2) "Quality Assurance" in these General Specifications.
The Ministry is responsible of Quality Assurance procedure by any standard testing that
the Ministry prefer, to insure that all works done by the Contractor are satisfying the requirements
of these General Specifications and the Special Specifications.
16.4.5 Measurement:
Traffic Lines and Traffic painting must be measured by the square meter based on the
dimensions shown on the plans or ordered by the Engineer for all areas of each type accepted by
the Engineer.
Cat eye, Ceramic Prizmatic Markers and Delineators must be measured by the number of
units for each used type.
16.4.6 Payment:
The amount of accepted works will be paid at the contract unit price in the Bi l l of
Quantities. Each price must include all required materials, equipment, tools, labor, and all other
items necessary for the proper completion of the work.
Costs for cleaning the surface and removing existing paint lines must be___________________________
included in the items shown in the quantity table (16.4.9).
450

Table 16.4.8: Quality Assurance Requirements

Item
Property
Reflection
Test
Sampling
Minimum one (1) sample

every
five hundred (500) units
Road Studs
Cat eye
Requirements
Table (16.4.5)
in these General
Specifications
Paragraph
(16.4.2.3)
in these General
Specifications
Table (16.4.2)
in these General
Specifications
Paragraph
(16.4.2.2)
in these General
Specifications
Paragraph
(16.4.2.2)
in these General
Specifications
Not more than
two percent (2%)
Tensile Test
ASTM C297
According to Manufacturer's
instructions and the Special
Specifications
Gradation
AASHTO M47,
ASTM D1214
Specifications
Crushing
Resistance
BS 6088
Specifications
Roundness
ASTM D1155
Water
absorption
ASTM C-373
Direct
Pressure
Direct
Pressure
Viscosity
AASHTO
M237,Class I
Specifications
instructions
Specifications
Specifications
Specifications
Pigment
All properties
mentioned in
the Special
Specifications
Specifications
Table (16.4.4)
in these General
Specifications
Steel
Products
All properties
mentioned in
the Special
Specifications
ASTM A27
Grade U-60-30,
A307, A325,
A193, A194
Specifications
Paragraph
(14.2.6)
" Steel Properties"
in these General
Specifications
Aluminum
Products
All properties
mentioned in
the Special
Specifications
Specifications
Paragraph
(16.2.2.4)
"Aluminum
Products" in these
General
Specifications
Glass
Spheres
Ceramic
Pavement
Marker
Prizmatic
Pavement
Marker
Epoxy
resins
adhesive
ASTM B108,
B209, B21 1 or
B221
680 kg/unit
Minimum
1000 kg/unit
Minimum
Table (16.4.3)
in these General
Specifications

Item No.
16.4.9.1
6.4.9.2
16.4.9.3
16.4.9.4
Item
Traffic Lines Type (.)
Reflective Thermoplastic Traffic Lines
Pavement Marker Type (.)
Delineators
Unit
Square Meter
Square Meter
Unit
Unit
451

16.5 Fences, Guardrails and Concrete Barriers:

16.5.1 Description:
This section consists the description and construction works of Fences, Guardrails and
Concrete barriers (New Jersey) used in urban roads.
1- Fences
Fences must be consist of wire mesh fixed on posts using tie wires or chains to keep
vehicles from moving in or out road way and also to separate traffic directions. Wire mesh
dimension and shape must be according to Special Specifications requirements.
The posts must be fixed on concrete bases at the determined locations by the plans, and
according to the construction method shown in the paragraph (16.5.3.1) "Fences" in these General
Specifications.
Gates must be made of the same materials of the used mesh, and locations of gates must be
determined by the Special Specifications.
2- Guardrails:
The Guardrail must consist of steel posts linked by metal plates designed in a suitable way
to prevent vehicles from moving out of the road borders and to minimize the effects of collisions.
Posts must be fixed on concrete bases at the locations determined by the Special
Specifications. All Guardrail elements and supports must satisfy the requirements of the paragraph
(16.5.2) "Materials" and "Galvanizing" in these General Specifications. The posts must be linked
by compound plates at four (4) to eight (8) meters apart. Guardrail end must be designed to avoid
sharpness or there must be suitable reflective sheeting Type I at the beginning of the Guardrail,
according to the paragraph (16.3.2.6) "Reflective Sheeting" in these General Specifications.
3- New Jersy Concrete Barriers:
New Jersy barriers are a concrete longitudinal barrier has a constant cross section and has
expansion joints every certain distance along the road side.
The sued concrete for casting the New Jersy barriers must satisfy the requirements of
section (14.3) "Concrete" in these General Specifications.
16.5.2 Materials:
1- Backfill Materials:
A l l backfill material must be free from organic materials, and must be according to the
item (5.6.4) "Backfilling" in these General Specifications.
2- Reinforcing Steel:
Reinforcing steel must be according to item (14.2.6), "Reinforcing Steel" in these General
Specifications.
3- Structural Steel: Structural Steel must be according to ASTM A36, A27.
4- Aluminum Products:
All Aluminum components must be according to ASTM B 108, B209, B211 or B221, as
appropriate. Aluminum alloys must have a minimum tensile strength of (250) Mpa, and a
minimum yield strength of (200) Mpa.
452

5- Concrete:
Concrete for setting posts and for casting concrete barriers must satisfy the requirements
of the Job Mix Formula according to section (14.3), "Concrete" in these General Specifications.
I f using Ready-mix concrete, it must satisfy the requirements of ASTM C94.
6- Chain Link Fence: Chain Link Fence must be according to ASTM A 491 or
ASTM A 392.
7- Wires and Mesh:
Wires and Mesh material must be according to ASTM A 585 Class I or ASTM A 121
Class I. Wire must be composed of minimum two and a half (2.5) millimeters diameter
(12AWG). High Tension Wire must be according to the requirements of AASHTO M 30, Type
II, Class A, with a minimum breaking strength of nineteen thousand four hundred (19,400)
kilograms and elastic modulus of (830) Mpa.
8- Combination Fence Fabric:
Combination Fence Fabric must be according to ASTM A584 Class I or ASTM A116
Class I. Minimum wire size must be three and four tenths (3.4) millimeter diameter (10 AWG).
9- Posts and Braces:
Posts and Braces must be according to ASTM A53, Schedule40 or ASTM A120,
Schedule40.
Rectangular hollow sections must be according to ASTM A501 or BS 4360 Grade 43C.
10-
Metal Beam Guardrail:

Guardrail elements and plates must be according to the requirements of AASHTO
M180, Class A, Type 2.
11-
Bolts:
Bolts must be according to ASTM A307, and ASTM A325 for High strength bolts.
12-
Galvanizing:
A l l materials for guardrail, fences, which are made of steel or iron, must be galvanized
in accordance with ASTM A123 or ASTM A153 as appropriate or AASHTO M280, M281 or
covered by Aluminum layer according to AASHTO M305 Type I.
16.5.3.1 Fences:
Fence posts must be designed to collapse at direct collision. Height and section of the
posts must be according to the Special Specifications and not less than one (1) meter from the
ground level, and its wall thickness must not be less than six (6) millimeters, where top
elevations of all posts must be in a smooth grade with curves at transitions.
453

The post must be made of steel according to the paragraph (16.5.2) of these General
Specifications. Posts must be set to concrete footings of at least one hundred twenty two (122)
centimeters length and one hundred (100) centimeters width and one hundred (100) centimeters
depth to resist any displacement that may happen while setting the post. The foundation for the
post must be as detailed on the manufacturer's working drawings and it must be of sufficient size
to ensure that it is not displaced when the post is knocked by errant vehicles, and withstand an
overturning moment of six thousand (6000) Nm.
The Mesh must be attached to the posts using tie wire according to the item (16.5.2) in
these General Specifications. Mesh must be fixed uniformly and tensioned by twenty five (25)
Kn.m,
16.5.3.2 Guardrails:
Guardrail must be installed at the locations shown on the plans or as ordered by the
Engineer. Posts must be installed by driving them vertically into the concrete to the required
grades or set in concrete as required by the Special Specifications.
When the pavement is within one (1) meter of the guardrail, the posts must be set before
placing the pavement. All curved guardrail with a radius of forty five (45) meters or less must be
bent in the shop. Rail elements must be erected in a smooth continuous line with the laps in the
direction of traffic flow, and must be designed to be spliced at intervals not to exceed four (4)
meters and such splices must be made at posts. The foundation for the post must be as detailed on the
manufacturer's working drawings and it must be of sufficient size to ensure that it is not displaced
when the post is knocked by errant vehicles, and withstand an overturning moment of six (6)
Kn.m.
The Guardrail end must be made according to the manufacturer's recommendations to
avoid sharpness or dangerous shapes with reflective sheeting fixed in the beginning of the guardrail.
The used reflective sheeting must satisfy the requirements of the paragraph (16.3.2.6) "Reflective
sheeting" in these General
16.5.3.3 Cable Barriers:
Cable protective barriers are composed of 4 galvanized high tension wire cables. Two of
these lie at 585 mm high from ground level in a crack at the upper portion of galvanized steel posts
fixed on the ground. Two cables are installed at low level of 490 mm from ground surface. They
are braided along the barrier between each adjacent post and at both ends of the barrier. The cable is
attached with ground anchor. The joint that links each cable and its fixing device is designed such
that it disconnects and separates in case of vehicle collision in the area where the fixing device
exists and in such a way that movement of the disconnected cable movement is checked by the
safety check rope. Medium fixing devices shall be installed when the length of the guard rail
protection cable exceeds 627 m in such a way that the maximum distance between two consecutive
devices cables shall not exceed 627 m. Spacing between these shall be as uniform as possible. To
provide continuity two cables shall be fixed one at the top and one at the bottom from the original
4 cables in each medium fixing device.
Protective guardrail cables are tied together with screws and the maximum length of each
cable is 154 m.
454

Before start of any fixing process a draw cable 6 m long shall be provided, it is then attached to the
ground installed fixing device. All cables, from each side, shall be fixed with grooved terminal
which starts from the right or left end as appropriate to ensure the existence of a grooved pin to the
left or right side in a screw to carryout the tension process. The process requires an insert jacket
minimum 25 mm long in each tension screw. The draw cable shall be grooved in right direction
from the end to be attached to the fixing device and the guardrail protection cable is installed
according to manufacturer instructions and work drawings.
The foundation of the post is completed according to the details shown on workshop
drawings prepared by the manufacturer, except otherwise stipulate contract due to ground
conditions at site. The foundation shall be of adequate size to ensure unchanging post location
when it is placed in foundation and to ensure a turning over moment of 6000 N.
When all the elements are in place, cables are tensioned uniformly 25 KN by turning
tension screws. Fill shall not be done over upper portions of the concrete footings of fixing
devices before tensioning cables.
16.5.3.4 New Jersey Concrete Barriers:

1- General:
A l l required works on which the barrier will be constructed on must be finished before
starting any work, and the base surface must be smooth level and homogenous according to the
horizontal and vertical dimensions shown on the plans.
The barrier materials must satisfy all requirements stated in item (16.5.2) "Materials" in
these General Specifications. The slump of the used concrete must not exceed seventy five (75)
millimeters when tested according to AASHTO T119, and the compressive strength must not be
less than (21) Mpa when tested at age of twenty eight (28) days according to AASHTO T22. The
minimum cement content is three hundred and fifty (350) Kilograms per cubic meter.
Dimensions of New-Jersy barrier section must be according to the drawings of the Special
Specifications. The height must not be less than one (1) meter, the base width must not be less than
eighty (80) centimeters and the top width must not be less than twenty five (25) centimeter. Slope
for all sides must be design to minimize the possibility of vehicles overturning according to
operational speed of the highway.
Expansion joints of one (1) centimeter width must be done every fifteen (15) meters, or
according to plans. Shrinkage joints of fifty (50) millimeters depth must be done every six meters
or less after the concrete set and before any shrinkage cracks exist, the joints are made by making
incisions on the setting concrete.
Excavation for the footing must be done accordance to the procedures in Paragraph (5.3)
"Excavation" in these General Specifications. The foundation for concrete barriers must be graded
level for a width equal to the width of barrier strips plus thirty (30) centimeters. The foundation
must be fully compacted with a smooth wheel vibratory roller and must meet the requirements
Base layer in paragraph (5.5) "Base layer", except where constructed on rock. Any foundation
soils found to be unsuitable must be removed and replaced according to the section (5.4)
"Backfilling".
455

3-Casting:
Before the Casting, the contractor must finish all preparation works which are required to
cast the units including homogeneous and smooth soil surface with proper horizontal and vertical
dimensions according to the plans of the Special Specifications.
A l l reinforcing steel, inserts and tubes must be set in place to the dimensions shown on
the plans before casting. The units must be cast on a flat level area with the correctly dimensioned
form.
The Slump must not be more than seventy five (75) millimeters according to the
AASHTO T119. The minimum cement content must be three hundred fifty kilograms per cubic
meter.
The used concrete must satisfy the requirements of the Job Mix Formula shown in
paragraph (14.3) "Concrete Works" in these General Specifications. When using ready-mix
concrete, it must satisfy the requirements of ASTM C94.
4- Curing:
The units cured for twenty eight days must develop not less than (21) Mpa compressive
strength according to the AASHTO T22.
Curing of units must be done according to the section (14.3) "Concrete Works" in these
5- Removal of Forms:
The fixed forms must be removed when the strength of the concrete developed to an accepted level
according to the Special Specifications or determined by the
Engineer, but not less than the required period to reach (7) Mpa compressive strength,
otherwise twenty-eight (28) days.
Transportation of units must only be allowed at a minimum of (24) Mpa.
6- Concrete Finishing:
The front face of each unit must have the finish as specified in the Special Specifications.
The Contractor must demonstrate his ability to produce the specified finish by constructing or
supplying a minimum of three (3) test panels. The test panel finish must be approved by the
Engineer before to beginning of the construction works.
The rear face of each unit must be left with a dense, rough texture with no open pockets of
aggregate or honeycombed areas.
7- Precast concrete barriers:
The used concrete barriers must satisfy the requirements of paragraph (14-3) "Concrete
Works" in these General Specifications.
Precast Concrete units must be cast in clean and plain steel forms with accepted concrete to
produce units with smooth surfaces without visible cavity or air sockets with more than two (2)
squire centimeters area. The strength of the unit must not be less than (21) Mpa when testing at age
of twenty eight (28) days according to the AASHTO T22 test. The captive air must not exceed
seven and a half percent (7.5%) and not less than four and a half percent (4.5%) of the total volume
of the unit.
The absorption for core sample must not exceed eight percent (8%) when tested by the
ASTM C642 test.
Curing of units must be done according to the section (14.3) "Concrete Works" in these
456


1- Quality Control:
to item (17.1.1) "Quality Control" in these General Specifications.
A l l works must satisfy the requirements of the seventeenth section "Quality Control" in
these General Specifications. The Contractor is responsible for the Quality Control procedure, and
he must present a quality control plan which will be followed during the contract period. The
Contractor is responsible of all costs related to the Quality Control procedures.
The Contractor has no right to start the works unless he got a written Clear and complete
material and equipment listings with shop drawings of fences, guardrails and concrete barriers
must be presented to the Engineer for approval within sixty (60) days after signing the Contract.
Partial listings and shop drawings will not be accepted. Material and equipment lists must include
catalog cutouts or published data sheets.
The manufacturer of guardrails and fences must be approved to a Quality Assurance
system complying with ISO 9002. The Contractor must provide Copies of Certificates of
Guarantee and test reports must be provided for the used components. Manufacturer's instruction
sheets and parts lists supplied must be delivered to the Engineer upon receipt of the equipment.
For each type of equipment used in the work, spare units of ten percent (10%) of the units
used with a minimum of one (1) must be provided to the Engineer. Unacceptable submittal will be
returned for correction. Any changes to the approved material or equipment lists must be requested
in writing without any additional costs. The Quality Control must be done according to the table
(16.5.1).
according to item (17.1.2) "Quality Assurance" in these General Specifications.
A l l materials and works must be tested to assure its quality. Testing must be according to
the requirements of these General Specifications and also according to the Special Specifications.
16.5.5 Measurement:
The completed and accepted works of installations and reinstallations and similar works
must be measured by the number of jobs. Fences, Guardrail, New Jersey Concrete Barrier
construction works must be measured in linear meter along the front face each accepted type
according to the special specifications.
Excavation, concrete filling or any other complementary works must not be measured separately,
but must be added to the items of table (16.5.2).
16.5.6 Payment:
The completed and accepted works will be paid for at the contract unit prices in the Bi ll
of Quantities. Each price must include all required materials, equipment, tools, labor, and all other
items necessary for the proper completion of the work. Payment must be according to the table of
quantities.
457

Table 16.5.1: Quality Control Requirements

Item
Property
Chain Link
Fence
All properties
mentioned in
the Special
Specifications
Combination
Fence Fabric
Posts and
Braces
Bolts and
nuts
Metal Beam
Guardrail
Tensile Wires
Test
Sampling
Requirements
ASTM A 491,
A 392, HDM, Volume 4
According to
Manufacturer's
Special
Specifications
Item (16.5.2)
"Chain Link Fence"
in these General
Specifications
All properties
mentioned in
the Special
Specifications
ASTM A 584 Class I

ASTM A 116 Class I
According to
Manufacturer's
Special
Specifications
Item (16.5.2)
"Combination Fence
Fabric"
in these General
Specifications
All properties
mentioned in
the Special
Specifications
ASTM A53 Sch. 40,

ASTM A120, Sch. 40,
For Rectangular hollow
sections: ASTM A 501,
BS 4360 Grade 43C
All properties
mentioned in
the Special
Specifications
AASHTO M164 Type 2,

AASHTO M232
Class C
ASTM A307, A325,
A449, A563, Grade A, A
563, Grade C
Item (16.5.2)
"Fasteners"
in these General
Specifications
All properties
mentioned in
the Special
Specifications
AASHTO M 180
Class A, Type 2
According to
Manufacturer's
Special
Specifications
Item (16.5.2)
"Metal Beam
Guardrail"
in these General
Specifications
All properties
mentioned in
the Special
Specifications
ASTM A585 Class I,

ASTM A121 Class I,
ASTM A112,
AASHTO M30
Type 2 Class A
According to
Manufacturer's
Special
Specifications
Item (16.5.2)
"High Tensile Wire"
in these General
Specifications
ASTM A 123,
ASTM A 153
Galvanizing
Concrete
Works
All properties
mentioned in
the Special
Specifications
All tested presented in

section (14-3) in these
Aluminum
Products
All properties
mentioned in
the Special
Specifications
ASTM B108, B209,

B21 1 or B221

beginning of the
production and when
changing materials
sources or mix.
Properties.
According to
Manufacturer's
Special
Specifications
Item (16.5.2)
"Posts and Braces"
in these General
Specifications
Item (16.5.2)
"Galvanizing"
in these General
Specifications
Section (14.3)
"Concrete Works"
in these General
Specifications
Paragraph (16.2.2.4)
"Aluminum Products"
in these General
Specifications
458


Item No.
16-5-2-1
16-5-2-2
16-5-2 -3
16-5-2-4
16-5-2 -5
16-5-2 -6
16-5-2-7
16-5-2-8
16-5-2 -9
Item
Chain Link Fence Type (.)
Combination Wire Fence Type (.)
High Tension Wire Type (.)
W-Beam Guardrail
Guardrail Approach End Type (.)
Reinstallation of Guardrail
New Jersey Concrete Barrier (Single Face / Double Face)
Concrete Barrier End Type (.)
Four wire Cable Fences
Unit
Linear Meter
Linear Meter
Linear Meter
Linear Meter
Unit
Job
Linear Meter
Unit
Linear Meter
459
DIVISION 17
WORK ACCEPTANCE
17.1 In trod uction

17.1.1 Quality Control
17.1.2 Quality Assurance
17.1.2.1 First Case Full-Time Supervision Staff
17.1.2.2 Second Case Part-Time Supervision Staff
17.2 Work Acceptance Methods
17.2.1 Acceptance By Visual Inspection
17.2.2 Acceptance By Certificate Of Compliance
17.2.3 Acceptance By Measured And Tested Conformance
17.3 Statistical Evaluation
17.3.1 Definitions
17.3.2 Statistical Evaluation Procedure
17.3.3 Pay Factor Determination
17.4 A cceptance And H andover
17.5 Inspection At Production Center
17.6 Work Handover
17.6.1 Preliminary Handover
17.6.2 Final Handover
463
463
463
465
466
466
466
466
466
467
468
468
471
472
472
476
476
476
477
Division 17- Work Acceptance
DI VI S I O N 17
WORK ACCEPTANCE
17.1 Introduction:
The evaluation and acceptance of works is done based on set of procedures, which shall be applied to
verify that such works have been executed using the materials and execution methods compliant with the
specifications and drawings within the approved allowance limits. These procedures include quality control and
quality assurance procedures.
Quality control and quality assurance works are carried out on the basis that the values of dimensions
shown on the plans and limits indicated in the specifications and other Contracts documents are targets which
shall be achieved within the allowable variations shown on the plans or work regulations in the Special or
General Specifications. In absence of such requirements, the reference shall be the technically acceptable and
practiced standards in the work field.
The fulfillment of these targets shall be ensured by applying a set of procedures and methods such as
inspection, compliance certificate, and/or sampling and testing before supply and during execution. The
Ministry has the right to perform or order to perform testing at any time and anywhere which it deems
convenient before the final handover of the project. Contractor has the right to obtain copies of the test reports
upon request.
The acceptable limit values (minimum and maximum) and allowable variations shall be shown on the
drawings or in the work regulatory items in the Special or General Specifications.
17.1.1 Quality Control:

The term (quality control) in these General Specifications means all the procedures carried out by the
Contractor during work execution to ensure that the final product and the materials used achieve the quality
requirements stipulated in the Divisions of these General Specifications and related items of Contract
documents. Those procedures shall include, and not limited to, the following
1.
2.
Material testing at source to obtain acceptance for their use.

Material testing at supply and at use.
3.
4.
Final product testing.

Measuring dimensions, levels, slopes, and smoothness of the final product using methods
specified in Contract documents.
5.
6.
7.
Applying the approved standard methods in representative sampling and testing.

Abiding with the minimum number of tests specified in Contract documents.
Abiding with the approved execution methods.
8.
Documenting, statistically-analyzing, and plotting test results with data for critical
characteristics.
Contractor shall prepare detailed quality control system conforming to the Contract documents and
submit it to the Engineer for acceptance before thirty (30) days from commencing the work on the project. The
system shall be compliant as to test types,
463
numbers, and sites, with Contract documents and Special and General Specifications. It shall at least include
the following:
1.
Numbers, qualifications and job descriptions of all the employees who are working in the
quality control system.
2.
Test equipment and devices list available in the laboratory required for applying the system.
3.
4.
Minimum and maximum limits of specifications and variation limits.

The standard methods used in sampling, testing, and locations and rates of sampling.
5.
Tests that can be accomplished by Contractors laboratory and those which can not be
accomplished in Contractor's laboratory.
6.
Proposed labs for carrying out tests which can not be accomplished in Contractor's
laboratory.
7.
Calibration methods for all the equipment and devices used in work execution and testing and
temperature control devices. Standard specification ASTM D-3666 for equipment calibration
frequencies may be used as a guide.
8.
9.
10.
Actions that shall be taken by Contractors upon failure of any test equipment or device.
Methods of monitoring, recording, analyzing, and presenting results by using quality charts and their
change through time, critical changes and statistical control plans.
The hierarchy of authorities of staff working in the quality control system.
After the quality control system is accepted, Contractor undertakes, on his own cost, to implement the
system in executing all project works, within the specifications and approved allowance limits and to perform
needed experiments, in his own laboratory or any other laboratory approved by the Ministry, till the work
completed and handed over.
Contractor shall submit to the Engineer adjustment and calibration certificate for all the testing equipments and
devices for compliance to standard specifications requirements.
The Ministry has the right to inspect Contractor's laboratories, equipments, systems, and follow up its
operational condition and notify the Contractor in writing about any defect or fault so that this defect or fault
may be adjusted. In case this defect or fault represents a great adverse effect, according to the view of the
Ministry's representative, Contractor shall stop work immediately until this defect or fault is corrected in an
acceptable way.
The Ministry or its representative has the right to implement quality control system in the Ministry's
laboratory or any approved laboratory to ensure the quality and suitability of the materials and works executed
according to Contract requirements and Special and GeneralSpecifications.Thissystemmaybeusedatpartialorfinalhandoveroftheproject and for
periodical payment.
Various Divisions of these General Specifications
which shall be performed by the Contractor to execute each work of urban road construction.
I f the statistical system, shown in Section 17.3 is applied for quality control, pay factor according to
the main Category of Table (17.3.3), shall not be less than one
(1) for considering that the executed work is under control.
indicate quality control procedures,
464
17.1.2 Quality Assurance:

The term (quality assurance) mentioned in these General Specifications means, all the procedures
carried out by the Ministry or its authorized representative, during and after work execution, to ensure that the
final product and the materials used achieve the quality requirements indicated in the relevant Divisions and
items of the various Contract documents. These procedures shall include, and not limited, to the following:
1.
Testing or direct supervision on testing materials at their sources for accepting their
2.
use.
Testing or direct supervision over testing the materials at supply and during use.
3.
4.
Testing or direct supervision over testing the final product.

Measuring or direct supervision on dimensions, levels, and smoothness of the final product by using
the methods specified in Contract documents.
5.
Inspection of Contractor's laboratory, methods of determining sample location, sampling, and

measurements to ensure that the approved standard methods are applied and that the equipment is
calibrated.
6.
Performing or actual supervision on performing the adequate number of tests and measurements to
obtain a separate record for quality assurance which enables the Ministry to judge the quality standard
of the executed work and materials used and to decide on accepting or rejecting the work.
7.
Abiding with standard approved methods when performing measurements or tests.
8.
Auditing quality control records and comparing them with quality assurance records.
Contractor shall, on his own account, remove any material or work or part of work, which does not
achieve Contract conditions and specification limits; and replace it with another compliant with the
specifications and Contract documents without any charges on the Ministry. The Ministry, as an alternative for
the removal and replacement, to follow one of the following two options according to a written request from
the Contractor:
First op tio n: Accepting the work as executed with a reduced price.

Sec on d option: Executing corrective measures, which make the executed work compatible with the Contract
conditions.
The request submitted by the Contractor shall be enclosed with a technical report issued by an
approved specialized agency indicating reasons for failure in achieving the requirements, the effect of that on
the overall performance of the work for the first option, and the repair method, which shall be applied for the
second option. In all circumstances the report shall include all the references, data, and test results on which the
proposal has been based. The Ministry has the right to decide on the issue. Contractor shall incur all the
resulting costs.
There are two practical cases for evaluating and accepting the works after ensuring their quality, which are
detailed in the following Sub items.
17.1.2.1 First Case: Full-Time Supervision Staff:

In this case, a resident supervision staff is continuously available to supervise the work execution and
material inspection at the project site. The supervision staff follows up quality control works and procedures
performed by the Contractor directly. In this case, quality control is considered quality assurance. When
applying the statistical system
465
Section 17.3, the pay factor shall be calculated for each item as a major category (I) of Table (17.3.3) of this
Division.
17.1.2.2 Second Case: Part-Time Supervision Staff:

In this case, there is no full-time supervision staff for the project. Ministry representative makes
non-programmed, unscheduled, and timely-distributed field visits and takes samples from the executed works
and tests them in the Ministry's laboratory or any independent laboratory approved by the Ministry. The
samples taken for each item during the payment period shall not be less than five (5) samples or ten (10) percent
of the samples taken by the Contractor for quality control whichever is greater. The results are analyzed and
compared with quality control results. The independent results obtained by the Ministry are considered as minor
category ( I I ) for determining pay factor as shown in Table (17.3.3) of this Division.
17.2 Work acceptance methods:

Supplied materials and executed works are accepted according to one or more of the methods applied
to determine compliance of the materials and works, these are: acceptance by inspection, acceptance by
compliance certificate and acceptance on the basis of measuring and testing. These are indicated in the following
Sub items:
17.2.1 Acceptance by Visual Inspection:

Work and materials used in its execution are accepted on the basis of visual inspection of the work
finishing related works and the general form of the executed work to ensure that they comply with the Contract
and prevailing industry standards in case inspection is difficult or if the defect is visually clear. Acceptance by
visual inspection is not considered a final acceptance of the work and it does not release Contractor from
carrying out the required tests.
17.2.2 Acceptance by Certificate of Compliance:

Materials or manufactured parts at approved factories are accepted according to the certificate of
compliance issued from the manufacturer provided that the following is achieved:
1.
The local manufacturer is approved by the Ministry and the foreign manufacturer is approved
in his country.
2.
Issuance of testing certificate from an agency or independent laboratory approved by the

Ministry.
3.
Submission of the "Certificate of Compliance" and "Certificate of Guarantee" that states the Work
complies with the specific Contract requirements and guarantees its quality.
4.
Enclosing the "Product Certificate" with each shipment of the material that shows date of
manufacture, manufacturer address, lot number or other means of cross referencing to the inspection
and testing system.
5.
6.
The Contractor shall furnish specific test results on material from the same lot upon request
The manufacturer shall be required to furnish a "product certification" for material commercially
produced to a standard specification. The manufacturer shall clearly mark the material or package
with unique product identification. One "Product Certificate" may apply to all the Work incorporated
into the project of the same material.
466
The manufacturer shall be required to submit a "Producer Certificate" in the following cases:
1.
2.
I f the material is specifically produced or manufactured for the project.

I f the material was produced or shipped in bulk state so that it is not readily identifiable as to
manufacturer and product.
The engineer has the right to inspect random samples from all the materials supplied to the site to
verify their compliance with the specifications. All costs in connection with Certificates of Guarantee and/or
laboratory tests and certificates shall be borne by the Contractor.
The issuance of a Certificate of Guarantee without having recently performed the required tests on
representative samples of the material in question shall render the Certificate invalid and such materials shall be
rejected. The Contractor shall hold the sole responsibility for transportation and handling of the rejected
materials, the removal of the works executed using the rejected materials, and reconstructing with acceptable
materials.
17.2.3 Acceptance by Measured and Tested Conformance:

Materials or manufactured parts or final product are accepted according to measuring or testing results
during execution. Results from inspection or testing shall be used to support acceptance of the work
incorporated into the project with values within the specified tolerances or specification limits of the Contract
documents. When no tolerance values are identified in the contract, the work will be accepted based on
customary manufacturing and construction tolerances.
The Special Specifications shall state the decision system for acceptance or rejection, which is made
according to the result of one-sample or the statistical method. When using the one-sample method, the work is
considered as accepted, i f the result of the one-sample is not less than the minimum limit or more than the
maximum limit. When the statistical method is used, the work is considered accepted if the pay factor is not
less that seventy-five (75) percent.
I f the pay factor of one (or more) of the characteristics of the work being evaluated is less than
seventy-five (75) percent, these characteristics are given pay factors equal to zero (0), and then the overall
average pay factor for all characteristics is calculated. I f this average is more than seventy-five (75) percent,
and the work is technically accepted based on a technical report issued by an approved specialized agency, the
Ministry has the right to accept the executed work and the Contractor is paid according to this pay factor. I f the
work is not technically accepted, the work is rejected and the Contractor shall remove the executed work and
re-constructed it according to the specifications without any compensation. I f the work is technically accepted
and the pay factor is less than seventy-five (75) percent, the Ministry has the right to accept the work without
asking the Contractor to remove it; however, the Contractor will not be paid any compensation.
17.3 Statistical evaluation:

17.3.1 Definitions:
Statistical E valuation: It is a method of analyzing inspection or test results to determine
conformity with the contract requirements using statistical ways. The statistical evaluation aims at minimizing
the chance role in the acceptance or rejection decision, and it encourages the Contractor to produce a work
which achieves the highest standard of quality to avoid work rejection or minimize its devaluation.
467
When the specifications stipulate work acceptance according to the statistical evaluation of the
measuring and testing results, the number of the samples shall be adequate for applying this method. These
samples shall be taken randomly to avoid the bias. Areas with apparent defects shall be excluded and shall be
dealt with as a different statistical lot and Contractor shall be instructed to repair them for completing
acceptance procedures. The statistical evaluation is composed of the following major factors:
1.
Quality Level: Accepted Quality Level (AQL) is the highest percentage of the work outside
specification limits, which may be accepted without affecting contract price. There are two (2)
acceptance categories. Major category (I) in which the risk for the Ministry and the Contractor is five
(5) percent, and minor category ( II ) in which the risk rate for the Ministry is ten (10) percent and the
Contractor five (5) percent.
2.
Characteristics: The quality and quantity characteristics to be measured and evaluated statistically
for acceptance purposes such as compaction level, thickness, asphalt content etc. Table (17.3.1) shows
these characteristics.
3.
L o t: The lot is a uniform discrete quantity produced or executed under the same conditions by
using the same materials and equipments. Values shown in Table (17.3.1) may be consulted to
determine the lot size if it was not specified in the Special Specifications. More than one lot may be
combined to obtain a compound lot. Unless otherwise Special Specifications indicate, the lot size
approved for quality control is specified in Table (17.3.1). However, the lot size for quality assurance
procedures is equal to ten (10) times the lot size in quality control procedures.
4.
Acceptance sampling frequency: The number of samples for the purpose of

quality control or assurance shall be adequate for carrying out the statistical evaluation and the number
of samples shall not be less than five (5) samples by any means or the number indicated in these
general specifications or special specifications whichever is greater. Table (17.3.1) shows the required
sample number for the purpose of quality control and assurance; however the lot size doubles ten (10)
times in the case of quality assurance.
5.
S am p li n g location: Sampling location shall be determined accurately by applying

a random method according to the standard specification ASTM D-3665.
6.
T e sting M e t hod s: These are the approved standard tests which shall be applied in sampling.
Table (17.3.1) standard methods used for approved materials and works in these general specifications
in the statistical evaluation.
Table 17.3.1: Characteristics subject to acceptance on statistical method

Sectio
n No.
5.4
Work
Embankment
Characteristic
Compaction
Testing
method
AASHTO T191/238
destructive test
Sam pling frequency ( 1 )

or any non-constructed
One test for each lot of five thousands
(5,000) cubic meters for each
layer
468
5.5.2
5.5.3
5.5.4
6.3
6.4
6.5
6.6
Non treated subgrade,

Lime treated
subgrade,
Cement treated
subgrade.
Aggregate subbase,
Aggregate base
courses
Compaction
AASHTO T 191/238
or any nondestructive test
One test for each lot of two thousands

(2,000) square meters for each
constructed layer.
Thickness
Core samples
Minimum five (5) tests for each lot of

two thousands (2,000) square meters
Strength Index
(CBR or
Compression)
AASHTO T193 or ASTM

D-1633
Minimum one (1) test for each lot of

five thousands (5,000) square meters
from each constructed layer.
Aggregate
Gradation
AASHTO T-27
Test for each lot of one thousands

(1,000) cubic meters from each
constructed layer.
Thickness
Core samples

two thousands (2,000) square meters.
Compaction
AASHTO T 191/238
or any nondestructive test

Strength index
(CBR)
AASHTO T193

one thousands (1,000) square meters
Aggregate
Gradation
AASHTO T-27

one thousands (1,000) cubic meters
Thickness
Core samples
One (1) test for each lot of two

thousands (2,000) square meters from
each constructed layer.
Compaction
AASHTO T191/T-205/ T310

from each constructed layer
Compression
test
ASTM D-1 633

one thousands (1,000) square meters
Aggregate
Gradation
AASHTO T164/
T-27

one thousands (1,000) cubic meters
Thickness
ASTM D-3549
One (1) test for each lot of two

thousands (2,000) square meters from
each constructed layer.
Compaction
AASHTO T 310

Cement treated base
Asphalt emulsion
treated base
Notes:
1. The number of samples and quantities above is used in quality control procedures while in the
case of quality assurance the lot value is multiplied by ten (10) as the case shown in Subitem
17.1.2.1. However, in the second case, the required number of samples is that indicated in
Subitem 17.1.2.2.
Table 17.3.1 (cont.): Characteristics subject to acceptance on statistical method

Section
No.
8.5
92
11 2
11.3
Work
Characteristic
method
Testing
(1)
One sample for each five

thousands (5,000) cubic meters or a
Asphalt concrete
Hot-mix recycling
Friction course.
Stone asphalt
Sampling frequency
Asphalt
content
AASHTO T-1 64/

T-308
minimum of one sample for each

working day from each constructed
layer.
469
mastic
9-3
10-2
14-2
Cold-mix
recycling
Single and
multiple surface
treatments
Structural cement
concrete
Aggregate
gradation
AASHTO T-30
One sample for each five

thousands (5,000) cubic meters or a
minimum of one sample for each
layer.
Compaction
ASTM D 2726
Minimum one test for each one

Thickness
ASTM D 3549
Minimum one (1) test for each

1000 square meters from each
constructed layer.
Surface
smoothness ( 2 )
Road roughness
device
Subitem 8.5.6.10 only for surface

layer for each one day production.
Surface skid
resistance ( 3 )
Road skid
resistance device
Subitem 8.5.6.11 only for surface

layer for each one day production.
Compaction
ASTM D 2726
Minimum one test for each lot of

2000 square meters from each
constructed layer.
Thickness
ASTM D 3549
One (1) test for each lot of one

Aggregate
gradation
AASHTO T-30
One (1) test for each working day

minimum from each constructed
layer.
As p halt
content
AASHTO T-164
One (1) test for each working day

minimum from each constructed
layer.
Asphalt
material
content
AASHTO T-164
Minimum of one (1) test for each

layer.
Compressive
strength
AASHTO T-23
AASHTO T-126
One set of six (6) samples

(cylindrical tests) for each fifty
(50) cubic meters ton and not less
than one set per each working day.
Percent air
void
AASHTO T-199
AASHTO T-152
Same previous samples
Thickness
Surface
smoothness ( 2 )
Core samples
Road roughness
measuring system
Same previous samples

According to Subitem 8.5.6.10
Notes:
1.
The number of samples and quantities above is used in quality control procedures while in the case of quality
assurance the lot value is multiplied by ten (10) as the case shown in Subitem 17.1.2.1. However, in the second
case, the required number of samples is that indicated in Subitem 17.1.2.2.
2.
For surface layer only
7.
S p e c if ic a tio n L i m its: These are the variation limits allowed by the general
specifications or special specifications or other contract documents. Some characteristics may have both
minimum and maximum limits and one of these limits.
8.
C ate gory: This determines the targeted quality level and is related to Contractor's and the Ministry's
risk level according to the importance of the work or
470
characteristic to be evaluated. Table (17.3.2) shows the payment factor against each category.
Unless the special specifications or contract documents specify the quality level category, the major
category (I) is the one to be used for evaluation in the first option of work follow-up which is the
existence of the a resident Ministry representative with the Contractor (Sub item 17.1.2.1), however
in the second option of work follow-up with no permanent representative for the Ministry in the
project (Sub item 17.1.2.2), then the secondary category (II) is the one to be used in evaluation and
in calculating payment factor.
17.3.2 Statistical Evaluation Procedure:

The statistical evaluation depends on using the Variability-Unknown Standard Deviation method in
determining the estimated percentage of the quantity that lies outside the specification limits. The percentage
is determined for work which lies outside the specification limits for each characteristic of the quality
characteristics according to the following steps:
1.
Calculate the arithmetic mean ( X ) for test values as follows: X
where:
X = Total of single testing values.

n = Total number of testing values.
2.
Calculate the standard deviation (s) for test values as follows:
3. 2n
4.
x2
x
() () -
___ __
n n - (1)
where:
(x ) = total of single testing value squares (
x ) =
total single
testing value
s=
squares 2
5.
Calculate upper quality index (QU) as follows:
USL-
=
Qu
s
where:
USL = Upper specification limit
x = Average of all values
s = standard deviation of all values
N o te: The USL equals the Contract specification limit or the target value plus allowable deviation.
6.
Calculate the lower quality index (QL) as follows:
=
QL
where:
LSL = Lower specification limit.
N o te: The LSL equals the Contract allowable
XL SL deviation.
s
specification limit or the target value minus
471
5.
Using Table (17.3.2), the percentage PU (the percentage of work outside the upper specifications
limit. PU corresponds to the upper quality index QU. I f the USL is not specified, then PU = 0
6.
Using Table (17.3.2), determine the percentage PL (the percentage of work outside the lower
specifications limit). PL corresponds to the lower quality index QL. If the LSL is not specified, then
PL = 0
7.
Calculate the percentage of work outside upper and lower specifications limits
(percentage of defective work) as follows:
8.
Defected work percentage = PU + PL

Repeat steps from 1 through 7 for each characteristic of the listed for acceptance.
17.3.3 Pay Factor Determination:

1.
The payment factor is determined according to the following steps:

Using Table (17.3.3), pay factor is determined for each characteristic for the total number of test
values and the estimated total percentage of the defective work outside specification limits from
step 7 above.
2.
The final pay factor is calculated by averaging all pay factors of all the measured
characteristics. Appendix No. 4 shows a detailed example of all above steps.
3.
Payment price is determined by multiplying the resulted pay factor (determined above) by the
Contract price each material or executed work. The pay factor shall not exceed 1. Works and
materials with pay factor less than seventy-five of the hundred (0.75) shall be rejected.
4.
When the executed work is technically accepted, and the calculated pay factor is less than
seventy-five (75) percent for any characteristic of the work, the resulted pay factor is considered
zero (0). Then the final acceptance or rejection will be determined as detailed in Section 17.2 in this
Division.
17.4 acceptance and handover:

Work lot will be accepted and paid for at a final pay factor when all inspection or test results are
completed and evaluated using one of the methods mentioned above.
A grand or total pay- lot tem quantity may be used for follow-up work progress i f specified in the
Special Specifications. The grand lot is allowed to agglomerate provided the current pay factor does not fall
below ninety hundredths (0.90). I f the current pay factor of a lot falls below ninety hundredths (0.90),
production shall be terminated. Production may resume after effective actions to improve the quality of the
production are taken by the Contractor and the actions taken are approved. The executed work shall be
accepted in each lot according to one of the following conditions:
472
Table 17.3.2: Estimated percentage of work outside specification limits

Estimated
percentage outside
specification limits
Upper Quality Index Qu or Lower Quality Index QL

n=5
n=6
N=7
n=8
n=9
n=10 to
n=11
n=12 to
n=14
1.72
1.64
1.58
1.52
1.47
1.42
1.36
1.33
1.28
1.26
1.21
1.18
1.14
1.10
1.07
1.03
1.00
0.97
0.93
0.90
0.87
0.84
0.81
0.77
0.74
0.71
0.68
0.65
0.62
0.59
0.56
0.53
0.50
0.47
0.45
0.42
0.38
0.36
0.33
0.30
0.28
0.26
0.23
0.18
0.16
0.13
0.10
0.08
0.06
0.03
0.00
1.88
1.75
1.66
1.59
1.52
1.47
1.41
1.36
1.31
1.27
1.23
1.18
1.14
1.10
1.07
1.03
0.99
0.96
0.92
0.88
0.86
0.82
0.79
0.76
0.73
0.70
0.67
0.64
0.61
0.58
0.55
0.52
0.49
0.46
0.43
0.40
0.38
0.36
0.32
0.30
0.26
0.23
0.20
0.18
0.15
0.13
0.10
0.08
0.06
0.03
0.00
1.98
1.82
1.72
1.63
1.56
1.49
1.43
1.38
1.33
1.28
1.23
1.19
1.15
1.10
1.07
1.03
0.99
0.96
0.92
0.89
0.86
0.82
0.79
0.76
0.72
0.69
0.67
0.63
0.60
0.57
0.54
0.51
0.48
0.45
0.43
0.40
0.37
0.34
0.32
0.28
0.26
0.23
0.20
0.18
0.16
0.13
0.10
0.08
0.06
0.03
0.00
2.07
1.98
1.75
1.66
1.58
1.51
1.46
1.39
1.33
1.28
1.24
1.19
1.16
1.10
1.06
1.03
0.99
0.95
0.92
0.88
0.85
0.81
0.76
0.75
0.72
0.69
0.66
0.62
0.58
0.57
0.54
0.51
0.48
0.45
0.42
0.39
0.37
0.34
0.31
0.28
0.26
0.23
0.20
0.18
0.16
0.13
0.10
0.08
0.06
0.03
0.00
2.13
1.91
1.76
1.68
1.60
1.52
1.46
1.40
1.34
1.29
1.24
1.18
1.15
1.10
1.06
1.02
0.99
0.95
0.91
0.88
0.84
0.81
0.76
0.74
0.71
0.68
0.66
0.62
0.59
0.56
0.53
0.50
0.48
0.46
0.42
0.38
0.36
0.34
0.31
0.28
0.26
0.23
0.20
0.18
0.16
0.13
0.10
0.08
0.06
0.03
0.00
2.20
1.96
1.81
1.71
1.62
1.54
1.47
1.41
1.35
1.28
1.24
1.19
1.15
1.10
1.06
1.02
0.98
0.96
0.91
0.87
0.84
0.81
0.77
0.74
0.71
0.68
0.66
0.62
0.59
0.56
0.53
0.50
0.47
0.44
0.42
0.39
0.36
0.33
0.31
0.28
0.26
0.23
0.20
0.18
0.16
0.13
0.10
0.08
0.06
0.03
0.00
2.28
2.01
1.84
1.73
1.64
1.55
1.48
1.41
1.35
1.30
1.26
1.20
1.15
1.11
1.06
1.02
0.98
0.94
0.91
0.87
0.84
0.80
0.77
0.74
0.70
0.67
0.64
0.61
0.58
0.56
0.55
0.50
0.47
0.44
0.41
0.38
0.36
0.33
0.30
0.28
0.25
0.23
0.20
0.18
0.16
0.13
0.10
0.08
0.06
0.03
0.00
(PU and/or PL)

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Note:
I f the value of QU does not exist in the table the next lesser value is used and if the value of
QU or QL is negative then PU or PL equal 100 (value QU or QL from the table)
473
Table 17.3.2 (contd.): Estimated percentage of work outside specification limits

Estimated
percentage outside
specification limits
(PU and/or PL)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Upper Quality Index Qu or Lower Quality Index QL

n=1 5 to
n=1 7
n=1 8 to
n=22
n=23 to
n=29
n=30 to
n=42
n=43 to
n=66
n t 67
2.34
2.04
1.87
1.75
1.65
1.56
1.49
1.42
1.36
1.30
1.26
1.20
1.15
1.11
1.06
1.02
0.98
0.94
0.91
0.87
0.83
0.80
0.77
0.73
0.70
0.67
0.64
0.61
0.58
0.55
0.52
0.49
0.47
0.44
0.41
0.38
0.36
0.33
0.30
0.28
0.26
0.23
0.20
0.18
0.15
0.13
0.10
0.08
0.05
0.03
0.00
2.30
2.07
1.88
1.76
1.66
1.57
1.50
1.43
1.36
1.30
1.26
1.20
1.15
1.11
1.06
1.02
0.98
0.94
0.90
0.87
0.83
0.80
0.76
0.73
0.70
0.67
0.64
0.61
0.58
0.55
0.52
0.49
0.46
0.44
0.41
0.38
0.36
0.33
0.30
0.28
0.26
0.23
0.20
0.18
0.15
0.13
0.10
0.08
0.05
0.03
0.00
2.44
2.09
1.91
1.76
1.67
1.58
1.60
1.43
1.37
1.31
1.26
1.20
1.15
1.11
1.06
1.02
0.98
0.94
0.90
0.87
0.83
0.80
0.76
0.73
0.70
0.67
0.64
0.61
0.58
0.55
0.52
0.48
0.46
0.43
0.41
0.38
0.36
0.33
0.30
0.28
0.26
0.23
0.20
0.18
0.15
0.13
0.10
0.08
0.06
0.03
0.00
2.48
2.12
1.83
1.79
1.65
1.59
1.61
1.44
1.37
1.31
1.26
1.20
1.15
1.11
1.06
1.02
0.98
0.94
0.90
0.87
0.83
0.90
0.76
0.73
0.70
0.67
0.64
0.61
0.58
0.55
0.52
0.49
0.46
0.43
0.41
0.38
0.36
0.33
0.30
0.28
0.26
0.23
0.20
0.18
0.16
0.13
0.10
0.06
0.05
0.03
0.00
2.51
2.14
1.84
1.80
1.68
1.59
1.51
1.44
1.37
1.31
1.26
1.20
1.15
1.11
1.06
1.02
0.98
0.94
0.90
0.87
0.83
0.80
0.76
0.73
0.70
0.67
0.64
0.61
0.58
0.56
0.52
0.48
0.46
0.43
0.41
0.38
0.36
0.33
0.30
0.28
0.26
0.23
0.20
0.18
0.15
0.13
0.10
0.08
0.05
0.03
0.00
2.54
2.16
1.96
1.91
1.70
1.60
1.52
1.44
1.38
1.31
1.26
1.20
1.15
1.11
1.06
1.02
0.98
0.94
0.90
0.87
0.83
0.78
0.76
0.73
0.70
0.66
0.63
0.60
0.57
0.54
0.52
0.49
0.46
0.43
0.40
0.38
0.36
0.32
0.30
0.28
0.26
0.23
0.20
0.18
0.16
0.13
0.10
0.08
0.06
0.03
0.00
Note:
I f the value of QU does not exist in the table the next lesser value is used and if the value of QU or QL is negative
then PU or PL equal 100 (value QU or QL from the table)
Table 17.3.3: Determination the pay factor values
474
Pay Factor ( 2 )
Major
Category
(I)
1.00
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0.91
0.90
0.89
0.88
0.87
0.86
0.85
0.84
0.83
0.82
0.81
0.80
0.79
0.78
0.77
0.76
0.75
Reject
Maximum allowable percent of work outside specification limits for a given pay factor
(Pu + PL ) ( 1 )
Minor
Category
(II)
1.00
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
091
0.90
0.89
0.88
0.87
0.86
0.85
0.84
0.83
0.82
0.81
0.80
0.79
0.78
0.77
0.76
0.75
Reject
n=5
22
24
26
28
30
32
33
35
37
38
39
41
42
43
45
46
47
49
50
51
52
54
55
56
57
58
60
61
62
63
64
n=6
20
22
24
26
28
29
31
33
34
36
37
38
40
41
42
44
45
46
47
49
50
51
52
54
55
56
57
58
59
61
62
n=7
18
20
22
24
26
28
29
31
32
34
35
37
38
39
41
42
43
44
46
47
48
49
50
52
53
54
55
56
57
58
60
n=8
17
19
21
23
25
26
28
29
31
32
34
35
36
38
39
40
42
43
44
45
46
48
49
50
51
52
53
55
56
57
58
n=9
n=10
to
n=11
n=12
to
n=14
n=15
to
n=17
n=18
to
n=22
n=23
to
n=29
16
15
14
13
12
18
17
16
15
14
20
19
18
16
15
22
21
19
18
17
24
22
21
19
18
25
24
22
21
20
27
25
24
22
21
28
27
25
24
22
30
28
27
25
24
31
30
28
26
25
33
31
29
28
26
34
32
31
29
28
35
34
32
30
29
37
35
33
32
30
38
36
34
33
31
39
38
36
34
33
40
39
37
35
34
42
40
38
36
35
43
41
39
38
36
44
42
41
39
37
45
44
42
40
38
46
45
43
41
39
48
46
44
42
41
49
47
45
43
42
50
48
46
44
43
51
49
47
46
44
52
51
48
47
45
53
52
50
48
46
54
53
51
49
47
55
54
52
50
48
57
55
53
51
49
Values greater than those shown above
11
13
14
16
17
18
20
21
22
24
25
26
27
29
30
31
32
33
34
36
37
38
39
40
41
42
43
44
45
47
48
n=30
to
n=42
n=43
to
n=66
n ~
67
10
11
13
14
16
17
18
20
21
22
23
25
26
27
28
29
30
31
33
34
35
36
37
38
39
40
41
43
44
45
46
9
10
12
13
14
16
17
18
19
21
22
23
24
25
26
28
29
30
31
32
33
34
35
36
37
38
40
41
42
43
44
8
9
10
12
13
14
15
16
18
19
20
21
22
23
24
25
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
(1)
To obtain a pay factor when the estimated percent outside specifications limits from Table (17.3.2)
does not correspond to a value in the table, use the next larger value
(2)
The major category (I) of payment factor is used for the first option of work inspection stated in
Subitem 17.1.2.1, while the minor category (II ) is used for the second option of work inspection
stated in Subitem 17.1.2.2.
Payment for the total work value: When all the executed works are in accordance
1.
with the technical contract conditions and all the work parts are acceptable completely regardless of the
handing over method applied, provided that the pay
475
factor produced by the statistical method, for the quality control, equals to one (1.00) for the
received work item.
2.
P a ym en t w it h reduced p rice: The Ministry has the right to accept the work with a
pay factor less than one (1.00) using statistical method provided the pay factor is at least seventy-five
hundredths (0.75) and there are no isolated defects identified by the Engineer. Moreover, the
Contractor shall submit a written request enclosed with a technical report from a specialized agency
according to Section 17.1. The final the paid amount shall be the product of multiplying Contract
price by the final pay factor for the concerned item.
All rejected works according to the measuring and testing method or any other method; or the
works which have not achieved seventy-five hundredths (0.75) pay factor by the statistical method, shall be
removed or repaired.
Rejected works and materials shall be replaced with new materials to raise the pay factor to one
(1.00) and samples are taken from the new material, tested and testing results are evaluated for handing over
purposes according to this secondary item.
When the rejected works are removed, the test results performed on the rejected works shall be excluded
from the test results used in calculating quality index.
17.5 Inspection at production center:

The Ministry has the right to examine and inspect production centers and to monitor production.
Manufacturing plants may be inspected for compliance with specified manufacturing methods. Samples of the
materials may be obtained to test them in the laboratory for compliance with quality requirements. Ministry
authorized representatives shall be allowed for full entry at all times into any part of the site where the work
is being produced.
17.6 Work handover:

All handover procedures shall comply to all guidelines and procedures adopted by the Ministry of
Municipality and Rural Affairs.
17.6.1 Preliminary Handover:

When the project is fully completed or partially so that the completed part can be utilized separately,
Contractor has the right to notify the Ministry in writing and requests to handover the executed work
completely or partially. The Ministry shall, without bias, evaluate the situation and accept or reject the
request. In all cases, Contractor shall maintain the work during the execution period and during the
guarantee period until the final project handover. The guarantee period is considered from the date of the
complete project handover.
When traffic is allowed to use executed sections of the road, parts of the road are starting to be used
Contractor shall continue to carry out maintenance works for these parts up to final handover.
17.6.2 Final Handover:

When the guarantee period for the completely or partially handover situations, Contractor shall
notify the Ministry in writing, and if the Ministry was convinced that the work has actually been executed
completely, the work is scheduled for final inspection by a technical committee before the Contractor or
Contractor's representative. After the
476
inspection is completed, the committee shall prepare a technical report which details comments on the
execution, if any, and methods and period for repair. The committee re-inspects the work after repair. I f no
comments that prevent full and safe utilization of the work, Contractor is notified in writing by the final
handover effective from the actual date of work completion and the end of guarantee period.
477
Appendix 1 Standard T esting Guide
481
478
Appendix 1- Standard Testing Guide
Appendix 1
Standard Testing Guide
Sample preparation, testing for materials and works indicated in these general
specifications shall be performed according to the latest edition (print) when announcing tender
according to standard specifications (test methods) indicated in this appendix. Priority for tests
shall be given to Gulf Standard Specifications then AASHTO and ASTM Standards. It is
important to consider that the indicated testing methods are not necessarily to be compatible in
all steps or type and requirements of specified test designation.
This guide shall not be considered as an alternative for testing methods indicated in their
original references but as an indicator to them. All the methods and safety methods practiced
shall be followed when performing sampling, testing and work handing over. Those carrying
out those works shall take the required precautionary measures and shall apply them in this
regard.
P r o vision of refer en c e s: Basic references for specifications and testing methods indicated in
this guide as the latest edition shall be provided at the time of the tender announcement for use
by the engineers and technicians at site.
Staff qualifications an d labs evaluation: It shall be confirmed that the laboratories carrying out
inspection task or the production of materials or execution have valid licenses and certificates
according to the regulations implemented in K.S.A. Also, it shall be ensured that these
laboratories are subjected to periodical inspection and investigation according to the standard
inspection, calibration and certification or the methods approved by the concerned authorities
in the kingdom for ensuring the qualifications of those working in this field. Safety measures
and suitability of the systems for testing shall be confirmed by calibration certificates issued by
agencies approved by the Ministry.
S am p lin g: It shall be ensured that the process of sampling, samples selection and storage is
done properly such that it does not lead to their damage or change in their properties. Those
samples shall be tested and results shall be analyzed according to the methods and techniques
indicated in this guide and other contract documents or according to a plan submitted by the
Contractor and approved by the Ministry.
T e s tin g a pp a r a t u s: Specifications of testing apparatus shall conform to specifications in the

standard method indicated in front of each test as to dimensions, weight, size, materials,
components, performance and accuracy. The Engineer shall ensure that the systems comply
with the required specifications using visual inspection and approved calibration records.
Contractor shall provide trained personnel to carry out maintenance works for laboratory
equipments and cleaning them throughout the construction period. The contractor shall give
more consideration to the balances, weights and thermometers used and protect them from
humidity and rust effects according to the special testing methods indicated in this guide or
according to other contract documents.
481
S a fe ty p rec a u tio n s: Contractor shall provide at least one person qualified in safety works to be
devoted and responsible for safety in the project to follow up provision of first aid, safety and
protection measures among the project staff.
The contractor shall provide communication means with hospitals, police, accidents,
emergency and civil defense. In addition protection shall be provided for electricity wires and
installations which shall be executed and install the related equipments in such a way that
eliminate the dangers.
The contractor shall provide an emergency entrances and exits, ventilation openings,
fire fighting equipments, and gas exhausts at the laboratory building and special safety tools for
the staff such as clothes, shoes, masks, gloves, and glass or plastic face protection masks
against heat and chemical materials according to the testing method requirements. The necessary
cautions and warnings about safe operation shall be provided at the locations of moving and
suspended parts, and testing equipments using harmful rays and at places of inflammable and
chemical materials. Those cautions shall be written in clear font and color according to the
instructions of protection and regulations used in the kingdom.
L a b o r a to r y in s p ec t io n: Contractor shall carry out periodical inspection, and inventory for testing
equipments and apparatus used in the project. He shall include the inspection plan within the
quality control plan submitted to the Engineer according to these general specifications and
according to the inspection and calibration periods implemented in the kingdom.
A plan shall be set out for sampling, testing, and result analysis according to the
following Tables.
482
1. Soil Tests:
N am e of Test
ASTM
Dry Preparation of Disturbed Soil and Soil Aggregate Samples for Test
Particles size analysis of Soils
Determining the Liquid Limit of Soil
Determining The Plastic Limit and Plasticity
Index of Soils
D-421
T -87
D - 422
T-88
T -89
D-4318
Density of Soil In - Place by Sand -Cone
Testing M ethod
AASHTO
T-90
D-1556
T-91
D-698
T-99
D-854
T-100
~~~~~~
T-134
~~~~~~
T-135
D-421
T-146
D-1557
T-180
California Bearing Ratio
D-1883
T-193
Density of soil in Site by rubber balloon method
D-2 167
T-205
D-22 16
T-265
D-2922
T-310
T -311
D- 1663
T-22
D-3551
D-5102
T -194
T -290
T -291
Moisture Density Relations of

(2.5Kg) Rammer and (305 mm) Drop
Soils
Using
Specific Gravity of Soils

Moisture- Density Relation of Soil-Cement
Mixture
Wetting and Drying Test of Compacted SoilCement Mixtures
Wet Preparation of Disturbed Soil Samples
for Tests
Moisture-Density Relationship
of Soils Using
Modified Method
Laboratory Determination of Moisture of Soil

Density of soil and soil aggregate in place by
nuclear methods (shallow depth)
Grain Size Analysis of Granular Soil Materials
Compressive strength of soil cement mixture
Method of laboratory preparation of soil-lime
mixture
Unconfined compressive strength of compacted
soil-lime mixtures
Determination of organic mater in soil by wet
combustion
Determining water soluble sulfate ion content in
soil
Determining water soluble chloride ion content in
soil
Hydrated & quick Lime with high Calcium
Content.
SASO
C-51
1538
483
2. Aggregate Tests:
Testing Method
Name of Test
ASTM
Amount of material finer than 0.075 mm sieve in
aggregate
Unit weight and voids in aggregate
Organic impurities in fine aggregate for concrete
Specific gravity and absorption of fine aggregate
Specific gravity and absorption of coarse aggregate
Sieve analysis of fine and coarse aggregate
Clay lumps and friable particles in aggregate
Resistance to abrasion of small size coarse aggregate
by use of Los Angles Machine
Soundness of aggregate by use of sodium or
magnesium sulfate
Plastic fines in graded aggregates and soils by use of
the sand equivalent test
Sampling of stone slag, gravel, sand, and stone blocks
for use as highway materials
Coating and stripping of bituminous aggregate
mixture
Flat and elongated particles in coarse aggregate
Determining the percent of fractured particles in
coarse aggregate
Standard practice for reducing samples of aggregate
to testing size
Potential alkali reactivity of aggregates
Wetting and drying compacted soil cement mixture
Cement content of soil cement mixture
Aggregate durability index
AASHTO
C-117
T-1 1
C-29 / 29M
C-40
C-128
C-127
C-136
C-142
T-19
T -21
T-84
T-85
T-27
T-112
C- 131
T-96
C-88
T-104
D-2419
T-176
D-75
D- 1664
T-2
T- 182
D-4791
D-5 821
C-702
T-248
C-1260
D-559
D-806
D-3744
T-144
T-210
3. C em ent Tests:
Testing
Method
Name of Test
ASTM
AASHTO
Time of setting of hydraulic cement by Vicat

needle
C-191
T-131
Sampling of hydraulic cement
C-183
T-127
Density of hydraulic cement

Compressive strength of hydraulic cement
mortar
C-188
T-133
C-109
T-106
Bortland cement Anti Sulfate
C 150
SASO
570
484
4. Cement Concrete Tests:

Testing Method
Name of Test
Compressive strength of cylindrical
concrete specimen
Making and curing concrete compressive
and flexural strength test specimens in the
site
Bending strength of concrete using simple
beam with three point loading
Slump of Portland cement concrete
Standard practice for sampling freshly
mixed concrete
Measuring thickness of concrete elements
using drilled concrete cores
Making and curing of concrete test
specimen in the laboratory
Splitting tensile strength of cylindrical
concrete specimens
ASTM
AASHTO
SASO
C-39 / C-39M
T-22
1253
C -31 / C-31M
T-23
1133
C-78
T-97
C-143 / C-143M
T-1 19
C-172
T-141
C-174/174M/
C- 1542 / 1 542M
T-148
C-192 / 192M
T-126
C-496
T-198
379
T-152 / T196 / T-199
Air content of freshly mixed concrete
C-173 / C-231
Reinforcement Steel Bars

Reinforcement Wire fabric
ASTM A- 615
ASTM A-185
2
224
C-936
1246
Interlocking brick
5. Tiles:
ASTM
Testing
Method
AASHTO
C-67
C-241
C-140
C-78
T-97
C-418
Name of Test
Sampling and testing structural clay tile
Abrasion resistance of stone subjected to
foot traffic
Sampling and Testing Concrete Masonry
Units and Related Units
Flexural strength of concrete using simple
beam with three point loading
Abrasion resistance of concrete by sand
blasting
Interlocking brick Testing Methods
SASO
T-24
1247
1248
1249
Precast Sidewalk edges
485
6. A sphalt Cement Tests:
Name of Test
Sampling Bituminous Materials
Flash and Fire Points by Cleveland Open
Cup
Asphalt Penetration Test
Ductility of Bituminous Materials
Softenipoint (ring and ball method)
Saybolt Viscosity
Effect of heat and air on asphalt material
Kinematics Viscosity of Asphalt
Absolute Viscosity of Asphalt
Specific gravity of simi-solid bituminous
materials
Effect of heat and air on moving film of
asphalt (RTFO)
Dynamic Shear Rheometer ( DSR)
Rotational Viscometer (RV)
Determining the flexural creep stiffness of
asphalt binder using the Bending Beam
Rheometer(BBR)
Determining the fracture properties of
asphalt binder in Direct Tension (DT)
Accelerated aging of asphalt binder using
Pressurized Aging Vessel (PAV)
Viscosity test
ASTM
D-140
Testing
Method
AASHTO
T - 40
D-92
T- 48
D-5
D-1 13
D-36
D-88
D-1754
D-2170
D-2 171
T -49
T-51
T - 53
T -72
T-179
T-201
T- 202
D-70
T-228
D-2872
T-240
D-4404
TP-5
TP-48
D-6648
TP-1
D-6723
TP-3
D-6521
SASO
1776
7. A sphalt Concrete Tests:
Name of Test
Effect of Water on Cohesion of Compacted Bituminous
Mixtures
Bulk specific gravity of compacted asphalt mixtures using
saturated surface-dry specimens
Sampling bituminous paving mixture
Quantitative Extraction of Bitumen From Bituminous
Paving Mixtures
Determining degree of particle coating of bituminous
aggregate mixture
Maximum specific gravity of bituminous paving mixture
Determining of degree of pavement compaction of
bituminous aggregate mixture
Testing
Method
ASTM
AASHTO
D-1075
T -165
D-2726
T-166
D-979
T-168
D-2172
T-174/T-164
D-2489
T -195
D-2041
T-209
T-230
486
Resistance to plastic flow of bituminous mixture using

Marshall Apparatus
Resistance of compacted bituminous mixture to moisture
induced damage
Asphalt content of hot mix asphalt by ignition method
Asphalt content of bituminous mixtures by the nuclear
method
Thickness or Height of Compacted Bituminous Paving
Mixture Specimens
Preparation of test specimen of bituminous mixtures by
means of gyratory shear compactor
Percent of air voids in compacted dense and open
bituminous mixture
D-5581
T -245
T-283
D-6307
T-308
D-4125
T-310
D-3549
D-4013
TP-4
D-3203
T-269
8. Geotextile, fabrics and Geocomposite:

Name of Test
Practice Sampling of Geosynthetics
Water Permeability of Geotextiles by Permittivity
Determining Apparent
Opening Size of a Geotextile
Grab Tensile Strength
Puncture Strength Index
Trapezoid Tearing Strength of Geotextile
Grab Breaking Load and Elongation of Geotextile
Hydraulic Bursting Strength of Textile
Fabrics-Diaphragm Bursting Strength Tester Method.
Tensile Properties of Geotextile by wide width strip Method
Mass per unit area of fabric
Deterioration of Geotextile by exposure to light and heat in a xenon arc
type apparatus
Water Absorption of plastics
Determining Resistance of Synthetic Polymeric Materials to Fungi
Peel or Stripping Strength of Adhesive Bond
In-Plane Flow per unit width and Transmissivity of Geosynthetic
Testing
M ethod
ASTM D-4354
ASTM D-4491
ASTM D-475 1
ASTM D-4632
ASTM D-4833
ASTM D-4533
ASTM D-4632
ASTMD-3786
ASTM D-4595
ASTM D-3776
ASTM D-4355
ASTM D-570
ASTM G-21
ASTM D- 903
ASTM D- 4716
487
Appendix 2
1.
2.
3.
4.
5.
6.
7.
8.
Superpave Volumetric M ix Design Example

General
Project Conditions
Material Selection
3.1 Adjusting Binder Grade Selection For Traffic Speed And Loading
Aggregate Selection
Selection of Design Aggregate Structure
5.1 Aggregates Preparation
5.2 Selections Of Initial Asphalt Contents
5.3 Evaluation Of Trial Blends Data
Select Design Asphalt Binder Content
Verification % Gmm at the M aximum Number of Gyrations
Evaluate M oisture Sensitivity
491
491
491
491
492
493
494
496
496
503
505
509
511
488
General Specification of Urban Road Construction Appendix 2- Superpave Volumetric Mix Design Example
APEENDIX 2
SUPERPAVE VOLUMETRIC MIX DESIGN EXAMPLE
1. General:
This supplementary section explain with an example Superpave Volumetric mix design
method
The volumetric mix design consists of the following four major steps:
Selection of materials (aggregates, binders).
Selection of a design aggregate structure.
Selection of a design asphalt binder content.
Evaluation of moisture sensitivity of the design mixture.
The data presented in this example basically were taken from Asphalt institute reference
"Superpave Mix design SP-2" dated 2001; the same method is also approved by AASHTO
specification under the designation TP-4 and T-PP2.
Selection of materials in superpave system depends upon traffic and environmental
factors, i.e., the binder selection is influenced by both traffic and environment conditions, while
the requirements of aggregate are selected according to traffic and location of the considered layer
with respect to pavement surface.
Selection of design aggregate structure is according to these factors by comparing the
properties of a series of trial mixtures having different parentages using samples from cold bins,
hot bins and/or stockpiles. This step consists of blending available aggregate stockpiles at different
percentages to arrive at aggregate gradations that meet Superpave requirements.
The determination of the design binder content is achieved by mixing the asphalt binder
with design aggregate structure to obtain the required volumetric and compaction properties which
are based on traffic and environmental conditions. This step also allows the designer to observe
the sensitivity of volumetric and compaction properties of the design aggregate structure to
asphalt content. The gradation that conform to volumetric properties should be approved as a
job-mix formula, then moisture sensitivity should be evaluated by testing the designed mixture by
AASHTO T-238 to determine i f the mix will be susceptible to moisture damage.
2. Project conditions:
The following Table reveals the design factors and project conditions in this example
Project location
Standard equivalent axle load
Nominal maximum size of the aggregate
location of the layer relative to pavement surface
Riyadh
18 ESAL
19 mm
Within the upper 100 mm of
pavement surface
3. Material Selection:
According to temperature zones for the Kingdom shown in the Figure (12.3.1 ) i these
specifications and the location of the project the required asphalt binder grade shall be PG 70-10.
491
3.1 Adjusting Binder Grade Selection for Traffic Speed and Loading:
The asphalt binder selection procedure described is the basic procedure for typical highway
loading conditions when assumed that the pavement is subjected to a design number of traffic loads. For
up normal design conditions when the speed is low or the volume of traffic exceeds certain limits the
selected high temperature binder grade shall be increased by one or two performance degree according
to traffic load and speed, and as indicated in Table (12.3.2) of these specifications. As an example PG
70 should be selected to replace PG64 i f the traffic speed is low, but i f the traffic is standing PG 76
should be selected to replace PG 64 by increasing the original grade by 2 performance degrees (one
performance degree equal to six temperature degrees). I n case the traffic speed in the proposed project
is more than 20Km/hr and less than 70 Km/hr the adjusted performance grade for this project w i l l be
PG76-16.
The next step is the selection testing of the binder that conforms to specification requirements
and the selected grade. Binder test results are summarized in Table (A.2.1).
In order to determine the mixing and compaction temperature ranges the rotational viscometer
test was carried out in temperature 135C and165C respectively, and the test results were plotted in
Figure (A.2.1) which shows that the suitable mixing range is 162C to 168C and the suitable
compaction range is between 148C to 154C.
Table A.2.1: Asphalt Binder Test Results

Original
RTFOT
Flash Pt:(230 oC)

Vis@135:837.5 Loss: 0.02 %
(3000 CP)
Grade Dynamic Shear Dynamic Shear
10 rad/s (1.6Hz) 10 rad/s (1.6Hz)
G*/sin (kPa) G*/sin (kPa)
t 1 kPa
t 2.2 kPa
PG 64
PG 70
PG 76
PG 82
RTFOT + PAV residue
Flexural
DT*
Dynamic Shear
Creep
(1mm/min)
10
(1.6Hz)
Stiffness, S Slope, (m) F. Strain
TempoC G*sin Temp
oC
~ 1.0%
~ 300 MPa ~ 0.30
~ 5 MPa
28
-6
25
-12
22
-18
19
-24
16
-30
34
0
31
-6
28
-12
25
-18
4.019
22
-24
37
3.404
0
34
4.788
-6
50.7
0.307
31
5.128
-12
92.9
0.281
1.801
3.282
28
-18
40
0
1.80
37
-6
34
-12
0.711
31
-18
* Required only if Creep Stiffness (S) is between 300 and 600 MPa, and m ~ 0.30.
492
As shown by the test result carried that the selected asphalt binder is conforms to the required
grade specifications PG 76-16 and it can be used in this project.
1 01 0
55
V i sco s it y P a. s e c
11
.
5
Compaction range
.
Mixing
range
Te mp e r atu r e c
Figure A.2.1: Mixing and Compaction Temperature Ranges

4. Aggregate Selection:
Next, the designer selects the aggregates to be used in the mixture for this project. For this
example, there are five stockpiles of materials consisting of three coarse materials and two fine
materials. Representative samples were taken, washed and the bulk, apparent specific gravity and
sieve analysis is performed for each aggregate for each aggregate. Aggregate specific gravity
values for this example listed in Table (A.2.2).
Table A.2.2: Aggregate Specific Gravity

Aggregate Size (mm)
19
12.5
9.5
Manufactured Sand
Screen Sand
Bulk Specific gravity

(Gsb.)
2.703
2.689
2.723
2.694
2.679
Apparent Specific gravity

(Gsa)
2.785
2.776
2.797
2.744
2.731
The consensus aggregate tests were performed to assure that the aggregates selected for
the mix design are acceptable also the source properties tests indicated in Table (4.3.12) were
performed.
The result of the coarse aggregates angularity test performed on the aggregate larger than
4.75 mm according to ASTM D 5821 Designation is shown in Table (A.2.3) below.
493
Table A.2.3: Coarse Aggregate Angularity Test Results

Aggregate Size (mm)
One Fractured
Face
Two Fractured
Faces (at least)
19
12.5
9.5
92
97
99
88
94
95
Comparison between these tests results and the requirement stated in Table (12.3.3) shows
that the 19 mm aggregate size does not meet either of the fractured faces criteria. However, this
material can be used as long as selected blend of aggregate meets the design criteria.
Table (A.2.4) lists the results for fine aggregate angularity test which is performed
according to AASHTO T 304 method.
Table A.2.4: Fine Aggregate Angularity Test Results

Aggregate type
Crushed Sand
Screen Sand
% Air Voids ( Loose )

52
40
Based on traffic and depth of the layer from the surface, even though the screen sand test
result is below the minimum criteria showed in Table (12.3.3), it can be used as long as the
selected blend of aggregates meet the requirement.
Flat and Elongated Particles test is performed on the coarse aggregates shows that it is
equal to zero. Also the Clay Content (Sand Equivalent) test results performed on fine aggregate
samples is 47 % and 72 for crushed and natural fine aggregate respectively, which are within the
required limits based on traffic volume in this project.
Table (A.2.5) shows the Test results of source property tests performed on coarse
aggregate samples which are conform to the specifications.
Table A.2.5: Clay Content (Sand Equivalent) Test Results

Test
Los Angeles Abrasion %
Sodium Sulphate Soundness%
Deleterious materials and friable particles %
Nominal Maximum Size

19
12.5
9.5
40
16
0.2
35
12
0.15
30
10
0.25
5. Selection of Design Aggregate Structure:

Prior selection of the design aggregate structure, the asphalt and aggregate materials shall
be selected according to requirement indicated in Division 12 from these general specifications. The
aggregate source properties tests shall be carried out for every individual source while the specific
gravity and absorption and consensus properties tests shall be carried on samples taken from the
combined trail blends.
494
The blend gradation shall be compared with the specification requirements for the
appropriate sieves according to design requirements selected based on nominal maximum size of
aggregate as indicated in section 12.4 and Table (12.3.7) from these general specifications.
Trial blending consists of varying the materials percentages or the available aggregates to
obtain blended gradations meeting the requirements for that particular mixture. Any number of
trial blends may be evaluated, but a minimum of three trial blends is required. It is recommended
for trial gradation to pass below the restricted zone and it is possible to pass over the restricted
zone but not through it. During preparations of aggregate blends the consensus properties, specific
gravities and source properties shall be evaluated through carrying actual tests on samples of
combined gradation for final approval.
For this example, three trial blends are used: an intermediate blend (Blend 1), a coarse
blend (Blend 2), and a fine blend (Blend 3). The intermediate blend is combined to produce a
gradation that is not close to any of the control point limits. The coarse blend is combined to
produce a gradation that is near the minimum allowable percent passing the nominal maximum
sieve, the 2.36 mm sieve, and the 0.075 mm sieve. The fine blend is combined to produce a
gradation that is close to the maximum percent passing the nominal maximum size and is just
below the restricted zone.
A l l three of trial blends are shown graphically in Figure (A.2.2) which is plotted using the
data shown in Table (A.2.6) shows the gradations of the three trial blends.
Once the trial blends are selected, a preliminary mathematical determination of the
blended aggregate properties is necessary.
Table A.2.6: Trial Gradations
19 mm
Blend 1
Blend 2
Blend 3
25%
30%
10%
12.5 mm
15%
25%
15%
9.5 mm
22%
13%
30.0%
Crushed
Sand
18%
17%
31%
Screened
Sand
20%
15%
14%
Blend 1
Blend 2
Gradation Gradation
Sieve
25.0 mm
19.0 mm
12.5 mm
9.5 mm
4.75 mm
2.36 mm
1.18 mm
0.600 mm
0.300 mm
0.150 mm
0.075 mm
100.0
76.1
14.3
3.8
2.1
1.9
1.9
1.8
1.8
1.7
1.6
100.0
100.0
78.1
26.0
3.1
2.6
2.4
2.3
2.2
2.1
1.9
100.0
100.0
100.0
49.9
4.8
3.0
2.8
2.6
2.5
2.4
2.2
100.0
100.0
100.0
100.0
95.5
63.5
38.6
21.9
11.0
5.7
5.7
100.0
100.0
100.0
99.8
89.5
76.7
63.5
45.6
23.1
8.4
4.7
100.0
94.0
76.6
63.7
31.7
28.3
21.1
14.4
7.9
4.0
3.1
100.0
92.8
71.1
51.9
31.7
23.9
17.6
12.0
6.8
3.6
2.9
495
Blend 3
Gradation
100.0
97.6
89.5
77.7
44.3
31.9
22.2
14.5
7.9
4.1
3.5
Based on the estimates, all three trial blends are acceptable and when the design aggregate
structure is selected, the blend aggregate properties will need to be verified by testing.
100
90
80
70
60
50
40
30
20
10
0
0
Sieve size raised to 0.45

Restricted Zone
Restricted Zone 1
Control Points
Figure A.2.2: Trial Blends of the Aggregate

Blend 1
5.1 Aggregates Preparation:
Three samples shall be prepared depending

on their final using; the sample that used for
compacted specimens requires about 4600 grams; however the maximum theoretical specific
gravity sample requires about 2000 grams according to AASHTO T - 209 or ASTM D-2041.
The third sample shall be prepared for moisture sensitivity test using AASHTO T-283
method, which requires specimen height of 95 mm and approximately 3700 grams of total
aggregate.
5.2 Selections of Initial Asphalt Contents:

After the evaluation of aggregate properties the next step is to compact the specimens and
determining the volumetric properties of each trial blend and the initial asphalt binder content shall
be estimated using the method detailed in AASHTO PP-28 or taken from Superpave Gyratory
Compactor records i f it is equipped by this property,
496
also it is possible to estimate the initial asphalt content using mathematical formula or it can be
taken from Table (A.2.7) assuming the total specific gravity for the aggregate is 2.65.
Table A.2.7: Estimated asphalt content

Primary asphalt ratio %
Nominal Aggregate Size mm
3.5
37.5
4.0
4.5
25.0
19.0
5.0
12.5
5.5
9.5
The method of calculating the initial binder content is consists of the following steps:
1. Effective specific gravity calculation (Gse):
Gse = Gsb + A ((Gsa Gsb)
The factor A shall be taken 0.8 or within the range 0.6 or 0.5 according to absorption of
the aggregates. Using the above equation, the blend calculations are shown below:
Blend 1: Gse = 2.699 + 0.8 ((2.768 2.699) = 2.754
Blend 2: Gse = 2.697 + 0.8 ((2.769 2.697) = 2.755
Blend 3: Gse = 2.701 + 0.8 ((2.767 2.701) = 2.754
2. The volume of asphalt
binder (Vba) absorbed into
the aggregate is estimated
using this equation:
_____________
1 ________________ 1 ______ 1 _____
s ____________________ a _
ba = ________________________________
________________________
-_____________
G G
Where:
Vba = volume of absorbed binder, cm3 / cm3 of mix Pb =
percent of binder (assumed 0.05).
Ps = percent of aggregate (assumed 0.95).
Gb = volume of air voids (assumed 1.02).
Va = volume of air voids (assumed 0.04 cm3 / cm3 of mix).
Blend No.
Blend 1
Blend 2
Blend 3
Gsa
2.768
2..769
2.767
Gsb
2.699
2.697
2.701
497
Using the above equation, bulk and apparent specific gravity values for the combined
aggregates in different blends as determined by test, the absorbed asphalt binder in each blend (Vba)
calculation result are shown below:
Blend 1: 0.0171cm3/cm3 of mix
3. The volume of the effective binder
(Vbe)
shall be determined from this equation: Vb e =
0.176-0.0675(log (Sn))
Where:
Sn = the nominal maximum sieve size of the aggregate blend (mm )
Using the above equation, Vbe for the three blends is = 0.089 cm3/cm3 of mix
4. Finally, the initial trial asphalt binder
content is calculated is from the following equation:
G(Pbi) V
h
b e
b+ ()
a
= __________________
bG i
(())
100
V
V
W
h
Where:
Pbi = percent (by weight of mix) of binder
Ws = weight of aggregate, gram and calculated from the following equation:
()V
-1
s
a
= _________
Ws
Pb
_
+ _P
s
_________
Gb
Gs
Using the above equations the initial binder content is calculated and shown in Table
(A.2.8 below:
Table (A.2.8) Initial Binder content for the three Blends

blend
1
2
3
W s (grams)
Initial binder content (P b i ) %
2.315
2.315
2.3 15
4.46%
4.46%
4.46%
A minimum of two specimens for each trial blend shall be compacted using the Superpave
Gyratory Compacter and the initial binder content, an aggregate weight of 4700 grams is usually
sufficient for the each specimen. Two samples are also prepared
498
for determination of the mixtures maximum theoretical specific gravity (Gmm) each sample of a
weight of 2000 grams is usually sufficient for the specimens used to determine maximum
theoretical specific gravity (Gm m ).
The asphalt mixture samples is aged in an oven its temperature not exceeding the
predetermined mixing temperature by more than 15C for two hours i f the aggregate absorption not
exceeding 2 % and for four hours i f the absorption exceeds that percent, also all devices and
equipments used in mixing such as spatula, mixing pans, mixing bowel and asphalt material shall
be heated to the required mixing temperature, the required time to complete these actions is
depending on the asphalt quantity and method of heating.
Specimens in this example are mixed at the appropriate mixing temperature, which is
ranged from 162C to 168C for the selected PG 76-16 binder. The specimens are then short-term
aged by placing the loose mix in a flat pan in a forced draft oven at the compaction temperature
(148C to 154C), for 2 hours. Finally, the specimens are then removed and either compacted or
allowed to cool loose (for Gm m determination).
The number of gyration used for compaction is determined based on the expected traffic
level for twenty years in the road, the number of equivalent standard axle load in this project is 18
EASL so the following compaction levels is selected:
Ni n i = 8 gyrations Nd e s =
100 gyrations Nma x = 160
gyrations
Each specimen will be compacted to the design number of gyration, with specimen height
data collected during the compaction process and tabulated for each Trial Blend. After
compaction is complete, the specimen is extruded from the mold and allowed to cool and the bulk
specific gravity (Gmb) of the specimens were determined using AASHTO T 166. The Gm m of each
blend is determined using AASHTO T 209. Gmb is then divided by Gm m to determine the %Gmm @
Nd e s . The %Gmm at any number of gyrations (Nx ) is then calculated using the following equations:
%Gm m @ Nx = (%Gm m @ Nd e s ) x (H @ Nd e s )
(H @ N X )
Tables (A.2.9) to Table (A.2.1 1) shows compaction data for the three trial blends and
Figures (A.2.3) through (A.2.4) illustrate the compaction plots and show %Gm m versus the
logarithm of the number of gyrations.
499
Tables (A.2.9) Densification Data for Trial Blend 1

Gyrations
5
8
10
15
20
30
40
50
60
80
100
G mb
G mm
Specimen 1
Ht, mm
%G m m
129.0
127.0
125.7
123.5
122.2
120.1
119.0
118.0
117.2
116.0
115.2
2.445
2.563
85.2
86.5
87.3
88.9
89.9
91.4
92.3
93.0
93.7
94.7
95.4
Specimen 2
Gyrations
Ht, mm
130.3
128.1
126.7
124.7
123.4
121.5
120.2
119.3
118.5
117.3
116.4
2.473
2.563
86.2
87.6
88.6
90.1
91.0
92.4
93.4
94.2
94.8
95.8
96.5
Average
%Gm m
85.7
87.1
88.0
89.5
90.4
91.9
92.8
93.6
94.3
95.2
95.9
Figure A.2.3: Densification Data for Trial Blend 1 at asphalt content 4.4 %
500
Tables A.2.10: Densification Data for Trial Blend 2

Gyrations
5
8
10
15
20
30
40
50
60
80
100
G mb
G mm
Specimen 1
Ht, mm
%G m m
131.7
129.5
128.0
125.8
124.3
122.2
120.1
119.6
118.7
117.3
116.3
2.444
2.565
84.2
85.6
86.6
88.1
89.2
90.7
91.4
92.7
93.4
94.5
95.3
Specimen 2
Gyrations
Ht, mm
132.3
130.1
128.7
126.5
124.9
122.7
121.5
120.1
119.2
117.8
116.8
2.447
2.565
84.2
85.6
86.6
88.1
89.2
90.8
92.4
92.8
93.5
94.6
95.4
Average
%G m m
84.2
85.6
86.6
88.1
89.2
90.7
91.9
92.7
93.4
94.5
95.4
501
Tables A.2.11: Densification Data for Trial Blend 3

Gyrations
5
8
10
15
20
30
40
50
60
80
100
G mb
G mm
Specimen 1
Ht, mm
%G m m
130.9
127.2
127.2
125.1
123.7
121.8
120.5
119.6
118.8
117.6
116.7
2.432
2.568
84.4
85.9
86.9
88.3
89.3
90.7
91.7
92.5
93.1
94.0
94.7
Specimen 2
Gyrations
Ht, mm
129.5
127.3
125.9
124.1
122.8
121.0
119.7
118.7
118.1
116.9
116.1
2.442
2.568
85.2
86.6
87.6
89.0
89.9
91.2
92.2
93.0
93.5
94.4
95.1
Average
%G m m
84.8
86.3
87.3
88.7
89.6
91.0
91.9
92.7
93.3
94.2
94.9
502
5.3 Evaluation of Trial Blends Data:

The average % Gm m is determined for initial and design number of gyration for each trial
blend is calculated and summarized in Table (A.2.12) below:
Table A.2.12: Maximum Theoretical Specific Gravity for Trial Blends

Trial Bland
%G m m @ N i n i
%G m m @ Nd e s
1
2
3
87.1
85.6
86.3
95.9
95.4
94.9
The % Gmm at the maximum number of Gyrations (Nmax) must also be evaluated by
preparation of two additional specimens compacted to Nmax for each of the trial blends as discussed
later in this example.
The percent of air voids (Va ), percent of voids filled with asphalt (VFA), voids in the
mineral aggregate (VMA) binder to dust ratio are determined at Ndes.
The percent air voids is calculated using this equation:
% Va = 100 - %Gmm @ Ndes
The percent voids in mineral aggregate are calculated using this equation:
G
_____
%
@
mm des mm
s
100 ( _________________
= - _________________________
VMA e s t i m a t e d
) Gmm
Where:
Va = percent of air voids at Ndes
%Gmm @ Ndes = percent of maximum theoretical specific gravity at Ndes VMA =
percent by volume of voids in mineral aggregate.
Gmm = maximum theoretical specific gravity.
Gsb = total specific gravity of aggregate.
Ps =percent of aggregate by weight of the mix.
Table (A.2. 13) shows the calculated results for the volumetric properties for the three
bends.
Table A.2.13: Compaction Summary of Trial Blends

Blend
1
2
3
AC%
4.4
4.4
4.4
G m m % @ Nd e s
G m m % @N i n i
87.1
85.6
86.3
95.9
95.4
94.9
Air Voids% VMA%

4.1
4.6
5.1
12.9
13.3
13.7
I f the estimated air voids is equal to 4% then the volumetric properties of the mix shall be
compared with the design criteria and the first phase of the mix design process is completed.
Otherwise as in this example the design asphalt content shall be estimated to adjust the air voids to
4 %, then the volumetric properties shall be calculated with the estimated design asphalt content.
503
The estimated design asphalt content shall be calculated at the design number of gyration
for each trial blend using the following formula:
Pb estimated = Pbi (0.4((4-Va))
The volumetric ( VMA and VFA ) and mixture compaction properties are then estimated
at this asphalt binder content using the equations below:
%VMA estimated = %VMA initial + C(4-Va)
(%- 4.0)
VMA
es tima ted
% V MA
%VFA estimated = 1 00
estima te d
%Gmm estimated @ Nini = %Gmm trial @ Nini (4.0 Va)

Where:
Pb estimated = estimated Percent binder content % Pbi =
initial (trial) Percent binder
Va = percent air voids at Ndes
%VMA initial = %VMA from trial asphalt binder content C =
constant (either 0.1 or 0.2).
Note: C = 0.1 if Va is less than 4.0 %

C = 0.2 if Va is greater than 4.0%
Finally, the dust to binder ratio shall be calculated as the percent by mass of the material
passing the 0.075 mm sieve (by wet sieve analysis) divided by the effective asphalt binder
content (expressed as percent by mass of mix).The effective asphalt binder content is calculated
using:
G -G
s e
s b
s e s b
Pbe - (Ps Gb) ( G G ) + Pb ,estimated

=
Where:
Pbe =effective asphalt binder content % of total mix. Ps =
percent of total aggregate of total mix.
Gb =specific gravity of asphalt binder.
Gse =effective specific gravity of aggregate. Gsb
=total specific gravity of aggregate.
Pb =content of asphalt binder % of total mix.
Dust Proportion is calculated using:
P ____
D P _____0.075
= __________
be
504
Where:
P0. 075 = Percent passing 0.075 mm sieve of aggregate. Pb e =
the effective asphalt content % by total mix.
Using all above equations and based on the estimated asphalt content which will give 4 %
air voids the following data shown in Table (A.2. 14) for the three trial blends is expected for the
designed mix:
Table A.2.14: Expected Volumetric Properties for The Three Trial Blends
Blend
initial
Asphalt
Content %
Estimated
Asphalt
Content %
Dust
Proportion%
1
2
3
4.4
4.4
4.4
4.4
4.6
4.8
0.84
0.76
0.85
Air
Voids%
VMA%
VFA%
G m m %@
Ni n i = 8
4.0
4.0
4.0
12.9
13.3
13.7
69.0
69.7
70.4
87.1
85.6
86.3
Tables (12.4.2) of these specifications show the volumetric properties requirements for the
nominal maximum size 19 mm.
The dust binder ratio range can be taken as 0.8 1.6 when the total combined aggregate
gradation is passing below the restricted zone.
After establishing all the estimated mixture properties, the designer can evaluate the values
for the trial blends and decide i f one or more are acceptable, or i f further trial blends need to be
evaluated.
Blend 1 is unacceptable based on a failure to meet the minimum VMA criteria. Both
Blends 2 and 3 are acceptable. The VMA, VFA, DP , and Nini criteria are met. For this example,
Trial Blend 3 is selected as the design aggregate structure.
What could be done at this point i f none of the blends were acceptable Additional
combinations of the current aggregates could be tested, or additional materials from different
sources could be obtained and included in the trial blend analysis.
6. Select Design Asphalt Binder Content:

Once the design aggregate structure is selected, specimens are compacted at varying
asphalt binder contents. The mixture properties are then evaluated to determine design asphalt
binder content.
A minimum of tow specimens are compacted at each of the following asphalt contents: -estimated
Binder content 0.5, and
-estimated Binder content +1.0 %.
A minimum of two specimens is also prepared for determination of maximum theoretical
specific gravity at the estimated binder content. Specimens are prepared and tested in the same manner
as the specimens from the Selected Design Aggregate Structure section.
Mixture properties are evaluated for the selected blend at the different asphalt binder contents, by using
the densification data at the different asphalt binder contents,
505
by using the densification data at Nini (8 gyrations) and Ndes (100 gyrations). The volumetric
properties are calculated at the design number of gyrations (Ndes) for each trial asphalt binder
content. The designer can generate graphs of air voids, VMA, and VFA versus asphalt binder
content the design asphalt binder content is established at 4.0% air voids.
Two samples should be compacted to the maximum compaction level Nmax using the
optimum asphalt binder content to insure that the Gmm% at Nmax is not greater than 98 %.
Table (A.2. 15) shows the test results for compacted specimens of trail blend 3 using
different asphalt content greater or less than the estimated asphalt content, while Tables from
(A.2.17) to Table (A.2.20) show the densification data in the same blends and asphalt content.
Figures (A.2.6) to Figure (A.2.9) show the volumetric properties of the compacted specimens,
while Table (A.2.16) shows the properties of blend 3 when compacted at the optimum asphalt
content (4.9 %).
Table A.2.15: Mix Compaction Properties Blend 3

Asp halt
b ind er
Co ntent%
VFA%
VMA%
Air
Vo id s%
Dust
Prop or tio n
G mm at
initial
gyr atio n%
G mm at
d esign
gyr atio n%
4.3
4.8
5.3
5.8
58.4
69.9
76.6
84.2
13.7
13.5
13.7
13.9
5.7
4.2
3.2
2.2
1.13
0.97
0.85
0.76
85.8
87.1
87.4
88.6
94.3
95.8
96.8
97.8
6
5
4
3
2
1
0
3 .8
4 .3
4 .8
5 .3
5 .8
6.3
Figure A.2.6: Asphalt Binder Percent Voids Relations
506
14.5
14.1
13.7
13.3
12.9
12.5
3.8
4.3
4.8
5.3
5.8
6.3
asphalt binder content %
Figure A.2.7: Asphalt Binder VMA Relationships
10
0
90
80
70
60
4.3
4 .8
5 .3
5 .8
6 .3
Aspha;t B indre Content %
Figure (A.2.8) Asphalt Binder VFA Relationships

Table A.2.16: Design Mixture Properties at 4.9 % Binder content
Mix property
Air Voids %
VMA %
VFA %
Dust Proportion %
% Gmm at Nini (8 gyrations)
Result
Criteria
4.0
13.5
71.0
0.9
87.2
4.0
13.0 min.
65 75
0.6 1.2
Less than 89
507
Table A.2.17: Densification Data for Trial Blend 3, 4.3 % Asphalt Binder
G yrations
5
8
10
15
20
30
40
50
60
80
100
G mb
G mm
Specimen 1
Ht. mm
% Gm m
131.3
129.0
127.5
125.4
124.0
122.1
120.9
119.9
119.1
117.9
117.0
2.430
2.582
83.9
85.4
86.4
87.8
88.8
90.2
91.1
91.9
92.5
93.4
94.1
Specimen 2
Ht. mm
% G mm
131.0
128.8
127.4
125.5
124.2
122.4
121.1
120.1
119.4
118.3
117.4
2.440
2.582
84.7
86.1
87.1
88.4
89.3
90.6
91.6
92.4
92.9
93.8
94.5
Average
% Gm m
84.3
85.7
86.7
88.1
89.1
90.4
91.4
92.1
92.7
93.6
94.3
G yrations
5
8
10
15
20
30
40
50
60
80
100
G mb
G mm
Specimen 1
Ht. mm
% G mm
130.4
128.2
126.8
124.8
123.5
121.5
120.3
119.3
118.5
117.2
116.4
2.462
2.562
85.8
87.2
88.2
89.6
90.6
92.1
93.0
93.7
94.4
95.4
96.1
Specimen 2
Ht. mm
% G mm
130.8
128.8
127.4
125.5
124.1
122.1
120.8
119.9
119.0
117.9
117.0
2.449
2.562
85.5
86.9
87.8
89.1
90.1
91.5
92.6
93.3
94.0
94.9
95.6
Average
% G mm
85.7
87.1
88.0
89.4
90.3
91.8
92.8
93.5
94.2
95.1
95.8
508
G yrations
5
8
10
15
20
30
40
50
60
80
100
G mb
G mm
Specimen 1
Ht. mm
% G mm
132.0
129.8
128.3
126.2
124.8
122.8
121.4
120.3
119.5
118.2
117.4
2.461
2.542
Specimen 2
Ht. mm
% G mm
86.0
87.5
88.5
90.0
91.0
92.5
93.5
94.4
95.1
96.1
96.8
132.6
130.4
128.9
126.7
125.2
123.2
121.7
120.7
119.0
118.3
117.7
2.458
2.542
85.8
87.4
88.4
89.8
90.9
92.4
93.5
94.3
95.0
96.0
96.7
Average
% Gm m
85.9
87.9
88.4
89.9
91.0
92.4
93.5
94.3
95.0
96.0
96.8
G yrations
5
8
10
15
20
30
40
50
60
80
100
G mb
G mm
Specimen 1
Ht. mm
% G mm
130.4
128.6
127.4
125.4
124.0
122.4
120.5
119.4
118.9
117.6
116.7
2.464
2.523
Specimen 2
Ht. mm
% G mm
87.4
88.7
89.5
90.8
91.9
93.1
94.6
95.5
95.9
96.9
97.7
131.5
129.4
128.0
126.2
124.9
123.1
121.3
120.2
119.5
118.2
117.2
2.467
2.523
87.2
88.6
89.6
90.8
91.8
93.1
94.5
95.4
96.0
97.0
97.8
Average
% G mm
87.3
88.6
89.5
90.8
91.8
93.1
94.5
95.4
95.9
96.9
97.8
7. Verification % G m m at the maximum number of gyrations:

Superpave specifies a maximum density of 98 % at Nmax. This will protect the mix from
the excessively compaction under traffic, which may lead to plastic mix, and produce permanent
deformation. After the selection of blend 3 as design blend at 4.9 % asphalt binder content two
additional samples were compacted to Nmax (160 gyrations) for mix verification. Table (A.2.21)
shows the compaction data for blend 3 using the optimum binder content and at Nmax. The % Gmm
is found to be 97.5 % which is comply with the requirements.
509
Table A.2.21:
G yrations
5
8
10
15
20
30
40
50
60
80
100
125
150
160
G mb
G mm
Nmax
Densification Data for Trial Blend 3, 4.9 % Asphalt Binder
Specimen 1
Ht. mm
130.4
128.2
126.8
124.8
123.5
121.5
120.3
119.3
118.5
117.2
116.4
115.6
115.0
114.5
2.495
2.554
% Gmm
85.8
87.2
88.2
89.6
90.6
92.1
93.0
93.7
94.4
95.4
96.1
96.8
97.3
97.7
Specimen 2
Ht. mm
130.8
128.8
127.4
125.5
124.1
122.1
120.8
119.9
119.0
117.9
117.0
116.2
115.5
115.0
2.490
2.554
% G mm
85.5
86.9
87.8
89.1
90.1
91.5
92.6
93.3
94.0
94.9
95.6
96.2
96.8
97.2
Average
% Gm m
85.7
87.1
88.0
89.4
90.3
91.8
92.8
93.5
94.2
95.1
95.8
96.5
97.0
97.5
Figure A.2.9: Densification Data for Blend 3
510
8. Evaluate Moisture Sensitivity:

The final step in the Superpave mix design is the evaluation of moisture sensitivity of the
design mixture. This step is accomplished by performing AASHTO T 283 test on the design
aggregate blend at the design asphalt binder content. Specimens are compacted to approximately 7
% air voids. One subset of three specimens is considered control specimens. The other subset of
three specimens is the conditioned subset. The conditioned subset is subjected to partial vacuum
saturation followed by an optional freeze cycle, followed by a 24-hour thaw cycle at 60C. All
specimens are tested to determine their indirect tensile strengths. The moisture sensitivity is
determined as a ratio of the tensile strengths of the conditioned subset divided by the tensile
strengths of the control subset. Table (A.2.22) shows the moisture sensitivity data for the mixture
at the design asphalt binder content. The criterion for tensile strength ratio is 80 %, minimum.
Trial blend 3 (82.6 %) exceeded the minimum requirement.
The Superpave volumetric mix design is now complete.
Table A.2.22: Moisture Sensitivity Data for Blend 3

Samp le
Diameter, mm
T hickness, mm
Dr y mass, g
SSD mass, g
Mass in Water , g
Vo lume, cc (B -C)
B ulk Sp . Gr avity ( A/E)
Max Sp. Gr avity
% Air Vo id s ( 100( G -F) /G)
Vo lume o f Air Vo id s (HE /10 0)
Lo ad , N
D
t
A
B
C
E
F
G
H
I
P
SSD mass, g
Mass in water
Vo lume, cc (K-L)
Vo l Ab s W ater, cc ( K -A)
% Saturatio n ( 100 N/1 )
% Swell (1 00( M -E) /E)
K
L
M
N
T hickness, mm
SSD mass, g
Mass in water, g
Vo lume, cc ( R-S)
Vo lume o f Ab s Water, cc ( R-A)
% Saturatio n ( 100 Y/I )
% Swell (1 00(T -E) /E)
Lo ad , N
Dr y Str . (20 00P/(t D P) )
W et Str . (2 000 Z/Q D P))
Aver age Dr y Str ength (K. pa)
Aver age W et Str ength (K. pa)
% T SR
Q
R
S
T
Y
Z
Std
Stm
1
150.0
99.2
3986.2
4009.4
2329.3
1680.1
2.373
2.558
7.2
121.8
2
150.0
99.4
3981.3
4000.6
2321.2
1679.4
2.371
2.558
7.3
123.0
Satur ated
4060.9
4058.7
2369.4
2373.9
1691.5
1684.8
74.7
77.4
61.3
62.9
0.7
0.3
Co nditio ned
99.5
99.4
4070.8
4076.9
2373.7
2080.3
1697.1
1694.6
84.6
93.6
69.5
76.1
1.0
0.9
16720
16484
3
150.0
99.4
3984.6
4008.3
2329.0
1679.3
2.373
2.558
7.2
121.6
4
150.0
99.3
3990.6
4017.1
2336.0
1681.7
2.373
2.558
7.2
121.7
20803
704
6
150.0
99.3
3984.4
4008.6
2329.0
1679.6
2.372
2.558
7.3
122.0
20354
858
870
4059.1
2372.8
1686.3
74.5
61.3
0.4
99.4
4074.8
2379.0
1695.8
90.2
74.2
1.0
17441
889
713
872
721
82.6%
5
150.0
99.2
3987.8
4013.9
2331.5
1682.4
2.370
2.558
7.3
123.4
20065
745
511
A ppendix 3 Random Sam pling Method
515
1. Introduction
2. Example 1 Selection Of Random Numbers
3. Example 2 Determining Locations Of Random Samples From Asphalt
Concrete Sections
515
515
517
Appendix 3-Random sampling method
APPENDIX 3
RANDOM SAMPLING METHOD

1. Introduction:
A l l the random tables are prepared on the presumption that the samples are selected
randomly. It means that at any time each sample which has not been selected from a certain product
has an equal chance to be the next sample to be selected.
Table (A.3.1) shows typical random number table. Such table may be used by entering it
randomly (without previous look) and moving in a certain direction (up, down, right, or left) to
obtain random numbers and using them for sample selection.
The random sampling method shall be used for choosing the time and location of
sampling. Following are two examples for the ways with which the random numbers are used to
select the sample.
2. Exam ple 1: Selection of Random N umbers:
Assume that it is required to select Fifteen (15) samples from a total of seven-hundred and
fifty (750) samples in a certain item. In such case, each sample in this quantity is given an
independent number varying from 1 to 750. What is required is selecting 15 numbers each
composed of three digits from the numbers varying between 001 and 750 by applying the following
method:
First it is necessary to determine a starting point in the table. Table (A. 3.1) contains 50
rows and 10 columns of digits listed in groups of four. The starting point for entering Table
(A.3.1) shall be selected randomly in the table. Assume, in this example, the starting point is the
point of row number 41 and column number 8. Assume that the decision was made in advance
that the starting digit chosen will be the first three digits of the four-digit number read to the right
and that succeeding numbers will be read down the column and to continue in the columns to the
right. The following numbers are obtained. (Numbers that are not between 001 and 750 must be
discarded; these are shown in parentheses. A number that has already occurred must also be
discarded; there are no such numbers in this example.)
482, (858), 601, 623, (953), 703, 723, 094, 582, 337, 163 (904), 187, (782), 590, (923), 544, 146,
120, 030
The selection of the sample is simplified i f the 15 numbers between 001 and 750 are rearranged
in order of increasing size as follows:
030, 094, 120, 146, 163, 187, 337, 482, 544, 582, 590, 601, 623, 703, 723.
515
Table A.3.1: Typical random num bers table

1
10
1306
0422
6597
7965
7695
1189
2431
2202
6541
6937
5731
0649
6168
5645
0406
3968
8085
5060
6243
8894
5606
5053
8656
7658
0441
5084
4722
6733
6903
8135
8947
6598
6364
9911
9797
3897
5044
7649
5740
7285
1636
9040
1871
7824
5905
7810
5121
4328
8520
9539
10
5160
2961
1428
3666
6543
7851
0551
4183
5642
6799
8464
0539
4312
4539
7454
6789
8288
5445
1561
9052
3938
7478
4854
7849
6689
4197
7565
9157
7520
1948
6511
5581
9158
2547
2574
0407
5771
5218
0756
9386
9239
5442
1464
1206
0304
2232
8761
3634
2033
7945
15
9975
4868
8239
8722
1330
6080
0956
7068
9191
9120
7423
7545
6694
3386
8785
3175
7723
5168
3443
8382
9377
8085
3117
0434
2929
6951
4948
1586
4586
7089
6519
2228
0237
4150
3109
8287
9583
6160
1224
6742
8994
4415
9585
6204
2468
5532
7065
1133
0937
7025
20
2296
3582
5872
1134
1403
2952
7052
9207
6324
4497
4764
3132
7222
6201
7390
9070
4519
6494
3792
8503
6356
9250
8973
5651
8239
9192
2486
3545
0538
4236
4012
0830
6967
4676
8022
0618
8472
8490
2064
2914
2219
2160
5264
0584
4368
1109
7046
9821
7996
4529
25
3393
1137
7437
8414
8398
7025
7896
5198
8820
5224
3381
3602
8772
3917
2749
3553
0060
6927
7238
7311
2128
7850
8527
9821
5740
1021
7626
6851
6073
9771
8353
0854
2709
6658
7826
6413
6565
5992
1280
9533
5161
4260
7383
9643
3800
8583
6220
1071
7761
4553
30
0995
6657
8875
8399
6703
8935
0755
8369
6702
1024
2939
9685
7868
0586
2064
3092
4017
0190
6423
0393
2496
6581
9278
7985
6815
0359
7292
1709
2979
8502
0318
5643
4253
4513
1375
4697
5064
9346
1970
4171
7181
1142
4335
1989
6970
4035
1297
3769
3105
1201
35
4730
8400
3647
6789
2630
1653
6834
8002
5197
2721
0932
3187
6726
8037
2810
0955
8688
0877
2354
2185
0957
1079
4552
9262
6323
7366
1480
3238
5497
5679
0325
6776
7542
0005
4931
5178
9888
7804
3986
8336
7958
7585
3933
1767
6662
5371
9998
9475
7981
3566
40
1374
1572
9678
0882
0006
8625
7625
2877
6781
4205
1644
9110
7579
3538
2389
3342
4409
4935
4090
4365
1587
0239
0449
3092
1981
0762
7059
8119
2365
8158
6057
3415
6969
6001
7784
8011
5537
5383
3446
6256
2666
2250
1717
9985
3842
3759
7292
6719
6007
5603
45
4661
1093
3374
3650
7292
9861
3784
3545
9676
5749
7916
4190
6865
1436
7877
9305
6332
8819
4374
7602
2074
1175
3342
4716
9205
9462
8599
1676
5548
3599
0254
9735
2264
8276
3880
4827
8584
6014
6235
9537
9198
6581
5012
6742
4423
3974
7194
2458
2154
2330
50
2353
1094
0568
5608
8285
8319
2009
4002
4070
7537
2850
8919
0587
5233
1181
4026
5676
7165
4339
2300
3027
7283
1094
6543
5294
1708
4982
2006
6695
6892
3518
9642
7471
5799
1627
7034
7235
0940
5821
3372
7132
8167
4366
3953
1952
6903
3366
9554
9458
3028
516
3. Exam ple 2: Determining Locations of Random Sam ples from A sphalt

Concrete Sections:
Assume that work is being carried out for constructing an asphalt concrete pavement
section for a one lane of three and six-tenths (3.6) meters wide and two-thousands and five
hundreds (2500) meters long. It is required that five (5) locations randomly distributed on the
width and length of this road section shall be determined.
To determine these samples two groups of numbers are selected from Table (A.3.1) each
group is composed of five (5) numbers so that the first group represents sampling locations on the
road length and the second group represents sampling locations on the road width.
By entering Table (A.3.1), using the method described in Example 1, the following
numbers were selected:
1. First group: 8527, 9821, 5740, 2496, 6581
2. Second group: 3092, 2365, 6001, 3446, 9985
The numbers of the first group are multiplied by the section total length (2500) and the
numbers of the second group are multiplied by the section total width (3.6) and dividing the
products in both cases by 10,000. The random sampling locations shall be as shown in the
following table:
Sam ple Num ber
Distance from the

beginning of the section
(meters)
Offset distance for the

right or left lane edge
(meters)
First
Second
Third
Fourth
Fifth
624
1,435
1,645
2,132
2,455
1.10
0.85
2.16
1.24
3.59
The previous locations of sampling may be used to perform all quality control or quality
assurance characteristic tests such as: density of road bed, aggregate base, subbase layers and tests
of measuring asphalt concrete layer thickness and compaction.
517
Appendix 4 Work Evaluation Using The Statistical Method
521
Appendix 4- Work evaluation using statistical method
APPENDIX 4
WORK EVALUATION USING THE STATISTICAL METHOD

Given Information:
An asphalt concrete layer was constructed with the following special specifications:
1. Asphalt layer thickness = 5 centimeters
2. Asphalt content in asphalt concrete mix = 5%
3. Gradation specifications of asphalt surface layer aggregate = Gradation No. 4
Table (7.3.4) and Job Mix Formula shown in Table (A.4.2) below.
4. Required compaction level = Minimum 91 % and Maximum 95%
5. Road service roughness according to International Roughness index (IRI) = 200
cm/km, maximum
When this road was tested for quality assurance purposes, results of tests for ten (10)
random samples were as shown on Tables (A.4.1) and (A.4.2) below.
Table A.4.1: Testing results of some characteristics of asphalt concrete road under stud
y
Specification Limits Number
Measurements
Standard
Characteristic
of
Average
Maximum
Minimum
deviation of
samples
t
Asphalt layer thickness
4.8
0.24
4.7
10
(cm)
Compaction degree (% )
92.8
1.452
95
91
10
Asphalt content (%)
4.98
0.50
5.4
4.6
10
Surface layer smoothness
using roughness IRI
185
25.4
200
10
measuring system (cm/km)
Quality Index
Characteristic
Asphalt layer thickness (cm)

Compaction degree (%)
Asphalt content (%)
Surface layer smoothness
using roughness IRI
measuring system (cm/km)
Maximu
Qu
Minimu
QL
---1.52
0.84
0.59
Work Outside Ratio
0.42
1.24
0.67
Maximu
Pu
0%
5.08%
20%
Minimu
PL
34%
10%
21.6 %
---
28 %
0%
Pay
Factor
88%
100%
81 %
92 %
Asphalt mix aggregate gradation results were as shown on Table (A.4.2).

Requirement:
Calculate total pay factor for this road considering only the characteristics mentioned
above. Methodology:
By using the following equations indicated in the Item 17.3.2 the quality index for
each characteristic is calculated with both its maximum and/or minimum limits
521
1.
Calculate upper quality index (QU) as follows:

USL-
= ________
Qu
s
Where:
USL = Upper specification limit
x = Average of all values

s = standard deviation of all values
Note: The USL equals the Contract specification limit or the target value plus
allowable deviation.
2.
Calculate the lower quality index (QL) as follows: XLSL
=
QL s
Where:
LSL = Lower specification limit.
Note: The LSL equals the Contract specification limit or the target value minus
allowable deviation.
3.
Using Table (17.3.2), the percentage PU (the percentage of work outside the upper
specifications limit. PU corresponds to the upper quality index QU. If the USL is not
specified, then PU = 0
4.
Using Table (17.3.2), determine the percentage PL (the percentage of work outside the
lower specifications limit). PL corresponds to the lower quality index QL. If the LSL is
not specified, then PL = 0
5.
Calculate the percentage of work outside upper and lower
specifications limits (percentage of defective work) as follows: PU + PL
6.
Pay factor is determined according to the following steps:
Using Table (17.3.3), pay factor is determined for each characteristic of those indicated in
Tables (A.4.1) and (A.4.2) for the total number of samples and the total estimated percentage
of the defective work outside specifications limit from step 5 above.
Major quality level Category (I) is used for aggregate passing through sieves between
sieve size 0.75 mm (No. 200) and sieve 4.75 mm (No. 4) while category (II), secondary quality
level, is used for coarse aggregate with a size larger than sieve 4.75 mm (No. 4), to calculate
pay value then the arithmetic average of the pay factor is averaged for all sieves for gradation
characteristic.
The final pay factor is calculated from the overall average of all pay factors of the measured
characteristics.
Table (A.4.2) shows pay factor calculations of total aggregate gradation. The resulted
average pay factor for the aggregate equals to 0.967. Table (A.4.3) shows pay factor
calculations of the remaining characteristics.
By calculating pay factors of the previous four characteristics the overall pay factor is:
(0.967 + 0.81 + 0.88 + 1.00 + 0.92) 5 = 0.915, which means that overall pay to the Contractor
will 91.5% of the values of all the characteristic items involved in the evaluation by the
statistical method.
522
Table A.4.2: Asphalt extraction results, pay factor of gradation and asphalt
content
Sieve size
Specification
limits
JMF
limits
37.5 mm (1.5 inch)

25 mm (1 inch)
19 mm (3/4 inch)
12.5 mm (1/2 inch)
9.5 mm (3/8 inch)
4.75 mm (No. 4)
2 mm (No. 10)
0.425 mm (No. 40)
0.180 mm (No. 80)
0.075 mm (No. 200)
100
75-90
65-80
55-70
46-60
3 1-46
18-33
5-18
3-13
2-9
100
79-91
67-79
56-68
47-59
34-46
18-28
7-13
4-10
3-6
Average
Gradation
and
asphalt
content
after
extraction
test
100
85.0
73.0
61.4
53.6
40.7
23.1
10.4
4.1
4.5
0
5.66
4.26
4.66
4.37
5.00
4.46
1.95
1.86
1.2
QU
QL
PU
PL
PU + PL
Pay
factor
0
1.06
1.41
1.41
1.24
1.06
1.1
1.35
1.54
1.28
0
1.06
1.41
1.71
1.02
0.84
1.06
1.06
1.41
1.35
0
14
7
7
10
14
13
8
5
9
0
14
7
3
15
20
14
14
7
8
0
28
14
10
25
34
27
22
12
17
1.00
0.97
0.95
1.00
0.99
0.88
0.93
0.96
1.00
0.99
The average pay factor for all sieves equal to 0.967.

Table A.4.3: Pay factor calculation for thickness, compaction, and surface
smoothness.
Characteristics
Asphalt layer
thickness (cm)
Asphalt
percentage
Compaction level
(%)
smoothness IRI
(cm /km)
Average
value of 10
samples
Standard
deviation
USL
LSL
QU
QL
PU
PL
PU + PL
Pay
factor
4.8
0.24
4.7
0.42
34
34
0.88
4.98
0.50
5.4
4.6
0.84
0.77
22
20
42
0.81
92.8
1.452
95
91
1.52
1.24
10
15
1.00
185
25.4
200
0.59
28
28
0.92
The overall average pay factor = 91.5 percent __

Important Note:
If the pay factor of one (or more) of the characteristics of the work being evaluated
is less than seventy-five (75) percent, these characteristics are given pay factors equal to
zero (0), and then the overall average pay factor for all characteristics is calculated.
If this average is more than seventy-five (75) percent, and the work is technically
accepted based on a technical report issued by an approved specialized agency, the Ministry has
the right to accept the executed work and the Contractor is paid according to this pay factor. If
the work is not technically accepted, the work is rejected and the Contractor shall remove the
executed work and re-constructed it according to the specifications without any compensation. If
the work is technically accepted and the pay factor is less than seventy-five (75) percent, the
Ministry has the right to accept the work without asking the Contractor to remove it; however,
the Contractor will not be paid any compensation.
523
Appendix 5
1.
2.
3.
4.
5.
6.
Traffic C alm ing Bumps
527
Introduction
Bump Shapes
527
527
2.1 Speed Bump

2.2 Speed Hump
2.3 Tabletop Type Speed Humps
2.4 Raised Intersections
527
527
528
528
Sites And Conditions Of Bump Construction
530
3.1 Site Conditions

3.2 Stipulations Of Bumps Execution
3.3 Handicapped Crossings Requirements
530
532
532
Engineering Design
Bum p C onstruction
533
535
5.1 Asphalt Bumps

5.1.1 Materials
5.1.2 Execution
5.1.2.1 Under Progress Asphalt Surfaces
5.1.2.2 Constructed Asphalt Surfaces
5.2 Pre-Cast Concrete Bumps
5.2.1 Materials
5.2.2 Execution
535
535
535
535
535
536
536
536
Traffic C ontrol Devises At Hum ps
536
6.1 Traffic Signs

6.2 Ground Marking
6.3 Ground Reflectors
536
537
537
7. Lighting
539
Appendix 5- Traffic calming bumps
APPENDIX 5
TRAFFIC CALMING BUMPS
1. Introduction:
Traffic calming bumps are a simple height in pavement layers constructed in certain areas for forcing drivers to
slow down their speed.
Bu mp s are constructed in different shapes and asphalt concrete or pre-fabricated concrete or rubber or plastic elements
are used in their construction.
This appendix contains the basic design requirements for bumps and their construction using asphalt concrete or
overlapping concrete bricks and also it includes traffic safety equipments and traffic signs related to these bumps.
2. Bump shapes:
Traffic calming bumps may be constructed in one of the following three shapes, the attached figures are only for clarification
(without scale) and all dimensions are in c m :
2.1 Speed Bump:

It is an area elevated from the road surface in the lateral direction with a height usually varying between 7.5-10 cm. and
between 35-100 cm. long. It is normally constructed on special roads and in parking areas. This type of bumps causes an
uncomfortable feeling for drivers and forces them to slow down their speed to 10 km/h, as shown in figure (A.5.1).
2.2 Speed hump:

A n elevated area from the road surface in a lateral direction and sometimes called waved surface or sleeping traffic
policeman, and such type usually varies between 7.5-10 cm. high and 3.5-4.5 m. long. This type causes a little uncomfortable
feeling for drivers and forces them to slow their speeds to 25 km/h up to 35 km/h as shown in figure (A.5.2).
527
Figure A.5.2: Speed humps elements
2.3 Tabletop type speed humps:

This figure represents a special form of speed h u m p and is characterized by a shorter length (2) m . normally designated
for pedestrian mo ve me n t at intersections as shown in figure (A.5.3).
2.4 Raised intersections:

It is a kind of raised b u mp s with leveling surface, but the whole intersection area is raised up, generally concrete tiles is used in this
type as shown in figure (A.5.4).
528
Figure A.5.3: Tabletop type speed humps elements
529
Figure A.5.4: Raised intersection 3.

Sites and conditions of bump construction:
3.1 Site conditions:
Traffic calming bumps shall be constructed at sites where calming speed is necessary for providing traffic safety for cars
and pedestrians such as school areas, educational centers, mosques, public parks and large commercial markets which are
characterized with high pedestrian movement and bumps may be necessary at pedestrian walkways and car parking
exits.
530
B u mp s shall be constructed only on local streets and they are not allowed to be constructed on collective or arterial streets, and
specified speed on the road shall be limited to 60 km/h,
Raised intersections shall be constructed at local roads, and it can used in collector and arterial roads when traffic
volume not more than ten thousands (10000) car/day, and the speed is limited to sixty 60 km/h.
It is not allowed to execute any type of bumps or raised intersections in roads with a dense movement of emergency cars like
ambulance fire engine, and crossing cars or cars with long chaises.
It is preferred not execute bumps on roads which the percent of vehicles and heavy cars in it, more than five (5%),
otherwise other roads are available.
Table (A.5.1) is shown road conditions in bumps sites
Table A.5.1: road conditions in bumps sites

Site and road conditions
Limits
Road classification
Local, and local collective streets where there

are problems related to excessive speeds, service
streets where there are service centers
60 or less
Traffic control speed in the street,( km/h)

Street length after deducting intersection
area lengths, (meter).
M i n i m u m 250 meters
Longitudinal gradation of the road on

which the bump shall be constructed, (%)
Maximum 8
Distance between consecutive bumps in a

series of bumps, (meter)
200-100
B u m p visibility distance, (meter)
Taken from table 5
Radii of horizontal bends of the road at

bump construction area, m
Minimum 100
When choosing bump sites adhere to a group of conditions, following are the most
important of these them:
1.
The construction of the bump shall not lead to interruption of water drainage and bumps shall not be
executed at water catch basins, drain openings, manholes and firefighting nozzles.
2.
It is not allowed to execute any type of bumps or raised intersections in roads with a dense movement of emergency
3.
B u m p s shall not be constructed at bus and public transportation vehicle parking areas, and the distance between
cars like ambulance fire engine, and crossing cars or cars with long chaises.
the bump and the entrances and exits of pockets designated for all such parking areas for entrance and exiting of
buses comfortably, shall not be less than 5 meters.
4.
The need for constructing bumps near pedestrian walkways shall be eliminated, and the bump shall be at a distance of not
less than 5 meters from the intersection plus providing a traffic pole for pedestrian intersection to draw the driver's
attention.
531

5.
Rout continuity of the handicapped movement shall be considered when constructing tabletop speed
bumps by executing a suitable slope for pavement sides and bump sides of not more than 1:12.
6.
The separating distance between the bump and the intersection shall not be less than 20 meters.
7.
Provision of vision conditions shall be considered, and to refrain from planting trees or plants which
may limit visioning traffic signs.
3.2 Stipulations of bum ps execution:

1-
W h e n there are service structures that require bump construction on local collective streets, two bumps shall be
constructed in traffic direction at a distance of 20 meters before the main gates of the service structures.
2-
W h e n the service structures are located on local streets, two bumps are executed at a distance of 20 meters before the
main gate.
3-
B u m p s are constructed around parking spaces surrounding mosques, schools and other service facilities, and bumps
shall be constructed inside these spaces when necessary, at distances of 30 meters between each two bumps.
4-
At local collective street intersections which are not provided with traffic signals, bumps are executed at a distance of 20
meters before the intersection, on the intersecting streets.
5-
B u mp s on local streets which link between local collective streets, at the rate of one bump at a distance of 50 meters from
the intersection, and at distances of 100 to 200 meters each, according to site requirements.
6-
At local street intersections of equal importance with no traffic signals, or when streets meet at an angle or two longitudinal
slopes which limit the intersection vision distance, bumps are executed on the intersecting streets 50 meters before the
intersection.
7-
At road closed ends or when roads end at non-constructed lands, one bump is constructed 50 meters before the
end, and when the end corresponds with a gradient two bumps are constructed at distances of 50 and 20 meters before
the end.
8-
W h e n the width of the street is changed a bump is executed at a distance of 50 meters before the beginning of the
change.
3.3 Disabled crossings requirements:

It is preferable to refrain from locating humps in locations designated for pedestrian walkways provided with special
ramps for handicapped people, and to place humps before those crossings.
W h e n constructing upper level surface humps designated for pedestrians a link shall be made between pavement and
crossing raised on the hump by constructing a special ramp that meets the conditions for wheelchair movement. The ramp slope
shall not exceed 1 to 12 (1:12), figure (A.5.5) shows example of relation between the side walk and curb ramp.
In all cases, provision for surface water drainage shall be considered at humps construction sites either by constructing draining
openings or additional lateral drains or providing a separating distance between the internal face of the curbing and the hump according
to site conditions.
532
Figure A.5.5: Example of relation between the sides walks and curb ramp 4.
Engineering Design:
Traffic calming bumps shall be designed and constructed such that they provide the possibility of crossing them by cars
smoothly and without feeling a strong shock.
There are no specifications for speed bump, but height usually varying between 7.5-10 cm. and the minimum long is 30 cm.
The most important bump designing factors are height, length, elevation gradation length, and the following table (A.5.2)
shows the most important factors.
533
Speed humps are designed according to parabola and the figure (A.5.6) shows the variation in height, which can be
calculated as in the vertical curves.
Tables (A.5.3) & (A.5.4) Shows the variation in height in bump edge and the other edge corresponding to it.
Table A.5.2: Bump factors dimensions

Bump factors
Dimensions (meter)
B u m p height, cm
Maximum 10
3.5-4.5 and when there is bus traffic
not less than 8 meters.
Tabletop speed bump length from

beginning to end, meter
Pedestrian paths
Level upper
surface, m
2
5-10 according to crossed roads width
and pedestrian walkside
Raised intersections
Gradation slope of elevation change
1:8 To 1:15 ,bus traffic 1:20
Figure A.5.6: Bump elements

Table A.5.3: Bump's Height with maximum height equal to 7.5 cm
Bump
length
(m)
3.5
4.00
4.5
Cumula
tive
75
Height
25
50
4.5
distance
100
according
from b u m p ' s
start
125
150
tobump's
length
(cm)
175
(cm)
200
225
6.5
7.5
5.5
6.5
7.5
7.5
6.5
7.5
7.5
Table A.5.4: Bump's Height with maximum height equal to 10 cm

Bump
length
(m)
3.5
4.00
4.5
C u m u l distance
25
50
75
3
2
5
4
6.5
100
Height
according
from bump's
start
125
150
175
200
tobump's
length
(cm)
8
7.5
9
8
9.5
9
10
9.5
10
9.5
10
225
10
Note: Tables (A.5.3) & (A.5.4) shows the values for one half of the bump and the other is corresponding to it.
534
5. Bump construction:
Different types of b u m p s shall be constructed at the designated sites according to the dimensions and shapes specified in
contract documents or according to the Engineer's instructions, using the materials indicated in the special specifications or contract
documents.
Contractor shall, before commencing execution, verify the b u m p site and obtain the Engineer's acceptance for it.
5.1 Asphalt bumps:

5.1.1 Materials:
Asphalt Materials and mixes shall be in compliance with those indicated in special specifications, drawings or these
general specifications. The asphalt materials used in executing the binding layer shall be achieved from liquid or emulsified asphalt,
except otherwise stated in the special specifications, and shall comply with the requirements indicated in division 7 of the
general specifications for urban roads construction.
The asphalt mix used shall achieve asphalt concrete requirements for surface layer indicated in division 8 of the general
specifications for urban road construction.
5.1.2 Execution:
Before commencing construction of asphalt concrete bumps, Contractor shall prepare surfaces over which the b u m p
shall be constructed, according to the following:
5.1.2.1 Under progress asphalt surfaces:

W h e n b u m p s construction coincides with the construction of asphalt layers, the execution, finishing, testing and handing
over by the Engineer, then b u m p s execution start, that asphalt is cut at the b u m p site immediately after completing compaction with a
thickness of not less than 5 c m throughout the b u m p area, and execution of the binding layer at the area designated for the
b u m p and painting asphalt cutting faces with the asphalt material used for the binder layer, the asphalt concrete is spread , compacted and
finished according to dimensions and levels s h o w n on drawings and special specifications, and Contractor has no right to claim
any additional cost for asphalt concrete removal works.
5.1.2.2 Constructed asphalt surfaces:

W h e n constructing b u m p s from asphalt concrete in executed asphalt concrete surfaces, b u m p s shall be executed
according to the above first case considering cleaning the b u m p area from all deleterious and loose materials, and caring in executing
the binder layer and painting cutting faces.
At all times, cutting asphalt shall be done with mechanical circular saws capable of cutting asphalt without creating any loosening
or disintegration for the asphalt layers, also cleaning surfaces from all loose and deleterious materials and binder layer shall be executed
according to the requirements and execution method stipulated in division seven and eight of these general specifications.
The constructed b u m p s shall be compatible as to dimensions and levels with what is stipulated in drawings and special
specifications and the level of the b u m p top shall not be different from the level specified by more than 1 cm.
535
W h e n b u m p s execution were in areas with one asphaltic concrete layer with thickness equal to or less than required
thickness for b u m p execution, the execution can be over aggregate layer (base or sub-base). In this case absorption layer shall be
executed according to divisions 7 & 8 in General Specification of Urban Road Construction , asphalt cutting in that areas shall not
lead to rarefaction or disunion in aggregate layer, and w h e n these happened, layers shall re impacted.
5.2 Pre-cast concrete bumps:

5.2.1 Materials:
The concrete elements (slabs) used in executing table top, speed humps, and raised intersections shall be from
overlapping concrete bricks, except otherwise allow special specifications, and the bricks used shall achieve the quality
requirements indicated for overlapping bricks exposed to car movements stipulated in special specifications or division 14 of
general specifications for urban road construction and shall be compliant as to shapes and dimensions with what is indicated in the
special specifications or according to Engineer's written instructions.
5.2.2 Execution:
Tabletop speed h u m p s shall be constructed from overlapping bricks at the sites and according to the dimensions and
levels shown on drawings and special specifications.
Surfaces shall be prepared, sand bedding shall be executed, overlapping bricks shall be installed and joints shall be filled
according to the special specifications or divisions 1 5 & 1 4 of the general specifications for urban roads construction or those
recommended by the manufacturer.
The upper surface level of the h u m p shall not differ from the levels specified by more than 1 cm.
6. Traffic control devises at hum ps:

Suitable devises shall be used for indicating existence of the hump. Those devises include traffic signs for h u m p in
addition to paint lines or ground reflectors or both.
6.1 Traffic signs:

Signs to be used shall be from materials and specifications compliant with the requirements indicated in Section 16.3
(Traffic signs & posts) of the general specifications for urban road construction. Signs shall be fixed according to the method
indicated in item 16.3.3.2 (Signs) of these general specifications. The distance from which the warning sign can be seen shall not
be less than the distances indicated in Table (A.5.5), figure (A.5.7) shows the position of the sign and its shape.
Table A.5.5: Visual Distance

85 Percentile speed km/h
Minimum required visual distance m
30
50
40
50
65
85
60
110
536
Since, percent speed 85 is the speed with which, it has been observed that, 8 5 % of
drivers drive their vehicles with a speed equal or less than it.
Figure A.5.7: Position of the sign and its shape
The sign shall be compliant with the standard approved in the M U T C D issued by
M.O.T. Figures (A.5.8) & (A.5.9) shows the dimension of bumps signs.
Figure A.5.8: Dimension of speed bump

sign
Figure A.5.9: Dimension of Tabletop

type speed humps sign
6.2 Ground Marking:

Paint materials used shall be compliant with the requirements of items 16.4.2.1 (Traffic Lines) & 16.4.2.2 (Thermal
Plastic Traffic Marking) of these general specifications.
Lines over the hump shall be installed with the method indicated in item 16.4.3.6 (Painting Works) of the general
specifications for urban road construction. Also, according to the color and dimensions specified in the special specifications and in
compliance with M U T C D issued by the M.O.T.
Painting lines may be in different shapes providing that they meet the following conditions:
- The line width should not be less than 30 cm.
- Lines should be in yellow color and from reflector thermal plastic type. Figures (A.5.10) show painting lines used on bumps.
537
Figure A.5.10: Painting lines dimension on the speed bump 6.3

Ground reflectors:
Ground reflectors are used for raising the driver's attention to the existence of the hump , on relatively w e a k lighted roads or
roads on which visibility range is limited due to fog or other natural factors. The used ground reflectors shall be compliant with the
requirements specified in item 16.4.2.3 (Ground road reflectors) of the general specifications for urban road construction.
Ceramic, prismatic, and cat eye (large, small and thermal) reflectors m a y be used. Also, two types or more of
reflectors m a y be used together.
Reflectors shall be fixed according to the methods indicated in item 16.4.3 of the general specifications for urban road
construction, according to the type of used reflectors, in straight line at a distance of not more than 150 c m and not less than 50 c m before
the hump. Figure (A.5.1 1) s h o w the position of the reflectors before the bump.
Figure A.5.11: Position of the reflectors before the bump
538
7. L i g h t i n g :
H u m p locations should be lighted at night and lighting strength should not be less than that approved for the road on which
the hump is being constructed, or the pedestrian crossings or intersections whichever the case. Lighting works shall be executed
according to the technical specifications and general conditions for roads, streets, and parks lighting issued by the M. M. R. A, and except
otherwise indicate the approved technical specifications, lighting strength should not be less than 6 Lucas.
R e fe r en c e s:
1- Artificial humps rules & specifications- Maintenance & Operation Directorate-Riyadh Municipality.
2-
General Specifications for urban road construction- M . O. T. 1998. K S A .
34-
M U T C D Ministry of Transport & Communications- K S A .

Traffic Engineering Handbook- Institute of Transportation Engineers
fifth edition-1999.
5-
Traffic Calming State of Practice - Reid Ewin-FHWA-ITE-1999.
6-
Traffic Calming Design Manual- Delaware Department of Transportation

-August - 2000.
539
REFERENCES LIST
1- Arabic References:

- ) (
.
- ) (
.
- ) (
.
- ) (
.
- ) ( .
- ) (
.
- -
- .
2- Foreign References
AASHTO (1993). AASHTO Guide for Design of Pavement Structures.
American Association of State Highway and Transportation Officials.
Washington D.C., USA.
1-
AASHTO GUIDE FOR DESIGN OF PAVEMENT

STRUCTURES-VOLUME 2, APPENDIX AA (Guidelines for the Design of
Highway Internal Drainage Systems), 1986.
2-
AASHTO (1998). Guide Specification for Highway Construction. American

Association of State Highway and Transportation Officials. Washington, D.C.,
USA.
3-
541
References List
5-
AASHTO (2000). Standard Specifications for Transportation Materials. Methods of

Sampling and Testing. Part II. American Association of State Highway and
Transportation Officials. Washington D.C., USA.
6-
AASHTO (2000). Standard Specification for Transportation Materials. Method of

Sampling and Testing Specification, Part I. American Association of State Highway
Transportation Official. Washington, D.C., USA.
7-
ACI Manual of Concrete Practice (2003). Parts 1, 2, 3, 5 and 6. American Concrete

Institute. Detroit, USA.
8-
ADOT (2000). Standard Specifications for Roads and Bridge Construction. Arizona
Department of Transportation, Arizona, USA.
9-
Alabama (1999). Alabama Standard Specifications, Alabama Department of

Transportation. Alabama, USA.
10-
Al-Abdul Wahhab, H., Ali, M. F., Asi, I. M. and Al-Dhubaib, I. (1994). Adaptation
of SHRP Performance-Based Asphalt Specifications to the Gulf Countries. Project
Number AR-14-60, Progress Report Number 2. King Abdulaziz City for Science and
Technology. Riyadh, Saudi Arabia
11-
Annual Book of ASTM Standards (1994). Vol. 04.01, 04.02 and 04.05. Philadelphia,
USA.
12-
Asphalt Institute (1977). Asphalt Cold-Mix Manual. The Asphalt Institute. Manual
Series MS-14. USA.
13-
Asphalt Institute (1979). A Basic Asphalt Emulsion Manual. The Asphalt Institute.
Manual Series MS-19. USA.
14-
Asphalt Institute (1981) Asphalt Hot-Mix Recycling. The Asphalt Institute. Manual
Series MS-20. USA.
15-
Asphalt Institute (1983). Asphalt Cold-Mix Recycling. The Asphalt Institute. Manual
Series MS-21. USA.
16-
Asphalt Institute (1995). Mix Design Method for Asphalt Concrete and Other
HotMix Types. The Asphalt Institute. Manual Series MS-2. Sixth Edition, USA.
17-
Asphalt Institute (2001). SuperPAVE Mix Design. The Asphalt Institute. Superpave
Series Number SP-2. USA.
18-
ASTM (2000). Roods and Paving Materials, Vehicle-Pavement System. American

Standards for Testing and Materials. Section 04, Volume 03, USA.
19-
Asphalt Institute (2003). Performance Graded Asphalt- Binder Speci Testing,

Superpave Series No.1 (SP- 1).
542
References List
20-
BCA (1999). Specifications for Stone Mastic Asphalt Materials. New Zealand
Pavement and Bitumen Contractors Association, BCA Number 9808. New Zealand.
21-
City of San Antonyo Standard Specifications for Highway Construction (1995).

Traffic Control Devices Handbook, James L. Pline-2001.
22-
Construction And Material specifications (2002). State of Ohio Department of

Transportation Colombus, Ohio.
23-
FHWA (1990). Open Graded Friction Courses. Federal Highway Administration

Technical Advisory Number TS040.3 1. Washington D.C, USA.
24-
FHWA (2003). Standard Specifications for Construction of Roads and Bridges on

Federal Highway Projects. Federal Highway Administration, Washington D.C, USA.
25-
FHWA (1997). Pavement Recycling Guidelines for State and Local Governments.
Federal Highway Administration Publication Number FHWA - SA-98-042.
Washington, D.C., USA.
26-
Highway Materials, Soils, and Concretes (1997). Third edition, Harold N. Atkins,
PE-Prentice Hall, New York, USA.
27-
Seepage, Drainage, and Flow Nets, second edition, HARRY R. CEDEGREN. John
Willy & Sons, 1977.
543
General Specification of Urban Road Construction
General Specification of Urban Road Construction

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GENERAL SPECIFICATIONS OF URBAN ROADS

A: Division 1 The Definitions of Terms and Abbreviations

Kingdom of Saudi Arabia

DEFININTIONS OF TERMS AND ABBREVIATIONS

BID SUBMISSION CONDITION

GENERAL RULES NOT USED

URBAN ROADS CHARACTERISTIC

SUBBASE AND AGGREGATE BASES

MATERIALS OF ASPHALTIC MIXES

ASHPHALTIC CONCRETE WORKS

SPECIAL ASPHALTIC WORKS

SUPERIOR PERFORMANCE ASPHALT PAVEMENT

REMOTE AREAS PAVEMENT WORKS

CEMENT PAVEMENT LAYERS

SIDEWALKS, CURBS AND MEDIAN ISLANDS

TRAFFIC SIGNALS, TRAFFIC SIGNS,

Standard Testing Guide

Superpave Volumetric Mix Design Example

Random Sampling Method

Work Evaluation Using The Statistical Method

Traffic Calming Bumps

These specifications also handle requirements for urban roads construction in

Road Engineering Designing Manual- MOMRA.

DEFININTIONS OF TERMS AND ABBREVIATIONS

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Program and Time schedule of work

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

BID SUBMISSION CONDITION

P relimin ary G u aran tee

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Prelim inary guarantee:

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Bid subm ission manner:

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

Kingdom Of Saudi Arabia

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

3.4.6 Client Commitments

General Specifications of Urban Roads Construction ____________________ Division 3- General Rules

Work scope and documents:

3.2.1 Contract purpose:

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

General Specifications of Urban Roads Construction ____________________ Division 3- General Rules

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

General Specifications of Urban Roads Construction ____________________ Division 3- General Rules

3.2.4 Additional drawings:

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

General Specifications of Urban Roads Construction ____________________ Division 3- General Rules

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

General Specifications of Urban Roads Construction ____________________ Division 3- General Rules

3.2.13 Site evacuation and cleaning after work completion:

Legal relations and responsibility towards the public:

3.3.1 Law abidance:

General Specifications of Urban Roads Construction ____________________ Division 3- General Rules

3.3.3 Patent right and ownership:

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia

General Specifications of Urban Roads Construction ____________________ Division 3- General Rules

Ministry of Municipal & Rural Affairs Kingdom of Saudi Arabia