Zambia Road Specifications

1 / GENERAL
SECTION No1
GENERAL PROVISIONS
1.1 TERMINOLOGY. UNITS OF MEASUREMENTS AND ABBREVIATIONS
1.1.1 Terminology
In these Specifications the following terms, words or expressions shall have the meanings
hereby assigned to them, except where the context otherwise requires.
Asphalt
A mixture to predetermined proportions of aggregate, filler and bituminous binder

material prepared off the road and usually placed by means of a paving machine.
Base
A layer of material of defined thickness and width constructed on top of the sub-base or,
in the absence thereof, on top of the sub-grade. A base may extend to outside the
carriageway.
Bituminous Courses
Bitumen bound layer or layers constructed on top of the base or sub-base and, in some
cases, the shoulders. Bituminous courses include bituminous base course, binder course,
wearing course, surface dressing etc.
Borrow
The term "borrow" applies to all borrow materials.
Borrow Material
Any gravel, sand, soil, rock or ash obtained from borrow areas, dumps or sources other
than cut within the road prism and which is used in the construction of the Works.
It does not include crushed stone or sand obtained from commercial sources.
Borrow Area
An area within designated boundaries, approved for the purpose of obtaining material. A
borrow pit is the excavated pit in a borrow area.
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Bridge
A structure erected over a depression, river, water course, railway line, road or other
obstacle for carrying motor, railway, pedestrian or other traffic, or services, and having a
length, measured between the abutment faces along the centre line at girder bed level, of
6 m or more, except that road-over-rail or rail-over-road structures are always classed as
bridges.
Carriageway
The area normally travelled by vehicles and consisting of one or a number of contiguous
traffic lanes, including auxiliary lanes but excluding shoulders.
Catch-water Drain or Bank
This is a longitudinal drain or bank outside the road prism for diverting water that would
otherwise flow onto the road prism.
Culvert
This is a structure other than a bridge, and provides an opening under the carriageway or
median for drainage or other purposes.
Cut
Cut shall mean all excavations from the road prism, including side drains, excavations
for intersecting roads, including interchanges, and, where classified as cut, excavations
for open drains.
Excess Overburden
Overburden within a borrow area which is not required or unsuitable for use in
construction.
Fill
That portion of the sub-grade composed of approved imported material which lies above
the roadbed and is bounded by the side slopes, shown on the typical cross-sections on the
Drawings, running downwards and outwards from the outer shoulder breakpoints and on
which the selected sub-grade, sub-base, base, shoulders and in the case of dual
carriageways, the median are to be constructed. Material which is imported to replace
unsuitable material excavated from the roadbed is also classified as fill.
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Grade Line
The grade line is a reference line on the Drawings of the longitudinal sections of the road,
indicating at regular intervals the elevations according to which the road is to be
constructed. The grade line may refer to the surface level of the completed road, base or
sub-grade and may indicate the elevations either along the carriageway centre line or
along any designated position on the road cross-section.
Inlet and Outlet Drain
Channels along which water is led into or discharges from culverts, storm-water conduits
and minor bridges.
Median
This is the area between the two carriageways of a dual carriageway road. It includes the
inside shoulders.
Median Drain
Longitudinal drain situated between the inside shoulders of a dual carriageway road.
Mitre Drain
Drain constructed at an angle to the centre line of the road to divert water from the side
drains. Mitre drains include mitre banks placed across side drains.
Pavement Layer
The pavement layer comprises of the upper layers of the road and constitutes the selected
sub-grade, sub-base, base, shoulders and surfacing.
Quarry
A quarry is an open surface working from which stone is removed by blasting or drilling
for use in the Works.
Roadbed
The natural in-situ material on which the fill or, in the absence of fill, any pavement
layers are to be constructed.
Road Prism
That portion of the road construction included between the original ground level and the
outer lines of the slopes of cuttings, fills, side fills and side drains. It does not include
selected sub-grade, sub-base, base, surfacing, shoulders or roadbed.
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Road Reserve
The area of land reserved for the construction and maintenance of the road and for the
accommodation of utility services.
Roadway
The roadway is the area normally used by vehicles and consists of one or a number of
contiguous traffic lanes, including auxiliary lanes and shoulders.
Selected Sub-grade
The selected sub-grade is the upper layer or layers of the sub-grade (when provision is
made for such a classifications in the Specifications of Particular Application, Drawings
and Bill of Quantities) which are controlled both in quality and density by requirements
more stringent than those for fill. It may include suitable roadbed material compacted in
situ.
Side Fill
The side fill is that portion of the imported material within the road prism which lies
outside the fills, shoulders, base and sub-base and is contained within such surface slopes
as shown on the Drawings or as directed by the Engineer. A distinction between fill and
side fill shall only be made if specified in the Specifications of Particular Application,
Drawings and Bill of Quantities.
Side Drain
Open longitudinal drain situated adjacent to and at the bottom of cut or fill slopes.
Site
The area within the road reserve together with all quarries and borrow areas authorized
for use by the Engineer and such other areas of land as the Engineer may designate in
writing from time to time.
Shoulder
(a) When shoulder is referred to as a surface: The area between the outside edge of the
carriageway and the shoulder breakpoint.
(b) When shoulder is referred to as a pavement: The layers on top of the sub-base or, in
the absence of a sub-base, on top of the sub-grade and lying between the outside edge
of the base and the shoulder breakpoint.
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Shoulder Breakpoint
This is the line along which the extended flat planes of the surface of the shoulder and the
outside slope of the fill or the cut intersect. This edge is normally rounded to a
predetermined radius.
Stabilization
The treatment of the materials used in the construction of the roadbed, fill or pavement
layers by the addition of a hydraulic binder such as lime or cement. Concrete and asphalt
are not considered to be materials that have been stabilized.
Slope
Unless otherwise stated, slope is given in terms of the ratio of vertical difference in
elevation between any two points and the horizontal distance between them.
This ratio may also be expressed as a percentage.
Spoil (Material)
Spoil is material originating from construction operations and which is not utilized for
construction purposes.
Spoil Area
A spoil area is a site upon which surplus or unsuitable materials arising out of the Works
are dumped.
Stockpile Area
A stockpile area is an area where material such as topsoil, fill material, gravel or
aggregate is stockpiled prior to use in the Work.
Sub-base
The sub-base is the layer of material of specified dimensions on top of the sub-grade and
below base and shoulders.
Sub-grade
The earthworks constructed on the roadbed up to the floor of the sub-base or, in the
absence of a sub-base, up to the floor of the base and shoulders.
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Subsurface Drain
Covered drain constructed to intercept and remove subsoil water, including any pipes and
permeable material in the drains.
Quarry
Open surface working from which stone is removed by blasting or drilling.
Surface Treatment
Surface treatment is the sealing or resealing of the carriageway or shoulders by means of

one or more successive applications of bituminous binder or tar and crushed stone
aggregate.
1.1.2 Units of Measurement
Symbols for units of measurement conforming to the SI system:
um micron = m x 10-6
mm millimetre
m metre
km kilometre
n mile nautical mile
mm2 square millimetre
m2 square metre
km2 square kilometre
ha hectare
m3 cubic metre
l litre
rad radian
o
C degree Celsius
kg kilogramme
g gram = kg x 10-3
mg/l milligram per litre
t tonne = kg x 103
kg/m3 kilogram per cubic metre
t/m3 tonnes per cubic metre
N newton
N/m2 newton per square metre (Pascal)
MPa megapascal = 106 x N/m2
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1.1.3 Abbreviations
The following abbreviations are used:
ACV Aggregate Crushing Value

AIV Aggregate Impact Value
ALD Average Least Dimension
BA Bitumen Affinity
CBR California Bearing Ratio
CR Crushing Ratio
FI Flakiness Index
LAA Los Angeles Abrasion Value
LL Liquid Limit
LS Linear Shrinkage
MC Moisture Content
MDD Maximum Dry Density
PI Plasticity Index
PL Plastic Limit
PM Plasticity Modulus
(PI x % passing 0.425 mm sieve)
SE Sand Equivalent
SG Specific Gravity
SI International System of Units (Le Système International d'Unités)
SSS Sodium Sulphate Soundness Test, loss on 5 cycles
STV Standard Tar Viscosity
TS Tensile Strength
UC Uniformity Coefficient
UCS Unconfined Compressive Strength
VIM Voids in Mix
VMA Voids in Mineral Aggregates
OPC Ordinary Portland Cement
no Number (units) as in 6 no
No. Number (order) as in No. 6
w/c Water / cement (ratio)
wt Weight
% Per cent
dia Diameter
h Hour
min Minute
1.2 SCOPE OF WORKS
1.2.1 Location and Extent of the Site
Location, extension and limits of the Site are defined and described in the Specifications
of Particular Application.
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1.2.2 Extent of Contract
The extent of the Contract is defined in the Specifications of Particular Application.
1.2.3 Drawings
The Drawings referred to in the Conditions of Contract are those listed in the
Specifications of Particular Application and such further drawings as shall be supplied
under the Contract.
1.2.4 Order of Work
The various operations pertaining to the Works shall be carried out in such a progressive
sequence as will achieve a continuous and consecutive output of fully completed road
works inclusive of all bridge works and culverts within the time limits specified in the
Contract. Generally the Contractor shall start at one end of the road and progress
continuously towards the other without leaving any isolated section or sections of
uncompleted road, provided always that the land upon which the Works are to be
constructed has been acquired in its entirety and the encumbrances and services thereon
removed.
1.2.5 Method of Construction
The Contractor shall submit to the Engineer not later than 28 days from the date of award
of the Contract a general description of his proposed arrangements and methods for the
execution of the Works, including inter alia temporary offices, buildings, access roads,
equipment and its intended production output, working shift arrangements, labour
strength, skilled and unskilled and supervision arrangements, power arrangements,
supply of materials including a materials utilization programme, stone crushing,
aggregate production and storage, cement handling, concrete mixing and handling,
methods of excavation, dealing with water testing methods and facilities.
During the execution of the Works, the Contractor shall also submit to the Engineer full
and detailed particulars of any proposed amendments to the arrangements and methods
submitted in accordance with the foregoing.
The Contractor shall submit in writing to the Engineer, the hours which shall be
considered normal working hours together with the day of the week which is to be set
aside for rest. When approved these shall be maintained throughout the continuance of
the Contract. If the Contractor wishes to execute permanent work outside these hours, he
shall obtain the written permission of the Engineer at least 24 hours in advance to enable
the Engineer to make provision for supervision of such work.
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1.2.6 Programme
In accordance with the terms of the Conditions of Contract, the Contractor shall submit to
the Engineer for his approval, a fully detailed and time related programme showing the
order of procedure and method in which he proposes to carry out the Works. The
Contractor shall supply together with his programme an expenditure chart superimposed
on it showing his monthly anticipated expenditure. The programme shall be submitted to
the Engineer not later than 28 days from the date of award of the Contract.
If at any time it should appear to the Engineer that the actual progress of the Works does
not conform to the programme referred to above, the Contractor shall produce, at the
request of the Engineer, a revised programme showing the modifications to the approved
programme necessary to ensure completion of the Works within the time for completion
as defined in the Conditions of Contract.
1.2.7 National Specifications
Certain specifications issued by national or other widely recognized bodies are referred to
in the Standard and Specifications of Particular Applications. Such specifications shall be
defined and referred to as national specifications as hereunder and shall be the latest
editions of such national specifications available twenty eight days prior to the date set
for the submission of Tenders.
The Contractor may propose that the materials and workmanship be defined in
accordance with the requirements of other equivalent national specifications and the
Contractor may execute the Works in accordance with such other national specifications
as may be approved by the Engineer. A copy of the national specification together with a
translation into English language of a national specification in another language shall be
submitted to the Engineer with request that it be adopted.
In referring to specifications the following abbreviations are used:
BS British Standard
BSCP or CP British Standard Code of Practice
AASHTO American Association of State Highway

And Transportation Officials
ASTM American Society of Testing and Materials
ISO International Organization for Standardization
1.2.8 General Construction Requirements
The following general requirements shall apply:
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(a) The Contractor shall provide adequate lighting where work is being executed at night
and shall provide and install any additional lighting which the Engineer may require
in order to watch and supervise the Works and carry out any testing and examination
of materials.
(b) Materials available on the Site or materials made available or supplied by the
Employer shall be used solely for the execution of the Works.
(c) The Contractor shall minimize the pollution of and disturbance to lands, roads and
other places on and around the Site. No trees or other vegetation shall be removed
except to the extent necessary for the Works.
(d) The Contractor shall ensure that temporary access is provided to all properties
adjacent to the Site for the duration of the Contract.
(e) The Contractor shall comply with the current Government regulations with regard to
the transport, storage and use of explosives and radio-active materials.
(f) The Contractor shall take all reasonable precautions:
(i) in connection with any rivers, streams, waterways, drains, water courses, lakes
and the like to prevent silting, erosion of beds and banks and pollution of the
water so as to affect adversely the quality of appearance thereof or cause injury
or death to human, animal or plant life;
(ii) in connection with underground water resources (including percolating water)

to prevent any interference with the supply to or abstraction from such sources
and to prevent pollution of water so as to effect adversely the quality thereof.
The Contractor shall provide, maintain and remove on completion of the Works,
settling lagoons and other facilities to minimize pollution due to the Contractor's
operations including but not limited to quarrying, aggregate washing, concrete
mixing and grouting.
(g) The Contractor shall provide weather recording equipment as directed by the
Engineer for measurement of temperature, humidity, rainfall and wind and shall keep
daily records of the weather on approved forms.
(h) If the Contractor provides a radio communications network around the Site, he shall
allow the Engineer reasonable use of the facilities. Any requirements of the provision
of radio communications for the sole use of the Engineer are stated in the
Specifications of Particular Application.
(i) All buildings erected by the Contractor upon the Site and campsites, and the layout
of the buildings and the sites, shall comply with Laws and all local Byelaws in so far
as they are applicable.
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(j) The Contractor shall be absolutely and solely responsible for the safety and security
of Temporary Works including (but not limited to) all work yards, pilings, staging,
dams, cofferdams, trenches, fencing or other works and for the equipment in
connection therewith which may be erected or provided for the carrying out of the
Contract and for the execution of the Works. This provision shall be applicable to all
temporary works and equipment whenever provided and erected by the Contractor
for the purpose of or in connection with the Works.
Examination by the Engineer or the Engineer's Representative of the Contractor's

Temporary Works or of the drawings connected therewith shall not absolve the
Contractor from any liability imposed upon him by the provisions of the Contract.
1.2.9 Water Supply
The Contractor shall provide a clean and sufficient supply of fresh water, both for
construction of the Works and for all houses, offices, laboratories and workshops. He
shall undertake all arrangements including pipe lines and meters for connecting to local
water mains and the provision of pumps, storage tanks and water conveyance where
necessary, payment for all fees and water charges and the satisfactory removal of all such
arrangements and provisions on completion of the Works.
The water shall be reasonably clear of suspended solids and free from any matter in
quantities considered by the Engineer to be deleterious to the work. Water supplied to all
the offices, laboratories and houses shall be wholesome and potable to the satisfaction of
the Medical Offices in the Area.
1.2.10 Use of the Site
The Contractor shall restrict his activities to within the Site and shall avoid entry on to
any other lands except where the Contractor has made his own arrangements for such
entry. Any trespass, damage or claims arising from such entry shall be the sole
responsibility of the Contractor, who shall hold the Employer indemnified against all
claims arising from such trespass or damage.
Existing access to all land or property outside the road reserve shall be maintained by the
Contractor during the continuance of the Works. The cost of such maintenance shall be
deemed to be covered by and included in the rates tendered for the Contract.
1.2.11 Protection of the Work
The general obligations of the Contractor in terms of the General Conditions of Contract,
"Care of Works", shall include, inter alia, the following:
(a) The provision of temporary drainage works such as drains, open channels, banks,
etc., and the furnishing and operating of temporary pumps and such other equipment
as may be necessary to adequately protect, drain and de-water the Works and
temporary works. This will be in addition to any permanent drainage works
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specified and installed, and in addition to any temporary drainage works specifically
paid for separately, as in the case of by-passes.
(b) Care shall be exercised not to allow material in borrow pits to become excessively
wet, to keep all completed layers properly drained, not to cause dumps of material on
completed layer work that inhibit surface drainage or form wet spots under and
around dumps, and to protect all parts of the work against erosion by floods and rain.
Material shall not be spread on a layer that is so wet that damage could be caused to
the layer during compaction of a subsequent layer or when the road is opened to
traffic.
When material is spread out on the road, it shall, during wet periods, be given a good
cross-fall and a light compaction on the surface with a steel-wheeled roller, in order
to facilitate run-off during rainy weather.
(c) Fill and cut slopes shall be promptly repaired whenever damaged by surface water.
Where erosion occurs on high fill, the slopes shall be repaired by cutting back to
form benches and compacting the backfill mechanically to the specified controlled
densities, using suitable small equipment.
(d) Excavations for pipe drains, culverts, service ducts and similar structures shall be
adequately protected against possible ingress of water during rainstorms.
(e) All completed layer work shall be protected and maintained until the following layer
is applied. Maintenance shall include immediate repair of any damage or defects
which may occur and shall be repeated as often as is necessary to keep the layer
continuously intact and in good condition.
(f) Before any completed layer is primed or a following layer constructed thereon, any
damage to the existing layer shall be repaired, so that after repair, or reconstruction if
necessary, it will conform in all respects to the requirements specified for that layer.
All repair work other than minor surface damage repairs shall be submitted to the
Engineer for inspection before covering up.
The previously constructed layer shall also be thoroughly cleaned of all foreign
material before construction of a following layer of application of a prime coat,
surfacing or surface treatment. In the case of all bituminous work in particular, the
existing layer shall be thoroughly broomed and all dung, clay, mud and other
deleterious material completely removed. Where necessary, the surface shall be
sprayed with water before, during and after brooming to remove all foreign material.
Work performed as part of the above obligations shall not be measured and paid for
separately, and the cost thereof is to be included in the rates tendered for the various
items of work requiring protection and for the Contractor's establishment on Site.
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1.2.12 Workmanship and Quality Control
The onus rests with the Contractor to produce work which conforms in quality and
accuracy of detail to the requirements of the Specifications of Particular Applications and
Drawings, and the Contractor must, at his own expense, institute a quality control system
and provide experienced engineers, foremen, surveyors, materials technicians, other
technicians and other technical staff, together with all transport, instruments and
equipment, to ensure adequate supervision and positive control of the Works at all times.
The cost of all supervision and process control, including testing, so carried out by the
Contractor shall be deemed to be included in the rates tendered for the related items of
work, except that the cost of certain tests and the provision of certain items of testing and
sampling equipment may be paid for separately as provided for in those sections of the
Specifications of Particular Applications where this applies.
The Contractor's attention is drawn to the provisions of the various sections of the
Specifications of Particular Applications regarding the minimum frequency of testing that
will be required for process control. The Contractor shall, at his own discretion, increase
this frequency where necessary to ensure adequate control.
On completion of every part of the work and submission thereof to the Engineer for
examination, the Contractor shall submit to the Engineer the results of all relevant tests,
measurements and levels indicating compliance with the Specifications of Particular
Applications.
1.2.13 Progress Photographs
Colour photographs showing the progress of the Works shall be taken every month by the
Contractor from positions to be selected by the Engineer.
The number of photographs required is given in the Specifications of Particular

Applications. Prints 200 x 150 mm of each photograph together with the negatives shall
be handed to the Engineer. Each photograph shall be numbered and a statement shall be
submitted giving the locations, date when taken and a brief description or title.
1.2.14 Final Clearance
Upon completion of each section of the Works, the Contractor shall cleanup the Site,
remove all temporary buildings, plant and debris. He shall level off and fine grade all
excavated material that is surplus to requirements. The whole of the Site shall be left in a
clean and workmanlike condition to the satisfaction of the Engineer.
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1.2.15 Measurement and Payment
No separate payment shall be made for any work included in this Paragraph and the costs
shall be deemed to be included in the rates of the relevant items entered in the Bill of
Quantities.
1.3 LEGAL RELATIONS AND RESPONSIBILITY
1.3.1 Preservation and Maintenance - Fences and Gates
The Contractor shall be responsible for ensuring the safety of persons and property on the
Site and for ensuring that livestock cannot stray as a result of his work. When existing
fences and gates have to be removed or altered for the proper execution of the Works, the
Contractor shall erect temporary fencing and gates and, if required, provide watchmen to
ensure that livestock cannot stray, provided always that the fences or gates referred to
have not been the subject of a negotiated agreement for compensation whereby the owner
or tenant has been made responsible for such removal or alteration.
1.3.2 Protection of Existing Works and Services
The Contractor shall acquaint himself with the position of all existing services such as
sewers, surface water drains, cables for electricity and telephone, telephone and lighting
poles, water mains, and the like, before commencing any excavation or other works
likely to affect the existing services.
Where work is to be carried out in the vicinity of overhead power lines, the Contractor
shall ensure that all persons working in such areas are aware of the relatively large
distance that high voltage electricity can "short" to earth when cranes, or other large
masses of steel, are in the vicinity of power lines. The Contractor's attention is drawn to
BS 162 which gives safe clearance for the various voltages.
The Contractor will be held liable for all damages to road, irrigation ditches, main pipes,
electric cables, lines or services of any kind caused by him or his Sub-Contractor's in the
execution of the Works. The Contractor must make good any damage without delay and,
if necessary, carry out any further work ordered by the Engineer's Representative. The
Contractor shall indemnify the Employer against any claims in this respect.
In all cases where such works or services are exposed, they shall be properly shored,
hung up or otherwise protected. Special care must be exercised in filling and compacting
the ground under mains, cables, etc., and to leave uncovered exposed water meters,
stopcock boxes and similar items.
Installations adjacent to the Works shall be kept securely in place until the work is
completed and shall then be made as safe and permanent as before.
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Notwithstanding the foregoing requirements, and without reducing the Contractor's

responsibility, the Contractor shall inform the Engineer immediately if any existing
works or services are exposed.
1.3.3 Dealing with Water
Except as otherwise specified, the Contractor shall be responsible for dealing with water,
whether from existing drainage systems, water courses, underground springs or any other
sources or cause. In discharging and diverting water he shall avoid flooding or damaging
other works or services, causing erosion and polluting water courses.
1.3.4 Health, Safety and Accidents
The Contractor shall ensure, so far as is reasonably practicable and to the satisfaction of
the Engineer, the health, safety and welfare at work of his employees including those of
his sub-contractors and of all other persons on the Site. His responsibilities shall include:
(a) the provision and maintenance of equipment and systems of work that are lighted,
safe and without risks to health;
(b) the execution of suitable arrangements for ensuring safety and absence of risks to
health in connection with the use, handling, storage and transport of articles and
substances;
(c) the provision of protective clothing and equipment, first aid stations with such
personnel and equipment as are necessary and such information, instruction, training
and supervision as are necessary to ensure the health and safety at work of all persons
employed on the Works all in accordance with Laws and all local Bye-Laws;
(d) designation as Safety Officer of one of his senior staff who shall have specific
knowledge of safety regulations, and experience of safety precautions on similar
works and who shall advise on all matters affecting the safety of workmen and on
measures to be taken to promote such safety;
(e) the provision and maintenance of access to all places on the Site in a condition that is
safe and without risk of injury;
(f) the provision of adequate water-borne sanitation, refuse collection and disposal,
complying with the Laws and all local Bye-Laws and to the satisfaction of the
Engineer, for all houses, offices, workshops, and laboratories erected on the camp
site or sites;
(g) the provision of suitable latrines and other sanitary arrangements at sites where work
is in progress to the satisfaction of the Medical Officer in the area and of the
Engineer;
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(h) the execution of appropriate measures in consultation with the appropriate Public
Health Authority to control within the Site, including the camp sites, mosquitoes,
flies and pests including the application of suitable chemicals to breeding areas;
(j) reporting details of any accident to the Engineer as soon as possible after its
occurrence.
(k) the provision and maintenance of adequately equipped first aid station on the site of
the works.
1.3.5 Accommodation of Traffic
Throughout the duration of the contract, traffic shall be maintained over a reasonably
smooth travelled way which shall be marked by all appropriate legal signs, delineators,
guiding devices and other methods in accordance with the Government Regulations.
The Contractor shall schedule the work to keep to a minimum and consistent with the
physical requirements of the Contract, the amount of existing pavement and/or facilities
that are destroyed or substantially torn up at any one time.
It is the responsibility of the Contractor to protect the public from damage to person and
property which may result directly or indirectly from any construction operation.
The Contractor is placed on notice that maintenance and protection of traffic over the
work during construction is considered as important as the construction itself. The
Contractor shall therefore, at all times, conduct his operations in a manner to insure the
convenience of the motorist, the pedestrian and the abutting property owners and their
safety as well as the safety of his own employees.
Quantities.
1.4 SERVICES AND TRAFFIC
1.4.1 Diversion of Services
The Contractor will be required to make all necessary arrangements with Local
Authorities, Corporations and owners for all necessary removal and reinstatement works
for existing services, which necessary removal and reinstatement works will generally be
carried out by or on behalf of the Local Authorities, Corporations or owners. The
arrangements for such works shall be agreed by the Engineer. The Contractor shall pay
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the costs of such works on behalf of the Employer and shall be reimbursed therefore by
the Employer.
1.4.2 Closure of Roads
When a road used by the Contractor for transporting labour or equipment or for delivery
of any material for the Works is closed, the Contractor shall obey such closure order and
shall suspend operations or use alternative roads. The fact that the Contractor is
performing work for the Ministry will give him no special privileges in this respect.
1.4.3 Access to Construction Site, Borrow Pits and Quarries
The Contractor shall be responsible for providing and maintaining access to and along
the Site for his own purposes, including whatever temporary river crossings he may
require.
1.4.4 Diversions
(a) General
Where in the opinion of the Contractor it is preferable not to pass the traffic through
the Works, the Contractor, upon previous approval of the Engineer, will be allowed
to construct and maintain diversions, provided that such diversions are passable to
traffic at all times.
It is the Contractor's responsibility to plan and execute the construction of any

diversions deemed necessary during construction works. Prior approval of the
diversion routes must be cleared with the land owners concerned and the Engineer
before commencing the construction of any diversions.
The length of the diversions shall be of the shortest practical length having regard to
gradient and obstructions and shall be sited as agreed between the Engineer and the
Contractor.
(b) Construction
For the diversion of an existing trunk road, the width of the temporary carriageway
shall be the same as the width of the existing carriageway or 6m whichever is the
lesser.
For the diversion of a minor public road or a private road, the width of the temporary
carriageway shall be the same as the existing carriageway, or such lesser width as the
Highway Authority or owner may agree, and to the satisfaction of the Engineer.
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The verges of the diversion shall be cleared and maintained clear for a width of at
least 1.5 m beyond the edge of the carriageway or such lesser width as the Engineer
may agree.
The gradient of any deviation shall not be greater than 10% except with the express
approval of the Engineer, and any acute intersection of gradient shall be properly
graded to a smooth vertical curve, to the satisfaction of the Engineer. The riding
surface shall have a minimum thickness of 150 mm gravel wearing course.
Temporary ditches and culverts of adequate size and strength shall be provided
alongside and under the temporary road to the satisfaction of the Engineer.
Official regulatory and warning signs shall be posted at each entry to the diversions
and inside the diversions as deemed necessary by the Engineer.
c) Maintenance
The surface of all diversions shall be maintained smooth, free from ruts and potholes
and loose material, and shall be graded and watered as required.
1.4.5 Haul over Completed Road
The operation of hauling equipment over portions of the road completed up to the top of
any stabilized layer, sub-base, base or surfacing shall be limited to equipment with an
axle load not exceeding the legal axle load limit.
1.4.6 Liaison with Government and Police Officials
The Contractor shall consult with officials of the Police and Government in the area
regarding their requirements in the control of traffic and other matters and shall provide
all assistance or facilities which may be required by such officials in the execution of
their duties.
(a) Diversion of Services
A provisional sum shall be entered in the Bill of Quantities to provide for the
Contractor's expenditures in connection with removal and reinstatement works for
existing services.
The Contractor will be reimbursed the net sum of such expenditure upon
presentation of receipts.
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1 / GENERAL
The Contractor's overhead and expenses in making the arrangements and affecting
payment shall be covered by a provisional item allowing a percentage of the net cost
to be entered by the Contractor.
(b) Other
Unless an item for construction and maintenance of diversions is specifically entered

in the Bill of Quantities, no separate payment shall be made for any work included in
this Paragraph and the costs shall be deemed to be included in the rates of the
relevant items entered in the Bill of Quantities.
1.5 EQUIPMENT
1.5.1 List of Equipment
Before starting any construction activity, the Contractor shall submit a detailed list of the
equipment to be used during construction to the Engineer.
The list will state:
type of equipment
identification codes (name and inventory code)
manufacturers name
year of manufacture
proposed assignments on the project.
1.5.2 Working Condition of the Equipment
All equipment on Site shall be in perfect working condition.
The Engineer shall check the performance and output of the equipment during the Site
Trials specified for each construction process and carried out as specified in Clause 2.3.1.
If the performance of the equipment does not conform to the output assumed to complete
the work as stated in the work programme or does not permit achievement of the
specified quality, the Engineer will not permit construction work on the road until the
Contractor proves full compliance with the working plan and specifications.
1.5.3 Maintenance of Equipment
The Contractor shall maintain his equipment on Site. Therefore, he shall furnish
workshop, skilled personnel and transport facilities to the Site and keep it during the
Contract at his own expense.
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1 / GENERAL
Quantities.
1.6 FACILITIES OF THE ENGINEER
1.6.1 Housing, Accommodation for Resident Engineer and Staff, Offices and
Laboratories
The Contractor shall, if so ordered, supply houses, offices, laboratories, survey and
laboratory equipment and furniture for the Resident Engineer and his staff including
senior staff, junior staff and technicians.
A description of the number and type of houses, offices, laboratories, equipment and
furniture required is given in the Specifications of Particular Application.
1.6.2 Time for Erection of the Resident Engineer's Staff Houses, Offices and
Laboratories
All houses, offices and laboratories to be provided under the Contract shall be handed
over to the Resident Engineer in finished and fully habitable condition not later than sixty
days after the Engineer's order to commence work and such buildings shall be to the
entire satisfaction of the Engineer.
Should the Contractor fail to hand over the houses, offices and laboratories within the
period specified, the Engineer will make such alternative arrangements as he considers
necessary. These arrangements may include the use of hotels, rented accommodation and
the hire or purchase of caravans, porta-cabins, etc. The Contractor will be responsible for
all costs of such temporary arrangements made by the Engineer, including that of
additional transport.
1.6.3 Maintenance of the Resident Engineer's Staff Houses, Offices, Laboratories,

Furniture and Equipment
The Contractor shall keep all buildings, accesses, services and facilities provided by him,
for the use of the Resident Engineer and his staff, in a well maintained, clean and fully
habitable condition, 24 hours per day until the expiry of the maintenance period, all to the
satisfaction of the Engineer.
The Contractor shall also provide an adequate refuse collection service for all houses,
offices and laboratories, to the satisfaction of the Engineer.
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1 / GENERAL
The Contractor shall also maintain all furniture and equipment provided by him in a
reasonable state of repair and usable condition and shall replace promptly any item which
becomes unserviceable or is lost, to the satisfaction of the Engineer.
1.6.4 Insurance and Ownership of the Resident Engineer's Staff Houses, Offices,
Laboratories, Furniture and Equipment
All buildings, furniture and equipment provided by the Contractor for the Resident
Engineer's staff houses (Senior and Junior), offices and laboratories shall be insured by
the Contractor against any loss or damage by accident, fire or theft for the duration of the
Contract, including the period of maintenance.
On completion of the Contract, the ownership of the laboratory equipment and survey
equipment shall revert to the Employer. Unless otherwise stated the ownership of all
houses, offices, laboratories and furniture shall revert to the Contractor.
1.6.5 Attendance upon the Resident Engineer and His Staff
In the Engineer's offices and laboratories the Contractor shall provide a full time office
attendant and cleaning equipment, and shall keep the offices and laboratories in well
maintained, clean and habitable condition.
The Contractor shall provide all tools, protective clothing, wooden pegs, iron pins and
pickets, water, cement and aggregate for concreting and all assistance as may be required
by the Engineer and his staff for setting out, measuring and checking the Works.
The Contractor shall provide adequate security by day and by night for the Resident
Engineer's offices, laboratory, vehicles and houses, and for the Resident Engineer's staff.
This shall include the provision of suitable gates and fencing and the full-time attendance
of permanent watchmen, all to the satisfaction of the Engineer.
1.6.6 Provision of Vehicles
The Contractor shall, if so ordered, supply new vehicles and maintain them for the use of
the Resident Engineer and his staff.
A description of the number and types of vehicles to be provided is given in the

Unless otherwise specified, the vehicles shall be owned by the Contractor and be licensed
and comprehensively insured by the Contractor for use on the public highway within the
country by any licensed driver authorized by the Resident Engineer together with
authorized passengers and the carriage of goods and samples. The Contractor shall
provide fuel, oil, maintenance including replacing defective parts, tyres and the like,
whenever required, in conformity with the vehicle manufacturers recommendations or as
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1 / GENERAL
may be necessary. The vehicles shall be fuelled, oiled and maintained as aforementioned
until release by the Resident Engineer. The vehicles on being released shall revert to the
Contractor. Each vehicle shall be fitted with a fire extinguisher, first aid kit, tow hook
and rope, tool kit, spare wheel, wheel wrench, jack and handle and seat belts.
The Contractor shall provide a similar replacement for any vehicle out of service for
more than twenty four hours, and shall replace any vehicle by a similar new vehicle after
it has completed 100,000 km if, in the opinion of the Engineer, such vehicle cannot be
maintained in a satisfactory condition.
The Contractor shall provide competent and licensed drivers approved by the Engineer
for the vehicles indicated above. Sufficient drivers shall be available at night and at
weekends whenever work is being carried out on Site.
1.6.7 Removal of Camps
Unless otherwise instructed, upon completion of the Contract, and after receiving
approval in writing from the Engineer, the Contractor shall take down and remove all
structures forming part of his own camp and that of the Resident Engineer, and shall
arrange for the disconnection of the water supply, remove all drains and culverts, backfill
trenches, fill in all latrine pits, soak-aways and other sewage disposal excavations, with
the exception of items and services which are required to revert to the ownership of the
Employer and shall restore the site, as far as practicable, to its original condition and
leave it neat and tidy to the satisfaction of the Engineer.
Facilities of the Engineer shall be paid for at contract price for each of the relevant pay
items described in the Specifications of Particular Applications and entered in the Bill of
Quantities, which prices and payment shall be full compensation for all labour, plant,
equipment, tools and incidentals necessary to complete the work prescribed in this
paragraph.
When the Bill of Quantities does not contain an estimated quantity or a lump sum, the
work shall not be paid for directly but shall be considered as a subsidiary obligation of
the Contractor under other contract items.
1.7 TAKE OVER OF THE SITE
1.7.1 Information Furnished by the Employer
This sub-clause shall be read in conjunction with the relevant sub-clauses in CCI and
CCII.
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1 / GENERAL
Certain information contained in these Contract Documents or provided separately is

being offered in good faith but in the circumstances pertaining to the type of information
supplied, no guarantee can be given that all the information is necessarily correct or
representative of the in situ conditions.
This applies specifically to all soil tests, soil mapping, drilling results, geophysical
surveys, geological reports, borrow-pit information, material surveys and reports and
similar information, the accuracy of which is necessarily subject to the limitations of
testing, sampling, the natural variation of material or formations being investigated and
the measure of certainty with which conclusions can be drawn from any investigations
carried out. It also applies to any materials utilization diagram supplied, as the diagram
may be subject to major alterations during the progress of the work, depending on site
conditions.
The Employer accepts no liability for the correctness or otherwise of such information
supplied or for the resulting damages, whether direct or consequential, should it prove
during the course of the Contract that the information supplied is either not correct or not
representative. Any reliance which the Contractor places on this information shall be at
his own risk.
The Contractor's attention is drawn to his obligation with regard to the inspection and
examination of the Site as detailed in the General Conditions of Contract.
The Engineer reserves the right to adjust foundation levels and other levels for
construction below ground level, in the light of information that becomes available as
general excavation proceeds upon the site.
1.7.2 Provision of Land
(a) The Employer shall make available free of charge to the Contractor all land to be
permanently occupied by the Works as indicated on the Drawings or as detailed in
the Specifications of Particular Application. Such land shall include the road
reserve, deviations, stockpile, spoil and borrow areas, and access roads thereto.
(b) All other land that may be required by the Contractor for the construction of the
works including temporary works as described hereunder will also generally be
provided by the Employer.
It is the Contractor's responsibility to acquire land for the positioning of all offices,
accommodation, stores and testing facilities for his and the Employer's organization,
and also for his equipment yards and workshops and for all temporary works and for
the reinstatement of such land on the completion of the Contract to the satisfaction of
the owners. The Contractor shall obtain the approval of the Engineer to the
positioning of offices, accommodation, stores, testing facilities, equipment yards and
workshops before such land is acquired and he shall indemnify the Employer against
all claims and charges in respect of the occupation, use and reinstatement of the land.
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1 / GENERAL
(c) Where it is necessary for the Employer, in fulfilling his obligations, to acquire any of
the above land during the Contract, the Contractor shall determine the ownership of
and shall pay the cost of the land or rent, and/or compensation as valued by the
Commissioner of Lands.
The Engineer's approval must be sought before entry upon such land. The Contractor
shall pay the costs of compensation including the compensation for crops in
connection with such acquisition on behalf of the Employer and be reimbursed
therefore by the Employer through the Contract.
Although the Contractor may, in the first instance, provide the money for the
purchase of the land, all such land shall be the property of the Employer.
(d) Where the Contractor chooses to use an alternative source of material to the borrow
pit or borrow area provided by the Employer, the terms of this Clause do not apply.
In that case the Contractor is solely responsible for acquisition of the land and its
disposal after completion of the Works.
Should the Contractor request the purchase of land for any purpose and this land is
subsequently not used, the Contractor shall be responsible for all costs associated
with the purchase and disposal of such land.
1.7.3 Setting Out
The Contractor's attention is drawn to the requirements of the General Conditions of

Contract regarding setting out.
The Contractor shall submit to the Engineer the method of setting out he proposes to
employ. To ensure beyond doubt that the complex elements of the road, such as traffic
interchanges, structures and other important features, are located truly and correctly, the
Contractor shall check all setting out by a different method. The Engineer may at any
time request the Contractor to submit proof that his setting out has been satisfactorily
checked.
Special care shall be exercised during construction not to damage, displace or disturb
property and trigonometry survey beacons. If such beacons are disturbed or destroyed by
the Contractor, they shall be replaced within three months by a registered land surveyor,
at the Contractor's expense. In cases where displacement of or damage to such beacons is
unavoidable, the Contractor shall notify the Engineer in good time so that he may arrange
to have such beacons suitably referenced and later on reinstated. The cost of such work, if
paid for by the Contractor, shall be reimbursed as "extra work" as prescribed in the
General Conditions of Contract.
To protect beacons, the boundary fences of the road reserve shall be splayed at corners so
as to avoid the use of corner posts in the same position as property and cadastral beacons,
all as shown on the Drawings.
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1 / GENERAL
Accurate control of line and level shall be provided by the Contractor at all stages of
construction. In respect of the road itself, control shall be at 25 m intervals, or such closer
intervals as may be directed, on horizontal and vertical curves. Wherever necessary, but
particularly on completion of the sub-grade and the base, the Contractor shall re-establish
stake-line pegs at sufficiently close intervals to accurately determine the edges of the base,
surfacing and especially kerbing, guard rails and other road elements permanently
exposed to the eye.
The Contractor shall make all provisions necessary for the Engineer to check the setting
out of the Works and shall be in attendance to agree measurements and levels before
construction works commence.
1.7.4 Notice, Signs and Advertisements
At each end of the Works and on an approved spot, the Contractor shall provide and erect
a signboard of sound weatherproof construction, painted by an approved firm of sign
writers, in accordance with the details shown on the Drawings or directed by the
Engineer.
These signs are to be erected not later than one month after the Contractor has been given
access to the Site.
The signboard shall be painted with the legend in English.
No sign boards other than those specified above will be permitted on or adjacent to the
Works, except that the Contractor may permit each of his sub-contractors to display one,
and only one, signboard of less than 2 m2 at the Works office.
The Engineer shall have the right to have any sign, notice or advertisement moved to a
better position or to have it removed from the Site of the Works if it should in any way
prove unsatisfactory, inconvenient or dangerous to the general public.
All advertisements, notices and temporary signs shall be removed by the Contractor by
the end of the maintenance period.
(a) Provision of land
A provisional sum shall be entered in the Bill of Quantities to provide for the
Contractor's expenditures in connection with purchase of land or rent and for
compensation of land acquired by the Contractor during the Contract on behalf of the
employer.
The Contractor will be reimbursed the net sum of such expenditure upon
presentation of receipts. The Contractor's overhead and expenses in making the
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1 / GENERAL
arrangement and affecting payment shall be covered by a provisional item allowing a

percentage of the net cost to be entered by the Contractor.
Royalties and other costs due on materials from whatever source shall not be
reimbursed, but shall be included in the rates for providing such materials.
(b) Setting out
Setting out shall not be measured and paid for directly and compensation for the
work involved shall be deemed to be covered by the rates of the relevant items
entered in the Bill of Quantities.
(c) Notice, Signs and Advertisements
No separate payment shall be made for providing and erecting signboards and the
work involved shall be deemed to be covered by the rates of the relevant items
entered in the Bill of Quantities.
1.8 OVERHAUL
1.8.1 Definitions
(a) Overhaul material
Overhaul material shall be transported material to which overhaul applies when

hauled in excess of the free haul distance and shall include only the following
materials:
(i) Gravel, soil, or rock materials used in the construction of fills, side fills, sub-
grade, gravel sub-base, gravel base, gravel shoulders, banks and dykes
(ii) Topsoil, gravel ordered by the Engineer as wearing course for bypasses and
selected gravel material used for backfilling drain and culvert excavations, but
excluding permeable material used in subsurface drains.
(iii) Spoil material resulting from the authorized excavations of the road prism,
drains, culverts and other structures and from fills in redundant bypasses.
(iv) Crushed material used in the construction of sub-base and base, but only when
overhaul applies
Overhaul shall not be measured for payment for graded crushed stone base course
material, crushed and/or screened crushed stone aggregate or chippings used in
asphalt base and surfacing, pre-coated chippings for gap-graded asphalt surfacing,
premixed bituminous material, slurry seal or concrete, regardless of the source of
supply.
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1 / GENERAL
(b) Overhaul
Overhaul shall be applicable to all overhaul material in respect of haul in excess of

the free haul distance and shall be measured by the product of the volume of material
hauled, multiplied by the overhaul distance.
(c) Haul distance
The haul distance for cut to fill or side fill shall be the distance between the centre of
volume of the overhaul material in the cut before excavation and the centre of
volume of the portion of the work constructed with the overhaul material.
The distance between the centres of volume shall be measured along the centre line
of the road, and any additional distance of haul due to following a different haul
route will not be considered. For computing overhaul quantities for payment, cut and
fill volumes for ramps, road approaches and connections on either side of the road
shall be considered as concentrated at the centre line of the main roadway under
construction, unless otherwise specified in the Specifications.
The haul distance for borrow material and cut to spoil material shall be measured
along the shortest route determined by the Engineer as feasible and satisfactory. If the
Contractor chooses to haul material over some other longer route, computations for
payment shall nevertheless be based on the haul distance measured along the shortest
route designated by the Engineer. The haul distance for borrow materials and cut to
spoil shall be measured to the nearest 0.1 km.
(d) Free haul distance
The free haul distance shall be the distance up to which overhaul material must be
hauled before overhaul becomes payable. The distance shall be 1.0 km in the case of
all overhaul materials unless otherwise specified in the Specifications.
(e) Overhaul distance
The overhaul distance shall be the haul distance as defined above less the free haul
distance measured to the nearest 0.1 km.
The quantity of material overhauled shall in all cases be measured in the same manner as
the item to which the overhaul applies.
The unit of measurement and payment shall be the cubic metre of overhaul material
hauled in excess of the free haul distance multiplied by the overhaul distance.
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1 / GENERAL
Overhaul of material in excess of that required for the completion of the Works or
otherwise not authorized by the Engineer will not be measured for payment purposes.
Items for overhaul shall be entered in the relevant Paragraphs of the Specification and the
Bill of Quantities.
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2 / CONTROL OF WORK AND MATERIALS
SECTIONNo 2
CONTROL OF WORK AND MATERIALS
2.1 AUTHORITY OF THE ENGINEER
2.1.1 Construction Requirements
When, upon examination by the Engineer or his authorised representative, any part of the
Works or any plant or material is found not to conform to the requirements or is at any
stage before final acceptance damaged so that it no longer conforms with the
requirements of the Specifications, the Engineer may order its complete removal and
replacement, at the Contractor's expense, with satisfactory work, plant or material or he
may permit the Contractor to apply remedial measures in order to make good any such
defects or damage. The actual remedial measures taken shall at all times be entirely at the
Contractor's own initiative, risk and cost, but subject to the Engineer's approval regarding
the details thereof.
In particular, remedial measures must ensure that the final product is in full compliance
with the Specifications, shall not endanger or damage any other part of the Works and
shall be carefully controlled and submitted to the Engineer for examination when
completed or at any intermediate stage as may be required.
For the guidance of the Contractor, an indication of what would normally be required in
the more common cases of defects or damage is given below, but the Engineer will in no
way be bound to approve of or adhere to the measures given below, as the actual
remedial measures will be dictated by the circumstances of each particular case.
(a) Earthworks
(i) Where a cut slope has been over-excavated or undercut, backfilling will not
normally be allowed and the entire slope may have to be trimmed to obtain a
uniform slope.
(ii) Where the floor of a cutting has been taken too deep, it will normally require
backfilling and re-compaction with selected gravel in the case of soil or gravel
excavation, and with crushed-stone material, suitably sized rock or mass cement
concrete in the case of hard excavations. All necessary measures shall be taken
to drain away ground water that may accumulate in backfill sections.
(iii) Excess width of fills will have to be trimmed down.
(iv) Where erosion has damaged the surface of cuts or fills, the damage shall be
made good by backfilling with suitable material and re-trimming. In more
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serious cases the slopes may have to be cut back and backfilled by benching and
compaction to the required standard of compaction with suitable small
equipment, and then re-trimmed.
(b) Stabilizing
Any sections failing to meet the requirements specified, or damaged to the extent that
they require breaking up and re-compaction, will have to be re-stabilized with the
type and quantity of stabilizing agent ordered by the Engineer. The Engineer may
also order that the layer be removed entirely and be replaced with fresh material to be
stabilized.
(c) Local Defects in Pavement Layers
Where remedial measures are taken to make good local defects, the length and width
of the area to be repaired by machines shall be such as will be necessary to
accommodate the full width of the machines used and a reasonable length to ensure
effective operation.
The depth to which material will have to be recovered will depend on the type of
material. Gravel will require breaking up to a depth of at least 75 mm and crushed
stone will usually require breaking up over its full depth. Asphalt material will
normally require removal to its full depth.
(d) Concrete
Repair of concrete work, when permitted by the Engineer, will normally require the
cutting back and complete removal of any weak or honeycombed sections and
making good, using special epoxy adhesives to bind fresh concrete to old concrete.
Cracks, when permitted to remain, shall be injected with suitable epoxy compounds
and test cores drilled to test the efficacy of the injection process.
2.1.2 Submission to the Engineer
Wherever the Specification requires that the Contractor shall submit to the Engineer
proposals, details, drawings, calculations, information, literature, materials, test reports
and certificates, the Engineer will consider each submission and, if appropriate, will reply
to the Contractor in accordance with the relevant provision of the Conditions of Contract.
Unless a defined period of time is stated in the Specification, each submission shall be
made by dates to be agreed with the Engineer having regard to the approved programme
and the need to give the Engineer adequate time to consider each submission.
Documents submitted, other than drawings and manufacturers’ literature shall be A4 in

English and any abbreviations shall be explained. All calculations and technical
information shall be in units conforming to the International System of Units (SI).
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All drawings shall be A1 in size to the ink border. Notes shall be in English. All
dimensions shall be in metres or millimetres and all weights in kilograms or metric
tonnes.
All drawings shall include the title of the Contract at the bottom of the drawing followed
by the title of the drawing concerned. All drawings shall have the appropriate scales
drawn on them.
The approval of the Engineer of any submission shall not relieve the Contractor from his
responsibilities under the Contract.
2.1.3 Notice of Operations
(a) Basic Survey:
The Engineer will provide sufficient basic survey information to enable the
Contractor to set out the Works and the Contractor shall be responsible for setting
out all necessary reference points and for the maintenance thereof.
Should the Contractor discover any error in line level, or dimension in the basic
survey information provided by the Engineer, he should at once notify the Engineer.
If the information is confirmed to be in error the Engineer will issue amended
drawings or instructions regarding the correction of the error.
Prior to commencing construction, the Contractor shall establish reference points, in

accordance with the Standard Drawings, to define the Road Reserve at 100 m
intervals on both sides or at other intervals instructed by the Engineer.
The Contractor shall establish temporary bench marks in accordance with the
Standard Drawings along the road at intervals not exceeding 200 m and shall provide
the Engineer with a schedule of their levels and locations.
(b) Detailed Setting Out:
The Contractor shall set out the line and level of the Works at intervals of not more
than 25 m or such lesser intervals as are required to construct the Works to the
tolerance specified in Clause 2.3.3 of this Section. Reference pegs clearly and
indelibly marked with all relevant information shall be provided clear of the road and
at right angles to it from which the centre line and level can be re-established at any
time. These shall be maintained by the Contractor for as long as they are needed by
the Engineer to check the work.
(c) Levels:
After completion of setting out and site clearance, the Contractor shall take ground
cross-sections at intervals of 25 m, or such intervals as the Engineer may require, and
these shall be plotted and submitted to the Engineer for agreement. If the Contractor
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fails to take the requisite levels, levels determined by the Engineer shall be taken as
correct.
The Contractor shall programme for a period of 21 days between submitting the
ground cross-sections and being issued with final road levels. Final road levels will
be determined by the Engineer and may be different from the road levels shown on
the Drawings.
(d) Survey Beacons:
The Contractor shall not remove, damage, alter or destroy in any way any plot
beacons or survey beacons of the Survey of the country. Should the Contractor
consider that any beacon will be interfered with by the works he shall notify the
Engineer who, if he considers necessary, will make arrangements for the removal and
replacement of the beacon.
If the Contractor removes or disturbs a beacon without permission of the Engineer,

he shall be liable for the full cost of its replacement and a fine under the Survey
Ordinance in force.
2.1.4 Ordering of Materials and Manufactured Articles
The Contractor shall, before placing any order for materials and manufactured articles for
incorporation in the Works, submit to the Engineer the names of the firms from whom he
proposes to obtain such materials and manufactured articles giving for each firm a
description of the materials and manufactured articles to be supplied, their origin, the
manufacturers specification, quality, weight, strength and any other relevant details. The
Contractor shall deposit with the Engineer samples of such materials and manufactured
articles when requested and where appropriate, manufacturers certificates of recent tests
carried out on similar materials and manufactured articles.
The Contractor shall provide the Engineer with copies of all orders for the supply of
materials and manufactured articles required in connection with the Works as the
Engineer may require.
2.1.5 Test Certificates
When instructed by the Engineer, the Contractor shall submit to him Certificates of Test
from the supplier of materials and manufactured articles to be used for the Contract. Such
Certificates shall certify that the materials and manufactured articles concerned have been
tested in accordance with the requirements of the Specification and shall give the results
of all the tests carried out. The Contractor shall provide adequate means of identifying the
materials and manufactured articles delivered to the Site with the corresponding
Certificates.
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2.1.6 Storage of Materials and Manufactured Articles
All materials and manufactured articles shall be stored on Site in a manner acceptable to
the Engineer and the Contractor shall carefully protect from the weather all work,
materials and manufactured articles which may be affected. Payment shall only be made
for quantities used in the Works.
Quantities.
2.2 INSPECTION OF WORKS
2.2.1 Routine Testing and Inspection by the Engineer
The Engineer will at regular intervals inspect and test materials and completed work for
compliance with the specified requirements, and where applicable the various judgement
schemes specified will be applied. The testing frequencies, sample and lot sizes for
routine testing shall be at the Engineer's discretion.
All sections of completed work shall be submitted to the Engineer for routine inspection
and testing and the Contractor shall not cover up or construct any work on top of sections
of completed work before being advised by the Engineer of the outcome of his inspection
and testing. The Contractor shall arrange the submission of work for testing in such a
manner that the Engineer will have all reasonable opportunity to inspect and to test the
work.
2.2.2 Taking and Submission of Samples
The Engineer shall have free access to the Works for the taking of samples. The
Contractor shall render any assistance necessary for the taking of samples and shall be
responsible for the reinstatement of pavement layers or other structures at the positions
where samples have been taken. Full compensation for rendering assistance with
sampling and for reinstatement where samples are taken shall be included in the rates
tendered for the various items of work tested, and no additional payments shall be made
in this respect.
Where it is required in these Specifications that the Contractor submit samples of

materials or mixtures to the Engineer for approval prior to their use in the Works, the use
of these materials or mixtures without the Engineer's written approval shall constitute
default on the part of the Contractor, for the consequences of which default he shall be
liable. All samples shall be submitted in sufficient time for proper testing.
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- 2.5 -
The Engineer's approval of any materials or mixture shall in no way relieve the
Contractor of his obligation to provide materials, mixtures and workmanship in
accordance with the Specifications.
All samples for testing shall be taken in a random pattern. Where specified, the random
sampling procedures shall be followed and where no specific random sampling
procedures are specified, the sampling procedure shall be as ordered by the Engineer.
The method of taking samples shall be as specified in the applicable sampling and testing
methods.
Table 2.2.2/1 below shall serve as a guide for the submission of materials in respect of
the time and quantity required for testing, approval and mix design. As the times stated in
this schedule makes no allowance for possible rejection and re-submission of alternative
materials, the Contractor shall submit any doubtful material at an early stage or together
with alternative materials in order to minimize any delays with regard to the final
approval.
The Contractor shall note that any samples submitted directly to the Engineer's laboratory
for approval shall be accompanied by a letter signed by the Contractor's Site Agent.
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Table 2.2.2/1 Schedule showing quantities and times for the submission of materials for approval and mix
designs
Submission for Quality Submission for Quality

approval only and mix design
Min. time Min. time to

to be allowed Min. quantity be allowed Min. quantity
Material Proposed for testing to be submitted for testing, to be submitted
submitted use and approval approval and
mix design
Coarse 2 weeks 50 kg of 10 weeks 150 kg of each

aggregate each size size of stone
for of stone for each class
concrete of concrete
Bituminous 2 weeks 50 kg of N/A N/A

Crushed surface each size
Stone dressing of stone
Asphalt 2 weeks 50 kg of each 6 weeks 100kg of each

mixes size of stone size of stone
Crushed 3 weeks 50 kg of N/A N/A

stone base each size
or sub-base of stone
Fine aggre- 2 weeks 50 kg of 10 weeks 150 kg of each

gate for each size type proposed
concrete of dust for use for
fraction each class of
concrete
Crusher Asphalt 2 weeks 15 kg of each 6 weeks 150 kg of each

dust and mixes size of dust type proposed
or sand fraction for use
Slurry seal 2 weeks 15 kg of each 6 weeks 50 kg of each

or sand seal type proposed type proposed
for use for use
Gravel Sub-base and 4 weeks 200 kg of N/A N/A

or base each sample
Other materials e.g. paint, cement, As directed by the Engineer

Additives etc.
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2.2.3 Tolerances
(a) General
(i) The work specified in the various sections of these Specifications shall comply
with the various dimensional and other tolerances specified in each case. Where
no tolerances are specified, the standard of workmanship shall be in accordance
with normal good practice. No representation is made that the full specified
tolerances will be available independently of each other and the Contractor is
cautioned that the liberal or full use of any one or more tolerances may deprive
him of the full or any use of tolerances relating to other aspects of the work. The
latter would apply particularly in respect of level tolerances on layer work and the
related requirements regarding layer thicknesses.
(ii) In the description of certain pay items where it is stated that quantities will be
determined from the "authorized" dimensions, this shall be taken to mean the
dimensions as specified or shown on the Drawings or, if changed, as finally
instructed by the Engineer, without any allowance for tolerances specified. If the
work is, therefore, constructed in compliance with the "authorized" dimensions
plus or minus any tolerances allowed, quantities will be based on the "authorized"
dimensions regardless of the actual dimensions to which the work is constructed.
(iii) Where the work is not constructed in accordance with the "authorized"
dimensions plus or minus any tolerances allowed, the Engineer may nevertheless
in his sole discretion accept the work for payment. In such cases no payment shall
be made in respect of quantities from the "authorized" dimensions and where the
actual dimensions are less than the "authorized" dimensions and minus any
tolerance allowed, quantities for payment shall be based on the actual dimensions
as constructed.
(b) Tolerances
(i) Horizontal Alignments
Horizontal alignments shall be determined from the centre line of the pavement
surface as shown on or calculated from the Drawings. The centre line of the
pavement surface as constructed, and all other parallel alignments, shall be
correct within a tolerance of +- 20 mm there from.
(ii) Thickness of Pavement Layers
The thickness tolerances of any pavement layer or improved sub-grade layer

when measured at five points in any length of 100 m shall be as specified in the
relevant Paragraphs for each layer.
(iii) Surface Levels of Pavement Layers and Formation
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The level tolerances shall be as specified in the relevant Paragraphs for each
layer.
For checking compliance with the level tolerances, measurements of surface

levels will be taken at points to be selected by the Engineer at 10 m centres
longitudinally and at 2 m centres transversely. At junctions, the grid point
spacings shall be determined by the Engineer.
(vi) Surface Regularity
The surface regularity of pavement layers shall be tested at points decided by the
Engineer with a straight edge of 3 m long placed parallel with or at right angles to
the centre line of the road. The maximum allowable deviation of the surface
below the straight edge shall be as given in column 1 of Table 2.2.3/1.
In addition, the longitudinal slope or transverse cross-fall shall not deviate from
that shown on the Drawings by more than the tolerances shown in column 2 of
Table 2.2.3/1.
Table 2.2.3/1 Surface Regularity
MAXIMUM DEVIATION
STRAIGHT SLOPE OR
EDGE CROSSFALL
LAYER mm %
Bituminous Wearing Course 4 ± 0.25

Bituminous Binder Course 6 ± 0.25
Base 6 ± 0.25
Sub-base 15 ± 0.50
Gravel Wearing Course 15 ± 0.50
Formation 20 ± 1.00
(v) Shoulders
Shoulders shall be constructed to the same thickness, level and surface regularity
requirements as for the adjacent pavement layers.
(vi) Cutting and Embankment Slopes
In the final trimmed slope of cuttings, a tolerance of 0.125 will be permitted, i.e.
if a slope of 1 in 2 is specified, the acceptable slope shall not be steeper than 1 in
1.875 or slacker than 1 in 2.125. The rate of change of slope shall not be greater
than 0.125 in 50 m subject to the tolerance, on width of the bottom of cuttings,
being complied with.
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In the final trimmed slopes of embankments, a tolerance of plus 0.25 will be

permitted, i.e. if the specified slope is 1 in 2, the acceptable slope shall not be
steeper than 1 in 2 or slacker than 1 in 2.25. The rate of change of slope shall not
be greater than 0.25 in 30 m.
(vii) Width of Cuttings and Embankments
The tolerance permitted in the width of the bottom of cuttings shall be 75 mm

between the centre line of the road and the toe of the cutting slope.
The width of embankments measured as the horizontal distance from the centre
line of the road to the top of the embankment shall not be less than that shown on
the Drawings.
2.2.4 Construction Control Testing
All earthworks and layers of pavement construction will be subject to construction control
testing by the Engineer, and the Contractor must allow in his rates and prices for any
disturbance or delays to the sequence of his operations occasioned by such control testing.
The Contractor shall request, in writing, the Engineer's approval for each section of each
layer of earthworks and pavement construction. Such requests shall be made only when
the Contractor is fully satisfied that the section of the work concerned is in the condition
required by the Specification.
The Engineer shall thereupon without undue delay test the section of the Works submitted
and inform the Contractor in writing of the results of the tests at the same time accepting
or rejecting the section or layer concerned.
Work on layers shall in no circumstances commence until the preceding layer has been
approved and accepted by the Engineer in writing. The Contractor is wholly responsible
for protecting and maintaining the condition of the work which has been submitted for
approval.
Notwithstanding the Engineer's approval of a layer, the Contractor shall be responsible at

his own expense for making good any subsequent damage due to traffic, ingress of water
or any other reason.
No separate payment shall be made for any work included in this Paragraph and the cost
Quantities.
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2.3 QUALITY CONTROL
2.3.1 Trials to Confirm Compliance with Specifications
2.3.1.1 Laboratory Trials
Laboratory trials shall be carried out by the Contractor on earth work and pavement
materials which are to be used in the Works in their natural state to establish a relationship
between their specified end product requirements and properties which can be readily
determined in the field for construction control purposes.
For materials that require to be mixed with bitumen, lime or cement before use in the
Works, the Contractor shall propose a composition based on the results of trial mixes
made and tested in the laboratory to check compliance with the Specification.
For mixed materials the composition which meets the specified requirements and is
accepted by the Engineer shall then be used in Site trials carried out in accordance with
Sub-clause 2.3.1.2) to establish that all specified requirements of the completed pavement
course can be achieved.
The laboratory trials on mixed materials shall be undertaken, and the Contractor's
proposals based thereon submitted to the Engineer, at least two weeks before the
Contractor proposes to use the mixed material in the Site trials.
2.3.1.2 Site Trials
Full scale processing, laying and compaction Site trials shall be carried out by the
Contractor on all earthwork and pavement materials proposed for the Works using the
equipment and methods proposed by the Contractor for constructing the Works. The trials
shall be carried out with the agreement and in the presence of the Engineer.
The trials shall be carried out to enable the Contractor to demonstrate the suitability of his
mixing and/or compaction equipment to provide and compact the material to the specified
density and to confirm that the other specified requirements of the completed pavement
course can be achieved.
Each trial area shall be at least 200 square metres and shall be laid to the specified depth
for the material. It may form part of the Works provided it complies with the
Specification. Any areas which do not comply shall be removed.
The Contractor shall allow in his programme for conducting Site trials and for carrying out
the appropriate tests on them. The trials on each pavement layer shall be undertaken at
least 14 days ahead of the Contractor proposing to commence full scale work on that layer.
The following data shall be recorded at each Site trial:
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the composition and grading of the material, including the bitumen content
and properties, if appropriate;
if appropriate, the moisture content at the time of laying;
the type and size of compaction equipment and the number of passes;
the maximum density or target density as appropriate and the density achieved
in the trial;
the maximum compacted thickness of layer;
any other relevant information.
At least ten sets of tests shall be made on each 200 square metres of trial area, and
provided nine out of ten sets of results meet the specified requirements for the material, the
Site trial shall be deemed successful. The above data recorded in the trial shall become the
agreed basis on which the particular material shall be provided and processed to achieve
the specified requirements.
If, during the execution of the Works, the construction control tests indicate that the
requirements for a material are not consistently being achieved, then work on that
pavement layer shall stop until the cause is investigated. Such investigation may include
further laboratory and Site trials on the material to determine a revised set of data as above
which, when agreed, shall be the basis on which all subsequent material will be provided
and processed to achieve the specified requirements.
Agreement by the Engineer to a set of data recorded as above in a Site trial shall not
relieve the Contractor of any responsibility to comply with the requirements of the
Standard or Specifications of Particular Application.
The requirements of Clause 1.2.12 and the details thereof given in the various sections
shall apply in respect of the Contractor's obligation to institute and carry out a process
control system to monitor the quality of the work during production.
For major concrete and asphalt production processes, the Engineer may order the
Contractor to amplify the above requirement by the introduction of a system of control
charts to monitor the various properties to be controlled. The specific system to be used
shall be subject to the Engineer's approval.
The Contractor shall take immediate steps to rectify any deviation from the specified
requirements indicated by his process control system and the Engineer shall have the right
to inspect and be given all details of tests and testing procedures in order to satisfy himself
that the Contractor is carrying out an adequate process control system.
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2.3.2 Control methods
2.3.2.1 General
In the Specifications certain requirements, limits and tolerances are laid down regarding
the quality of materials and workmanship to be supplied. Compliance with these
requirements shall, where so specified, be judged by the applicable control method as
described in the relevant clauses or in this clause.
Where no applicable control method is specified, full compliance with the specified
requirements, limits or tolerances will be required.
Two types of control methods are described in this paragraph:
(i) Statistical control methods utilizing the actual variability of the work as determined
from samples taken from the construction, hereinafter referred to as Type A control
methods.
(ii) Control methods not utilizing the actual variability of the work, hereinafter referred to
as Type B control methods.
Despite acceptance of those properties judged by these control methods, the materials or
portions of work submitted will be rejected when other characteristics fail to meet the
requirements of the Specifications or where there are other causes for rejection, such as
obviously defective or excessively non-uniform material, excessive variation due to any
assignable cause, visible signs of poor workmanship and similar causes which may not
require further testing in order to constitute sufficient grounds for rejecting the work.
The Engineer shall have the right to carry out such tests as he may consider necessary on
any localized portion of a lot which appears to be defective.
If required, the defects in a localized portion shall be rectified before it is included in a lot
for submission. The results of such special tests on localized portions shall not be included
as part of the random tests required for statistical control methods.
In all cases where the statistical control methods are used, they shall be strictly adhered to
and decisions based on these schemes shall not be altered, so as not to distort the
Contractor's or the Employer's risk. It shall be a condition of the Contract that the
theoretical validity of the various statistical control methods be accepted and that the
validity of the decisions made on the basis of these control methods cannot be disputed on
the grounds of statistical theory or a specified or implied producers risk.
2.3.2.2 Control Method Type A, Statistical Control
This control method covers the use of statistical methods for judging certain properties of
products or portions of the work for compliance with the requirements of this Contract.
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Only those properties of the products or portions of the work specified to be judged by
statistical methods will be treated according to this method.
(a) Definitions
(i) Lot
A lot is a sizeable portion of work or quantity of material which is assessed as a

unit for the purpose of quality control and has been selected to represent material
or work produced by essentially the same process and from essentially the same
materials.
(ii) Random Sample
A random sample is a group of n test measurements at n separate test positions or

on sample portions obtained from the "lot" in an unbiased way.
(iii) Sample Mean, x n
x n is the arithmetic mean of a set of n test results constituting the sample.
(iv) Sample Standard Deviation, sn
The sample standard deviation, sn , is defined by
2 2
x - xn
sn =
n-1
where
xn is the sample mean
x is the value of an individual sample portion, i.e. an individual test result or

measurement
n is the number of sample portions, i.e. the number of individual test results
or measurements.
(v) Specification Limit, Ls
This is the limiting value of any product property outside of which not more than
a certain specified percentage of the population of values representing an
acceptable product property is allowed to lie. The specification limit may be a
single lower limit, LLs, or a single upper limit, ULs, or a double limit consisting
of a lower limit and an upper limit.
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(vi) Statistical Constant, k
This constant is used to calculate the limiting value of the sample mean within
which the lot will be accepted.
The value of k is dependent on the number of sample portions in the sample and
the acceptance criteria. The acceptance criteria normally used where statistical
control of materials and workmanship are applied is that the specification limit,
Ls, is satisfied for more than 90% of the lot and that the risk of accepting a lot
that does not satisfy the specified requirement is less than 25%.
The values of k determined according to the above criteria are given in table
2.3.2.2/1
Table 2.3.2.2/1 Values of k
Sample
size n 0 1 2 3 4 5 6 7 8 9
0 - - - 2.50 2.14 1.96 1.86 1.79 1.74 1.70

10 1.67 1.64 1.62 1.61 1.59 1.58 1.56 1.55 1.54 1.54
(b) Control Procedure
The control procedure for each characteristic shall be applied as follows:
(i) Sampling and Testing
Take a sample of n random observations where n is not less than 3.In the case of
layer work, a grid shall be established to cover the lot and tables of random
numbers shall be used to locate test positions in the grid. The tests shall
subsequently be carried out on these positions in the lot.
(ii) Defining the Sample Properties
Calculate the sample mean, xn, and the standard deviation, sn.
(iii) Outliers
Test results shall be scanned for possible outliers. Where there is reason to
believe that a test result may be erroneous, it shall, if possible, be reinvestigated
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by further testing and if there is reasonable evidence that the result is erroneous, it
shall be regarded as an outlier. Where reinvestigation of a test result is not
possible, the procedure described below shall be used for identifying outliers:
Calculate the value of To from
abs.( xo - x n )
To =
sn
where xn and sn are the arithmetic mean and the sample standard deviation
respectively
and xo is the value of the test differing most from the mean.
Compare the value of To with the value of T for the applicable value of n from
the table 2.3.2.2/2:
Table 2.3.2.2/2
Number of Critical value

Observations
n T
4 1.46
5 1.67
6 1.82
7 1.94
8 2.03
9 2.11
10 2.18
11 2.23
12 2.29
13 2.33
14 2.37
15 2.41
16 2.44
17 2.47
18 2.50
19 2.53
20 2.56
if To is greater than T, then xo is an outlier.
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Every outlier shall be disregarded and replaced by another random test value. The
sample mean, xn, and the sample standard deviation, sn, shall then be
recalculated. If an outlier cannot be replaced, the sample mean and the standard
deviation shall be calculated using the remaining test results. The final number of
test results used in the assessment, after the elimination of outliers, shall never be
less than three.
(c) Acceptance Criteria
(i) For a lower limit specification
xn = LLs + snk
Accept the lot if the sample mean, xn, satisfies the expression , otherwise reject
the lot.
(ii) For an upper limit specification
xn = ULs - snk
Accept the lot if the sample mean, xn, satisfies the expression, otherwise reject
the lot.
(iii) For a double limit specification accept
LLs snk =xn=ULs - snk
Accept the lot if the sample mean, xn, satisfies the expression, otherwise reject
the lot.
(d) Characteristics to be controlled
The characteristics to be controlled in accordance with this control method shall be

those stated in the Specifications and may be one or more of the characteristics listed
in table 2.3.2.2/3.
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- 2.17 -
Table 2.3.2.2/3
Structure Characteristic
Embankment fill Relative compaction

Sub-grade Relative compaction
Sub-base Relative compaction
Crushed-stone base or sub-base Relative compaction
Asphalt base Relative compaction
Binder content of mix
Asphalt surfacing Relative compaction
Binder content of mix
Stabilized layers Relative compaction
Stabilizing agent content
Concrete Compressive strength at 28 days
2.3.2.3 Control method Type B
The following control method Type B shall apply except in respect of those properties
which, in accordance with the specifications, are to be controlled by control methods Type
A.
(a) Sample Size
The sample size (number of tests per lot) submitted for judgement shall not be less
than 5 unless otherwise agreed on by the Engineer. The number of surface levels and
thickness measurements per lot shall not be less than 20 and preferably over 30.
(b) Acceptance Criteria
(i) Surface Levels
The lot shall be deemed to comply with the requirements specified for surface
levels if at least 90% of all surface levels are within the H90 tolerance as specified
in the relevant section for each layer before any level corrections are made.
Individual spots where the surface level deviates by more than Hmax tolerance
specified in each case shall be repaired to bring them to within H90 tolerance.
(ii) Layer Thickness
The layer shall be deemed to comply with the requirements specified for layer
thickness if at least 90% of all thickness measurements taken are equal to or
thicker than the specified thickness minus the D90 tolerance as specified in the
relevant section for each layer before any thickness corrections are made, and the
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average layer thickness for the lot is not less than the layer thickness specified
minus the Dave tolerance specified in each case.
Individual spots where the actual thickness is less than the thickness specified
minus the Dmax tolerance specified in each case shall be locally repaired to bring
them to within the D90 tolerance.
(iii) Relative Compaction
The layer shall be deemed to comply with the requirements specified for relative
compaction if the mean density is equal to or more than the mean density
specified in the relevant section for each layer and if no single value is less than
the lower limit for individual values specified in each case.
2.3.3 Sampling Criteria
(a) Random Sampling
When testing any lot, whether a normal-sized lot or an isolated section which is
obviously defective or exhibits abnormal variation of the characteristics under
consideration, all samples shall be taken in a random pattern. For this purpose, use
shall be made of tables of random numbers.
(b) Lot size
(i) Road Construction Layer
The lot size shall normally be a section laid and compacted in one process and for
which essentially the same materials were used. Where production is on a
continuous basis, a lot shall normally mean one days production and shall not
exceed two full days production. However, a lot of any smaller size may be
ordered by the Engineer for investigating compliance with the Specifications if
the factors affecting the characteristics under investigation exhibit

abnormal variation within the normal lot size;
an area is obviously defective or of poorer quality than the rest;
the rate of production is very high.
(ii) Concrete
The lot size shall be determined by the Engineer with due regard to the size and
type of structure in which the concrete is placed, the specified portion of the
structure and the total amount of concrete placed in a day. The lot sizes in
concrete structures could therefore vary considerably, and particularly in the case
of small structures it could be necessary to combine samples of the same grade of
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concrete for different structures, provided that the concrete is obtained from the
same concrete equipment and is cast in the same period.
No separate payment shall be made for any work connected to the quality control as
described in this paragraph and the cost shall be deemed to be included in rates of the
relevant items entered in the Bill of Quantities.
2.4 SAMPLING AND TESTING OF MATERIALS
Where national standard sampling and testing methods exist which differ from the above
mentioned they may be used as an alternative provided the necessary adjustments are
made to the compliance limits for material and construction quality.
2.4.1 Soils and Gravels
(a) Samples and Sampling
Sampling of soils and gravels shall be carried out as specified or as directed by the
Engineer.
Samples shall be prepared for testing in accordance with AASHTO T 87 (or Clause
1.5 of BS 1377)
(b) Standard methods of testing.
Tests on soils and gravels shall be performed in accordance with the standard methods
given in Table 2.4.1/1.
It is further specified that:
(i) Sieve analysis shall be carried out using ISO sieves. The standard sieve series
shall be as follows:
63 - 50 - 37.5 - 31.5 - 25 - 19 - 16 - 12.5 - .5 - 8 - 6.3 - 4.75 - 4 - 2 - 1 - 0.5 -

0.425- 0.25 - 0.125 - 0.075 mm
The Engineer may require the use of additional ISO-sieves.
In various standard test procedures quoted in this Section, American or British

sieves shall be replaced by the nearest ISO sieves.
(ii) Wherever in the text of the Specification the term "x% of the MDD (AASHTO
T99 or T180)" is used it shall mean that a degree of compaction shall be achieved
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such that the dry density of the compacted material is x% of the maximum dry
density determined from the AASHTO T99 or T180 compaction test.
(iii) When the material is susceptible to crushing during compaction, a separate and
new sample shall be used in the determination of each point on the
moisture/density curve.
(iv) In method A of AASHTO T99 and T180, moulds having a diameter of 102 mm
shall normally be used. However, existing moulds to BS 1377 (diameter 105 mm
- volume 1 litre) may also be used. The number of blows shall then be increased
from 25 to 27, so as to obtain the same compacting energy per volume unit.
Table 2.4.1/1 Test Procedures Applicable to Disturbed Samples of Soils and Gravels
Determination Test Procedure applicable
Test (Alternative test)
Moisture Content AASHTO T 265 (BS 1377 - Test 1 (A))

Liquid Limit AASHTO T 89 (BS 1377 - Test 2 (B))
Plastic Limit AASHTO T 90 (BS 1377 - Test 3)
Plasticity Index AASHTO T 90 (BS 1377 - Test 4)
Linear Shrinkage AASHTO T 92 (BS 1377 - Test 5)
Specific Gravity of Soils AASHTO T 100 (BS 1377 - Test 6)
Particle Size Analysis
of Soils AASHTO T 88 (BS 1377 - Test 7 (A) and (D)).
Organic Content AASHTO T 267 (BS 1377 - Test 8)
Total Sulphate Content BS 1377-Test 9
pH Value BS 1377-Test 11(A)
Density-Moisture Content
Relationship
(2.5 kg rammer) AASHTO T99-Method A
AASHTO T99-Method D
Relationship
(4.5 kg rammer) AASHTO T180-Method A
AASHTO T180-Method D
Relationship
(Vibrating Hammer) BS 1377-Test 14
California Bearing Ratio AASHTO T193
Sand Equivalent AASHTO T176
Density of soil in place
by the sand cone method AASHTO T 191 (BS 1377 - Test 15)
Relative density of
cohesionless soils ASTM D 2049
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2.4.2 Stone, Aggregates, Sands and Fillers
a) Sampling and Preparation of samples.
Sampling shall be carried out and the samples prepared in accordance with AASHTO
T 2, T 87 and T 248 (or BS 812)
b) Standard methods of testing.
Tests on stone, aggregates, sands and fillers shall be performed in accordance with the
standard methods given in Table 2.4.2/1. and as described below.
Table 2.4.2/1 Test Procedures Applicable to Stone, Aggregates, Sands and Fillers
Determination Test Procedure applicable
Sieve analysis of fine and

coarse aggregates AASHTO T 27 (BS 812)
Sieve analysis of mineral
filler AASHTO T 37
Clay lumps and friable
particles in Aggregate AASHTO T 112 (BS 812)
Flakiness Index BS 812
Specific gravity and absorption
of fine aggregate AASHTO T 84 (BS 812)
Specific gravity and absorption
of coarse aggregate AASHTO T 85
Moisture Content AASHTO T 255 (BS 812)
Aggregate Crushing Value BS 812
Soluble Chloride Content BS 812
Organic Impurities in Sands AASHTO T21
Los Angeles Abrasion AASHTO T96 (ASTM C131, ASTM C535)
Sodium Sulphate Soundness AASHTO T104 (ASTM C 88)
Sand Equivalent AASHTO T176
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(i) The Average Least Dimension of an aggregate shall be determined as follows:
By means of a riffler divide out a representative sample of such a size as to give

at least 200 aggregate particles of each fraction to be tested. Sieve the sample
through a sieve with an aperture size half the nominal size of the aggregate to be
tested and discard the particles passing the sieve (the nominal size is the smallest
sieve through which at least 85% of the aggregate will pass).
By means of callipers with platens of at least 5 mm diameter (or square) measure

the smallest dimension of each particle retained on that sieve accurate to 0.1 mm
and record the measurement and the number of particles tested. The average least
dimension is then calculated as the sum of the smallest dimension of the particles
divided by the number of particles measured.
(ii) The Grading Modulus (GM) is determined as the cumulative percentage by mass
of material in a representative sample of aggregate, gravel or soil retained on the
2 mm, 0.425 mm and 0.075 mm sieves, divided by 100.
(iii) The Crushing Ratio (CR) of an aggregate is determined for the material retained
on the 2 mm sieve.
A crushed particle is defined as a particle having at least 2 fractured faces. The

Crushing Ratio shall be determined as the mass of crushed particles taken as
percentage of the total mass of the size fraction tested.
CR shall normally be determined on each of the following size fractions

(provided they constitute more than 5% of the total material): 2-4 mm, 4-8 mm,
8-16 mm and 16 - 31.5 mm
2.4.3 Cement
Ordinary and Rapid Hardening Portland Cement shall be sampled and tested in accordance
with BS 4550.
2.4.4 Lime
Building limes shall be sampled and tested in accordance with and shall comply with all
requirements of BS 890.
Lime for treatment of road materials shall be hydrated calcium lime or quicklime and,
unless otherwise specified, shall comply with the following requirements:
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Hydrated lime Quicklime
Fineness:
Residue on 0.2 mm sieve,

Maximum 1% 10%
Residue on 0.075 mm sieve,
Maximum 10% 50%
Chemical requirements:
Free lime content, Minimum 50% 80%

Hydrated lime content,
Maximum 5%
2.4.5 Cement or Lime Treated Materials
(a) Samples and Sampling
Sampling of cement or lime treated materials shall be carried out as specified or as

instructed by the Engineer.
Samples shall be prepared for testing as indicated in Clause 1.5.3 of BS 1924, except
that samples containing particles larger than 20 mm shall be prepared for compaction
and CBR tests as indicated in AASHTO T99 or T180. (The fraction coarser than 19
mm shall be rejected but replaced by an equal weight of 4.75-19 mm material).
(b) Standard methods of testing
The tests on cement or lime treated materials shall be performed in accordance with
the standard methods given in Table 2.4.5/1.
It is further specified that:
Compaction tests: when cement is used, compaction must start within one
hour and be complete within two hours after the start of mixing
operations.
Determination of the CBR: the specimens shall be dynamically

compacted with a 4.5 kg rammer, the number of blows being governed by
the relative compaction chosen (Dynamic Compaction - Method D). If it
is required to soak the specimen, the mould shall be immersed in water to
allow free access of water to top and bottom of the specimen. During
soaking, the water level in the mould and the soaking tank shall be
maintained approximately 25 mm above the top of the specimen.
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Curing and soaking temperature: during the curing and soaking periods,
the specimens shall be kept at a temperature of 27oC ± 2oC.
Table 2.4.5/1 Test Procedures Applicable to Cement and Lime Treated Materials
Determination of Test Procedure applicable
Moisture Content AASHTO T 265

Density-Moisture
Content Relation-ship
(2.5 kg rammer) AASHTO T99 - Method A
(Materials passing a 5 mm sieve)
AASHTO T99 - Method D
Relationship (4.5 kg rammer) AASHTO T180 - Method A
AASHTO T180 - Method D
(Materials passing a 20 mm sieve and containing more
than 5% retained on a 5 mm sieve).
Relationship (Vibrating Hammer) BS 1924 - Test 5
Unconfined Compressive Strength
(UCS) BS 1924 - Test 10, 11, 12
California Bearing Ratio AASHTO T 193
Wetting and Drying test of

compacted soil-cement mixtures AASHTO T 135
Freezing and thawing test of

compacted soil-cement mixtures AASHTO T 136
Cement Content BS 1924 - Test 14

Lime Content BS 1924 - Test 15
2.4.6 Concrete
Sampling and testing on concrete shall be carried out in accordance with BS 1881:
Part 1 Methods of sampling fresh concrete

Part 2 Methods of testing fresh concrete
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Part 3 Methods of making and curing test specimens

Part 4 Methods of testing concrete for strength
Part 5 Methods of testing hardened concrete for other than strength.
It is further specified that the test specimens shall be cured at a temperature of 27oC ± 2oC.
Water to be used in concrete shall be tested as specified in BS 3148.
2.4.7 Bituminous Binders
a) Samples and Sampling
Sampling of straight-run and cut-back bitumen shall be carried out in accordance with
AASHTO method T40 (ASTM D 140).
Sampling of bitumen emulsion shall be carried out in accordance with BS 434, except
that where a delivery is made in drums or barrels, the number of samples shall be as
indicated in AASHTO Sampling Method T40 para. 11.1.
b) Standard methods of testing
(i) Straight-run Bitumen
Tests on straight-run bitumen shall be carried out in accordance with the

following test procedures:
Penetration AASHTO T49 (ASTM D 5)

Softening point
(Ring and Ball) AASHTO T53 (ASTM D 2398)
Flash and fire points
(Cleveland open cup) AASHTO T48 (ASTM D 92)
Loss on heating AASHTO T47 (ASTM D 6)
Water content AASHTO T55 (ASTM D 95)
Thin film oven test AASHTO T179 (ASTM D 1754)
Solubility in organic
solvents AASHTO T44 (ASTM D 2042)
Specific gravity AASHTO T228 (ASTM D 70)
(ii) Cut-back bitumen
Tests on cut-back bitumen shall be carried out in accordance with the following
test procedures:
Kinematic viscosity AASHTO T201 (ASTM D 2170)

Flash point
(Tag open cup) (RC-MC) AASHTO T79 (ASTM 1310)
Flash point
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(Cleveland open cup) (SC) AASHTO T48 (ASTM D 92)

Distillation AASHTO T78 (ASTM D 402)
Water content AASHTO T55 (ASTM D 95)
Specific gravity AASHTO T228 (ASTM D 3142)
Asphalt residue of
100 pen (SC) (ASTM D 243)
Tests on residue from
distillation:
- Penetration AASHTO T49 (ASTM D 5)
- Solubility AASHTO T44 (ASTM D 2042)
STV viscosity BS 3235
(iii) Bitumen emulsion
Tests on bitumen emulsion shall be carried out in accordance with BS 434 test
procedure:
Residue on 0.710 mm sieve

Residue on 0.150 mm sieve
Stability to mixing with coarse aggregate
Stability to mixing with cement
Binder content
Engler viscosity
Redwood II viscosity
Storage stability (short period)
Storage stability (long period)
Particle charge
2.4.8 Bituminous Mixes
a) Samples and Sampling
Sampling bituminous mixtures shall be carried out in accordance with AASHTO

method T168 (ASTM D 979).
b) Standard methods of testing
Test on bituminous mixtures shall be carried out in accordance with the following test
procedures:
Moisture and volatile

distillates AASHTO T110 (ASTM D 1461)
Quantitative extraction of
bitumen AASHTO T164 (ASTM D 2172)
Specific gravity of compacted
mixture AASHTO T166 (ASTM D 1188)
(and D 2726)
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Recovery of bitumen from

solution AASHTO T170 (ASTM D 1856)
Coating and Stripping AASHTO T182 (ASTM D 1664)
Degree of particle coating AASHTO T195 (ASTM D 2489)
Coating and Stripping

(with adhesion agent) (ASTM D 2927)
Maximum Specific gravity AASHTO T209 (ASTM D 2041)
Degree of pavement compaction AASHTO T230
Marshall stability AASHTO T245 (ASTM D 1559)
Hubbard-Field Stability (ASTM D 1138)
Dynamic Immersion Test Sub-clause 5.6.1.3
2.4.9 Sampling and Testing Equipment
The minimum laboratory equipment to be provided shall be that required to undertake the
relevant tests prescribed in this paragraph in accordance with the latest revision of their
respective AASHTO, ASTM and/or BS designation and all the relevant secondary tests
and/or prescriptions, as well as any other equipment required to comply with the testing
methods prescribed for the works and materials.
2.4.10 Sampling and Testing Frequencies
Guidelines for sampling and testing frequencies are given in table 2.4.10/1 a through d.
Table 2.4.10/1a
ITEM Bulk Upper 0.3 m Improved

Original Earth Earth Sub-grade
Ground Works Works Course
QUANTITY m2 m3 m2 m2
TEST
Grading 3000 4000 3000 3000

Atterberg Limits 3000 4000 3000 3000
Laboratory
Compaction 1500 2000 1500 1500
CBR Test 6000 8000 3000 3000
Sand Equivalent - - - 1500
Deleterious Matterial - - - 1500
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Table 2.4.10/1b
ITEM: Natural Crushed Stabilized Backfill

Gravel Stone Sub-grade for
Sub-base Sub-base Sub-base Structures
and Base and Bas and Base
QUANTITY m2 m2 m2 Unit
TEST
Grading 3000 3000 3000 1

Atterberg Limits 3000 3000 3000 1
Laboratory
Compaction 1500 1500 1000 1
CBR Test 6000 E E 1
Los Angeles
Abrasion E E - -
Crushing Ratio - 6000 - -
Sand Equivalent 1500 1500 1500 1
Flakiness Index - E - -
Deleterious Matter E E E E
Strength - - 1000 -
Table 2.4.10/1c
PORTLAND CEMENT CONCRETE
ITEM : Coarse Fine Concrete

Aggregate Aggregate Mix Cement Water
QUANTITY m3 m3 m3 tonne m3
TEST
Grading 200 100 100 E -

Water Content - - 100 - -
Los Angeles
Abrasion E - - - -
Crushing Ratio E - - - -
Sulphate Soundness E E - - -
Deleterious Matter 200 100 - - E
Flakiness Index 200 (1) - - - -
Slump - - 100 - -
Strength - E (2) 200 E -
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Table 2.4.10/1d
SURFACE TREATMENTS AND BITUMINOUS MIXES
ITEM : Coarse Fine Bituminous

Aggregate Aggregate Mix Bitumen Filler
QUANTITY : m3 m3 m3 tonne m3
TEST
Grading 200 200 200 - 100

Specific Gravity 200 200 E 20 100
Water Content - - - 20 -
Los Angeles
Abrasion E - - - -
Crushing Ratio E - - - -
Sulphate Soundness E E - -
-
Angularity E - - - -
Flakiness Index 200 - - - -
Deleterious Matter E E - - -
Bitumen Absorption E E - - E
Penetration - - - 20 -
Bitumen Content - - 200 - -
Marshall Stability - - 200 - -
Field Compaction - - 20 - -
NOTE:
(E) at opening up and when the Engineer orders it

(1) If crushed gravel is used
(2) Relative mortar strength
a) Process Control
The cost of testing undertaken by the Contractor in terms of his obligations under
Clause 1.2.12 in respect of process control, including the taking of samples,
reinstating where samples have been taken, and all testing equipment, labour,
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materials, etc., shall be included in the rates tendered for the various items of work
supplied and shall not be paid for separately.
b) Provision of Certificates
Where the properties of materials or manufactured products have been specified by

reference to standard specifications published by a specifications authority, the
Contractor shall, when called upon to do so, produce certificates from the
manufacturer that the materials or products supplied comply with the relevant
specifications. The cost of providing such certificates shall be borne by the Contractor.
c) Testing of Materials and Products Covered by Certificate
The Engineer shall have the right to order tests to be made on products and materials
of which certificates of compliance may be required as described in Sub-clause (b)
above. The Contractor shall be paid at the applicable rates, if the cost of such tests are
itemized in the Bill of Quantities, or if no applicable rates exist such tests shall be
classed as "extra work" in terms of the General Conditions of Contract, provided
always that such tests indicate compliance with the Specifications, otherwise the cost
shall be borne by the Contractor.
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3 / EARTHWORKS
S E C T I O N No 3
EARTHWORKS
3.1 GENERAL
3.1.1 Definitions
Earthworks shall include all excavations, filling, embankment and cut forming, and all
other work, operations and processes contingent upon or related to excavations required
by the nature of the Contract.
In relation to earthworks the following words and expressions shall have the meaning
hereby assigned to them:
(i) "Existing ground level" means the ground level existing before the
commencement of the Works.
(ii) "Stripped ground level" means the level calculated by subtracting the thickness
of topsoil directed by the Engineer for removal on any section of the Works
from existing ground level.
(iii) "Finished excavation level" means the level of completed excavation after any
trimming, compacting and preparation of the excavation as calculated from the
Drawings or as instructed by the Engineer.
(iv) "Construction width" shall mean the width of the Permanent Works measured
between the outer extremities of the side drains, cutting or embankment slope as
the case may be.
(v) "Formation level" shall mean the level of completed earthworks ready for
pavement construction and shall be synonymous with "Sub-grade Level".
(vi) "Formation width" shall mean the width of the earthworks measured between
the points of intersection of side drain or embankment slopes at formation level.
3.1.2 Classification of Materials
Material will be classified as "rock", "material other than rock" and "unsuitable material".
(a) Rock
"Rock" shall include all material which requires blasting for its removal. Materials
that can be extracted by ripping or can be effectively removed or ripped by a single
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tine operated by a track type tractor of not less than 425 horse power will not classify
as rock. The use of explosives by the Contractor to excavate does not imply that the
material is rock in terms of this specification. The cost of proving rock shall be
included in the Contractor's rates and no extra payment will be made for this cost.
(b) Material other than rock or "common material"
"Material other than rock" shall be all suitable material not classified as "rock".
(c) Unsuitable material
"Unsuitable material" shall be deposits of saturated or unsaturated mixtures of soils

and organic matter not suitable for incorporation into the permanent construction.
Unsuitable material shall include:
(i) Material from swamps and marshes;

(ii) Logs, stumps, roots, vegetable matter and perishable matter
(iii)Slurry and mud
(iv) Anthill material.
(v) Any material which has excessive moisture content, and which cannot be dried
to optimal moisture content within 4 working days of dry weather and frequent
scarification and mixing of the material.
(vi) Clay with LL > 80% and or PI > 50%
3.1.3 Use of Materials
The use of topsoil shall be restricted to surface layers in positions not subject to loading
by pavements or structures.
No excavated suitable material shall be removed from the Site except on the direction or
with the permission of the Engineer.
Before commencing work on any section of the road, the Contractor shall ensure that he
has adequate instructions concerning the use of suitable excavated material.
Spoil material shall be material which, being obtained from cuttings, is surplus to that
required for fill.
The Contractor's attention is drawn to the fact that no payment will be made for spoil of
material except where the Engineer instructs the Contractor to remove material. Spoil
material shall be brought to spoil areas as directed by the Engineer.
Where excavation reveals a combination of suitable and unsuitable materials, the

Contractor shall, unless otherwise agreed by the Engineer, carry out the excavation of
suitable materials separately for use in the Works without contamination by the
unsuitable materials.
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The Contractor shall submit to the Engineer a proposal about arrangements for the
stockpiling of topsoil and/or suitable material.
No excavation for any purpose whatever shall be made on the Site, except as shown on
the Drawings, without the permission of the Engineer.
3.1.4 Materials Sources and Spoil Areas
The Contractor shall give the Engineer at least thirty days' notice of his intention to enter
a borrow area which had been available for inspection at the time of Tender and shall not
enter thereon until the approval of the Engineer has been given.
For quarries, borrow pits, stockpile and spoil areas proposed by the Contractor for the
approval of the Engineer during the Contract the Contractor shall submit not less than
ninety days before each site is required a detailed survey plan showing the area required
including working plan, access road and blasting safety zone. Such areas will, if
approved, be made available by the Employer within the ninety day period.
The Contractor shall, before entering upon any land provided by the Employer, satisfy
himself that legal rights of entry have been obtained.
Where it is necessary to agree on levels for the calculations of quantities, the Contractor
shall not enter the area until such levels have been agreed and the Engineer's approval
obtained.
The Contractor may be required to mix the selected materials by bulldozing into
stockpiles and/or by face loading by shovel.
Materials are to be stockpiled only where permitted by the Engineer and only over such
area and to such height as he may approve.
A separate stockpile shall be used for each type and grading of material.
When removing material from stockpiles, none of the underlying material shall be mixed
with it, and generally at least the bottom 100 mm layer shall be left behind.
Material remaining in stockpiles at the completion of the Contract will not be paid for.
The Contractor shall comply with the By-Laws of the Local Authority regarding public
health and safety in respect of the operation of quarries, borrow pits, stockpile and spoil
areas, and in the absence of, or in addition to such By-Laws, shall comply with the
following conditions:
(i) All quarries being worked shall be drained and kept drained. Where a quarry or
borrow area has been excavated so that it will not drain naturally, it shall be kept
pumped dry while being used.
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3 / EARTHWORKS
(ii) The Contractor shall confine his operations solely to the areas provided and
shall demarcate the boundary of the area and erect temporary or permanent
fencing as instructed by the Engineer.
(iii) Where the height of any face constitutes a danger, the Contractor shall provide,
erect and maintain at his own expense stock proof fencing and gates to prevent
unauthorized access to the top of the working face.
(iv) On completion of work all faces shall be neatly trimmed to such slope as shall,
in the opinion of the Engineer, be stable and safe for pedestrians and animals to
negotiate. Where this is impracticable or where the working face is to be left
exposed, the edge shall be permanently fenced, as instructed by the Engineer.
(v) Unless otherwise instructed by the Engineer, the Contractor shall clear the sites
of all quarries and borrow areas and access roads thereto.
All existing fences, trees, hedges and other features which the Engineer instructs
shall be protected.
The Engineer shall instruct whether top soil from quarries and borrow areas
shall be stripped and stockpiled separately or shall be excavated and spoiled
together with the overburden.
On completion of the work and where instructed by the Engineer, top soil shall
be spread to a depth of 100 mm over quarries and borrow areas.
3.1.5 Protection from Water
The Contractor shall keep the whole of the Works free from water and allow in his prices
for all dams, cofferdams, pumping, piling, shoring, temporary drains, sumps, etc.,
necessary for this purpose and shall clear away and make good at his own cost and to the
satisfaction of the Engineer all damage caused by ingress of water. Drainage work
generally shall be carried out in advance of the other works. No payment will be done for
removal of unsuitable material due to water-logging caused by temporary works.
The Contractor shall, at his own expense, take all necessary precautions to minimize
damage due to erosion and siltation during construction. On cessation of earthworks the
surface of the completed layer shall be trimmed such that ponding and concentrations of
surface run-off do not occur.
Any damage to the Works or to adjacent properties resulting from the Contractor's failure
to take the necessary precautions shall be made good at the Contractor's expense.
Well in advance of commencing earthworks over swampy or waterlogged ground the

Contractor shall, at his own expense, cut drains and ditches and carry out any other works
necessary to effectively drain the original ground. Should such works, in the opinion of
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3 / EARTHWORKS
the Engineer, form part of the permanent drainage system, then payment will be made
accordingly.
Should any water accumulate on any part of the earthwork, either during construction or
after construction until the end of the Period of Maintenance, giving rise to soaking or
eroding conditions, the Engineer may order the Contractor to remove and replace at the
Contractor's expense any material which has been so affected.
Water shall not be allowed to accumulate at any point in the earthworks. The Contractor
shall arrange for the rapid disposal of all water from the Works, whatever the source may
be, and shall at his own expense effectively drain and keep dry the whole of the Works
during the period of the construction.
Such provision shall include carrying out the work of forming the cuttings and
embankments in such a manner that their surfaces have at all times a sufficient minimum
cross-fall and longitudinal gradient to enable them to shed water and prevent ponding.
3.1.6 Testing and Quality Control
All materials shall be tested by standard methods and at intervals specified in Paragraph
2.4. The quality control of materials and construction shall be made as specified under
Paragraph 2.3 and relevant Paragraphs describing the works.
No separate payment shall be made for any work included in this Paragraph unless
particular items of working the materials sources are described in the Specifications of
Particular Applications and entered into the Bill of Quantities. The Contractor is liable
for payment of Royalties and other costs due on materials from any source and the cost
shall be included in the rates for provision of such materials.
3.2 SITE CLEARANCE
3.2.1 Clearing and Grubbing
(a) Clearing
Clearing shall consist of the removal of all trees, brush, other vegetation, anthills,
rubbish, fences and all other objectionable material resulting from the clearing and
grubbing.
It shall also include the removal and disposal of structures that obtrude, encroach
upon or otherwise obstruct the work and that can be cleared by means of a bulldozer
with a power of approximately 150 kW (200 flywheel horsepower). Structures which
cannot be cleared in this manner shall be broken down in accordance with the
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3 / EARTHWORKS
requirements of the Specifications of Particular Applications for the removal and

disposal of structures.
Clearing shall include the removal of all rocks and boulders of up to 0.15 m3 in size
and which are exposed or lying on the surface.
(b) Grubbing
In the roadway all stumps and roots larger than 75 mm in diameter shall be removed
to a depth of not less than 600 mm below the finished road level and a minimum of
75 mm below the original ground level. Where the roadbed has to be compacted, all
stumps and roots including matted roots shall be removed to a depth of at least 200
mm below the roadbed.
Except in borrow areas the cavities resulting from the grubbing shall be backfilled
with approved material and compacted to a density not less than the density of the
surrounding ground.
(c) Conservation of Topsoil
Where suitable topsoil exists within the limits of the area to be cleared and grubbed,
the Contractor shall, ordered by the Engineer, remove the topsoil together with any
grass and other suitable vegetation. If not used immediately, the topsoil shall be
transported and deposited in stockpiles for later use.
Where topsoil can be removed without the necessity of first performing clearing and
grubbing, no payment will be made for clearing and grubbing under this Paragraph.
(d) Areas to be Cleared and Grubbed
Normally the portions of the road reserve that fall within the limits of the road prism,
as well as certain borrow areas shall be cleared and/or grubbed. The Engineer shall
designate the areas to be cleared and/or grubbed and such areas shall not necessarily
be limited to those mentioned above.
The areas occupied by an existing road prism will not normally be included.
No clearing and grubbing shall be done other than on the written instructions of the
Engineer, who shall designate in detail the exact areas to be cleared and grubbed and
the time at which it shall be done. The Contractor shall note that in order to avoid re-
clearing, the clearing and grubbing may have to be done at the last practicable stage
of construction.
(e) Cutting of Trees
The Contractor shall take the necessary precautions to prevent damage to structures
and other private or public property. If necessary the trees shall be cut in sections
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from the top downwards. The branches of trees to be left standing shall be trimmed
so as not to intrude into a space of 7 m above the roadway.
(f) Dealing with Anthills
Where anthills are encountered within the limits of the road prism, they shall be
excavated to a depth as directed by the Engineer, but not less than 1.0 m below the
finished road level and the material carted to spoil. Cavities resulting from the
clearance of anthill material shall be backfilled with approved material and
compacted to a density not less than that of the surrounding ground.
Where directed by the Engineer, the area covered by anthills shall be treated, after
excavation and before backfilling of cavities, with an approved ant control chemical.
(g) Disposal of Material
Material obtained from clearing and grubbing shall be disposed of as indicated by the
Engineer, in borrow pits or other suitable places and be covered up with soil or gra-
vel. The burning of combustible material will not normally be permitted and may
only be done with the prior written approval of the Engineer.
All tree trunks and branches in excess of 150 mm in diameter shall be cleaned of
secondary branches, sawn into suitable lengths and stacked at sites indicated by the
Engineer. Such timber shall not be used by the Contractor for any purpose and shall
remain the property of the Employer unless otherwise agreed on with the Engineer.
Fencing wire shall be neatly wound into reels and all such wire, together with all
fence posts and other suitable material from structures, etc., shall be stacked at sites
indicated by the Engineer.
The unit of measurement for clearing and grubbing shall be the hectare. The quantity
shall be taken as the plan area in hectare (to the nearest 0.1 ha) designated by the
Engineer and cleared and grubbed in accordance with these Specifications.
The girth of trees or stumps shall be measured at the narrowest point of the tree of stump
in the first metre of its height above ground level. Trees and stumps with a girth in excess
of 1 m shall be measured individually and classified according to size in increments of 1
m.
Where construction is carried out through plantations or where the number of trees with a
girth of more than 1 m renders individual measurement impracticable, the Specifications
of Particular Application will provide that the clearing and grubbing of trees in such areas
be measured in hectare. If this method of measurement is used, the areas to which it is
applicable will be shown on the Drawings, stated in the Specifications of Particular
Application or be indicated to bidders at the site inspection.
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The tendered rate shall include full compensation for all work necessary for the clearing
of the surface, the removal and grubbing of trees and tree stumps (except large trees and
stumps as defined above), cutting of branches, the removal of anthills, backfilling of
cavities, demolishing and disposal of structures except where otherwise provided for in
the Specifications of Particular Application, and the removal, transporting and disposal of
material, all as specified in this Paragraph.
Where the Specifications of Particular Application provides for payment of clearing and
grubbing of large trees per hectare in certain specific cases, the tendered rate shall include
full compensation for all work in connection with individual trees, as described above.
Pay Item Unit of

No. Name Measurement
3.2-1 Clearing and Grubbing Hectare
3.3 EXCAVATION AND CUT FORMING
Hauling of material from cuttings or borrow pits to embankments or other areas of fill
shall only take place when sufficient compaction equipment is operating at the place of
deposition to ensure compliance with Clause 3.4.3. Any excess depth excavated below
the formation level tolerance shall be made good by scarifying and backfilling with
suitable material of similar characteristics to that removed, and compacted in accordance
with Clause 3.4.3. Where excavation reaches rock, formation level will be established by
filling all depressions with crushed stone in dry areas. Where water is present or may
access through the pavement, mass concrete will be used. The formation shall be
constructed with a cross section which enhances water run-off.
The slopes of cuttings shall be cleared of all rock fragments which move when prised by
a crow-bar. Where in the slopes of cuttings layers of rock and softer material alternate
and the Engineer considers that the slope immediately after dressing will not permanently
withstand the effect of weather, the Contractor shall excavate any insecure material to an
approved depth and build up the resulting spaces with mass concrete or masonry using
rock similar to the adjoining natural rock so as to ensure a solid face.
Blasting shall be carried out in strict accordance with the latest Government Regulations,
and at all times shall be carried out and supervised by fully qualified persons in terms of
these Regulations. If in any situation blasting is considered dangerous, the Engineer's
decision in this respect shall be final. Should any damage of any kind occur, the
Contractor shall be solely responsible for such damage or any claims that may arise there
from, and shall, at his own expense, carry out repairs or restoration as the Engineer may
direct.
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Care shall be taken that no unused cartridges are allowed to remain in the excavation.
Careless or indiscriminate use of explosives will result in the Engineer withdrawing
permission for their use, and under such circumstances the Contractor shall resort to other
methods of excavation.
The Contractor shall obtain the written permission of the Engineer for each location
where the Contractor requires the use explosives.
The slopes of cuttings and embankments shall be trimmed by hand or by approved

mechanical means to uniform batters as shown on the Drawings or as instructed by the
Engineer. Such trimmings shall be completed before the commencement of sub-base
construction.
Any rock or boulder appearing in the face of a cutting or embankment shall be trimmed
back to within the tolerance specified and in addition any such rock or boulder which, in
the opinion of the Engineer, is unstable shall be completely removed and the resulting
void filled with compacted material to the approval of the Engineer.
During the excavation the Contractor shall limit vertical and other temporary faces to
such heights as are suitable to the nature of the soil exposed. If in the course of the Works
any slips, slides or subsidence extend below the line and slopes or below the levels
shown on the Drawings, the excess excavation shall be at the Contractor's own expense,
and he shall make good in a manner satisfactory to the Engineer unless the Contractor
can show that the slip, slide or subsidence was not due to his failure to comply with the
Specifications.
Excavation of unsuitable material shall be measured by the cubic metre as the volume of
voids of the excavation formed.
Measurement of spoil of surplus material shall be measured by the cubic metre of "cut"
from the mass haul diagram.
Overburden excavated from borrow areas shall not be measured for payment, unless a
specific item for such excavation is entered into the Bill of Quantities.
The rates for excavation of unsuitable material or spoil shall include for the cost of:
(a) all survey work necessary whether before earthworks are commenced, during, or
after completion and for submission of records;
(b) providing spoil tips in accordance with the relevant provisions of this Standard
Specification;
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(c) excavating, transporting for any distance within the "Free Haul Distance" of one
kilometre, unloading, spreading, levelling, trimming banks and providing temporary
access roads up to 200 m in length for each spoil tip.
Pay Item
Unit of
3.3 -1 Excavation of unsuitable material Cubic metre
3.3 -2 Excavation to spoil of surplus Cubic metre

material
3.3 -3 Overhaul, Spoil Cubic metre x km
3.4 FILL AND EMBANKMENT FORMING
3.4.1 Scope
This Paragraph covers provision, placing, breaking down, watering and compaction of
materials for fill and embankment forming to 0.3 m below formation level.
Construction of sub-grade, from 0.3m depth to finished formation level is dealt with in
Paragraph 3.5.
3.4.2 Materials Requirements
Materials for fill shall be obtained from areas of cut and excavations, including side
drains, or from approved borrow pits. Subject to the approval of the Engineer side drains
may be widened to provide additional suitable fill.
Suitable fill material shall meet the following requirements:
(i) The Plasticity Index (PI) shall not exceed 30.
(ii) The percentage passing the 0.075 mm sieve shall not exceed 50%.
(iii) The CBR shall be not less than 4% at the density required for the layer and with
a surcharge not greater than the one which corresponds to the load of the
pavement structure. (Normally equal to 6 surcharge rings).
(iv) The CBR swell shall not exceed 4% after soaking for 96 hours.
(v) The maximum laboratory dry density as determined by the AASHTO T99
Compaction Test shall not be less than 1,500 kg/m3.
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(vi) The material shall not contain particles with a maximum dimension exceeding
two-thirds of the specified layer thickness after compaction except in the case of
rock fill.
Rock fill shall be of such a size that it can be deposited in horizontal layers not exceeding
750 mm loose depth extending over the full width of the embankment.
No stone exceeding the compacted layer depth in any one direction shall be used in rock
fill embankments.
3.4.3.1 General
Before the placing of any fill, or after the removal of unsuitable material, the surface of
the ground over the width of the carriageway and shoulders, or over the bottom width of
the embankment, if the Engineer so instructs, shall be compacted and tested as indicated
in Clause 3.4.4.
Whenever, in the Engineer's opinion, the existing ground is unsuitable in quality for
receiving fill, the Contractor shall excavate to the depth instructed, remove the material
to a spoil tip and replace it with approved material as specified in Clause 3.4.2.
Where fill material can be obtained from cuttings, the Contractor shall use this material
before taking material from a borrow pit.
The Contractor may, if he prefers, take approved fill material obtained from cuttings to
spoil but he must then substitute at his own cost an equivalent quantity fill material of at
least equal quality from a borrow pit.
Where materials of differing quality are available for placing in embankments the
Engineer may instruct that certain materials should be excluded from the upper layers of
fill. He may also instruct that other materials should be set apart or obtained from borrow
areas and used only for these upper layers. The Contractor shall adjust his earthworks
programme to comply with any such instruction by the Engineer.
The Contractor shall ensure that earthwork proceeds towards completion in an orderly
and continuous manner. Final approval of previous work will only be given immediately
prior to the placing of each subsequent layer and the Contractor shall submit a written
request for approval at least 12 working hours before he intends to cover a completed
layer.
Fill materials shall be placed immediately after approval of the previous layer has been
given to ensure retention of moisture content.
Should any layer be left unprotected for more than 24 hours subsequent to approval, the
Contractor shall request re-approval by the Engineer.
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The Engineer may instruct that any embankment layer, cutting or original ground be
proof rolled with a loaded scraper or truck. All such proof rolling will be at the
Contractor's expense.
The slopes of embankments shall be trimmed by hand or by approved mechanical means

to uniform batters as shown on the Drawings or as instructed by the Engineer. Such
trimmings shall be completed before the commencement of sub-base construction.
Any rock or boulder appearing in the face of an embankment shall be trimmed back to
within the tolerance specified and in addition any such rock or boulder which, in the
opinion of the Engineer, is unstable shall be completely removed and the resulting void
filled with compacted material to the approval of the Engineer.
3.4.3.2 Embankments of Common Material
(a) Construction
Fill other than rock fill shall be deposited in layers not exceeding 150 mm compacted
depth unless, as a result of Site compaction trials, the Contractor has satisfied the
Engineer that his compaction equipment is capable of achieving the specified
densities at a greater depth; in no case shall this depth exceed 300 mm. Each layer
shall extend over the full width of the embankment.
During the construction of embankments, the Contractor shall control and direct
constructional traffic uniformly over the full width. Fill material shall not be
stockpiled on embankments, unless this is permitted by the Engineer.
When constructing embankments up to bridges and over culverts, the Contractor

shall raise the embankment equally on each side of such structures.
Isolated boulders, each within the range 0.025 m3 to 0.1 m3 in size may be
incorporated more than 500 mm below formation level in embankments constructed
with material other than rock at the discretion of the Engineer, provided that the
specified compaction requirements are met.
The moisture content of fill material immediately prior to compaction shall be within
plus or minus 2 per cent of the optimum moisture content for the densities specified
and shall be kept within these limits until compaction is complete.
If necessary, the moisture content shall be adjusted by mixing and harrowing and
leaving to dry if the moisture content is too high or by mixing in water by sprinklers
if the moisture content is too low.
The Contractor shall provide all water necessary for compaction. The water to be
used shall be clean and fresh, free from salts and shall be obtained from a source
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approved by the Engineer. Where directed, the Contractor shall arrange for the
analysis of water at his own expense.
The Contractor shall provide all equipment necessary for conveying and distributing
water. Water shall be evenly sprinkled on the surface of the fill material by pressuri-
zed sprinkling machines of a type approved by the Engineer, and capable of
distributing water at a predetermined and constant rate.
(b) Compaction
Each type of fill material shall be compacted by equipment which is suitable for the
purpose. Suitable means shall be provided for compacting fill adjacent to structures
and in other places where heavy equipment cannot operate. The distribution of the
wheels on any roller shall be such that the whole of the ground surface within the
width of the roller is loaded during each pass. Rollers or other heavy equipment may
be used in the vicinity of concrete structures only after the concrete has been
sufficiently cured and when the Engineer has given permission.
In accordance with Clause 2.3.1 of this Standard Specification, the Contractor shall
submit to the Engineer his proposals for the compaction of each main type of
material to be used in the embankments, including the types of equipment, the
number of passes and the compacted depth of layer. The Contractor shall carry out
site trials for earthworks and shall satisfy the Engineer that all the specified require-
ments regarding compaction can be achieved. Site compaction trials shall be
completed before permanent work will be allowed to commence.
Natural ground under embankment to a depth of 300 mm and each layer of fill
material shall be compacted to a dry density at least fulfilling the compaction
requirements specified in Table 3.4.3.2/1.
TABLE 3.4.3.2/1: Tests and Required limits for compaction of natural ground
and Embankment Fills
Type of Soil Cohesive Granular

Depth from formation
level D (m) 1<D 0.3<D<1 1<D 0.3<D<1
Action Com- Com- Com- Com-

pact pact pact pact
Material Test AASHTO T99 T99 T99 T99
Required Compaction
Limit LLs% 90 93 92 95
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3.4.3.3 Rock Fill Embankments
(a) Construction
Rock fill shall be deposited in horizontal layers not exceeding 750 mm loose depth
and shall extend over the full width of the embankment except for specified external
cover to slopes. The materials shall be spread and levelled by a crawler tractor
weighing not less than 15 tonnes. Each layer shall consist of reasonably well graded
rock and shall be blinded with smaller rock fragments and gravel so far as to fill as
many of the voids as possible before the next layer is placed. Rock fill shall not be
used for the top 300 mm of the embankment.
Where specified in the Specifications of Particular Application or instructed by the

Engineer, the Contractor shall place rock as fill to swampy or waterlogged areas. The
material shall have a maximum dimension for any piece of 300 mm. The first layer
of material shall be tipped and pushed out to a uniform layer of maximum thickness
750 mm, or as directed by the Engineer, and be rolled and trafficked until it is fully
embedded over the whole area instructed.
(b) Compaction
Each layer of rock used as fill in embankments shall be systematically compacted by

at least 8 passes of a vibrating roller with a static load of at least 36 KN per 1 metre
width of roll or a grid roller with a static load of at least 80 KN per 1 metre width of
roll or other equipment approved on site trials in accordance with Clause 2.3.1 of
these Standard Specifications.
3.4.4 Control and Acceptance Tests
The Contractor shall make such tests in advance of excavation as are considered
necessary by the Engineer to determine the suitability of materials to be excavated for use
as fill. Tests may include gradings, Atterberg Limits, compaction and CBR tests and shall
normally be carried out according to the frequency specified in Clause 2.4.10.
In-situ density tests of fills shall be carried out at a frequency of one per 100 m per layer
or as directed by the Engineer.
The compaction to be obtained in any part of the earthworks shall be expressed as a

percentage of the maximum dry density (MDD) of the soil at optimum moisture content
as measured by tests specified in Table 3.4.3.2/1.
The minimum standards of compaction to be achieved are given by the lower

specification limits, LLs, for compaction in Table 3.4.3.2/1 together with the procedure
for statistical control according to control method A, outlined in Sub-clause 2.3.2.2.
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Alternatively, the Contractor may choose to use control method B as outlined in Sub-
clause 2.3.2.3. In such case, the mean density shall be LLs + 6% and the lower limit for
individual values shall be LLs + 3%.
The Contractor shall obtain the approval of the Engineer's Representative to each layer of
fill before spreading a further layer on top.
Testing will be carried out in accordance with Clause 2.4.1. The Engineer may at any
time carry out tests on compacted fill. If the test results show the compaction to be
inadequate, the Contractor shall at his own expense carry out such further work as is
necessary to bring the compacted fill within the specification.
Earthworks shall be measured by the cubic metre of compacted material measured in the
completed embankment. No separate measurement or payment shall be made for
excavation, except as extra over for excavation of rock as described below.
The quantity shall be computed from average end areas taken at intervals not greater than
25 m along the centre line of the road. The end areas shall be calculated from ground
levels taken after excavation of unsuitable material, clearing, grubbing and top soil strip
and after preparation and compaction as specified in Clause 3.4.3 and the designed cross
section of the embankment.
Material shall be classified as either Rock or Material other than Rock, in accordance
with Clause 3.1.2 of this Standard Specification.
Excavation of rock shall be measured by the cubic metre of material classified as rock,
measured in place before excavation.
The tendered rate shall be extra over the rate for fill and shall include full compensation
for all additional costs of drilling, blasting and handling of rock material.
The rates for fill shall include the cost of:
(i) provision of the material including excavation in cutting, side drain, borrow area
or bench, selecting, handling, hauling for any distance within the "Free Haul
Distance" of one kilometre, stockpiling, processing, depositing in position,
spreading, watering and compacting in layers and to cambers, trimming slopes
to profiles, trimming and regulation, and blinding;
(ii) the effect of consolidation, settlement, bulking and shrinkage, within and
beneath the fill including any additional material requiring to be placed;
(iii) adjusting the moisture content of the material as necessary prior to and after
placing, mixing to ensure a uniform material and even moisture distribution, and
for protection from water including the use of impermeable membrane and for
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the replacement of any material lost after deposition by erosive action of wind or
water or any other causes;
(iv) in the case of filling with rock, special compaction effort and filling of voids as
specified in Sub-clause 3.4.3.3;
(v) proof rolling;
(vi) forming and trimming of cuttings and side drains and drainage of original
ground prior to earthworks.
(vii) all survey work necessary whether before earthworks are commenced, during, or
after completion and for submission of records;
(viii) provision of samples, testing and submission of records and carrying out
laboratory and Site trials in accordance with the Specification.
Pay Item
Unit of
No Name Measurement
3.4 -1 Embankment Fill Cubic metre

Common Material
3.4 -2 Extra over Item Cubic metre
for rock excavation
3.4 -3 Overhaul, Fill Cubic metre x km
3.5 SUBGRADE
3.5.1 Scope
This Paragraph covers provision, placing, watering and compaction of materials for the
sub-grade, defined as the layer from a depth of 0.3 m to the finished formation level and
preparation of existing road bed in cuttings to meet the specifications for sub-grade.
3.5.2 Materials Requirements
(a) Suitable material as defined in Clause 3.4.2 shall have a soaked CBR not less than
8% when tested at the dry density required for the layer.
(b) "Selected material" shall meet the following requirements:
(i) The plasticity index (PI) shall not exceed 12
(ii) The liquid limit (LL) shall not exceed 40
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(iii) The percentage passing a 0.075 mm sieve shall not exceed 35%
(iv) The sand equivalent shall not be less than 20
(v) The soaked CBR shall not be less than 10% when tested at the dry density
required for the layer and the material shall not swell in the CBR test
(vi) The maximum dry density determined by the AASHTO T180 compaction shall
not be less than 1,900 kg/m3
(vii) The material shall not contain particles with a maximum dimension exceeding
100 mm.
(c) Stabilized materials shall meet the specifications stated in Clause 5.3.2.
The sub-grade shall be constructed as specified in Clause 3.4.3, apart from the
compaction requirement which for the sub-grade shall meet the requirements of Table
3.5.3./1.
The level tolerances referred to in Sub-clause 2.3.2.3 shall be as follows:
H90 = ± 25 mm
Hmax = ± 35 mm
When stabilized materials are laid, construction shall be carried out as specified in Clause
5.3.2.
TABLE 3.5.3/1: Tests and Required Limits for Compaction of Sub-grade
Type of Soil Suitable Selected Granular

Cohesive Granular Material
Depth from forma-
tion level D (m) 0<D≤0.3 0<D≤0.3 0<D≤0.3
Material Test
AASHTO T99 T99 T180
Required Compac-
tion Limit LLs% 95 97
94
Material Test
BS 1377-14 (1) 1377-14
Required Compac-
tion Limit LLs%
94
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(1) Vibrating hammer to be used for granular materials with less than 15% by weight
passing 0.075 mm sieve.
3.5.4 Control and Acceptance Tests
Construction compliance shall be based on in-situ density tests carried out at a frequency
of one per 100 m of laid material per layer or as directed by the Engineer.
The minimum standards of compaction to be achieved are given by the lower

specification limits, LLs, for compaction in Table 3.5.3/1, together with the procedure for
statistical control, method A, outlined in Sub-clause 2.3.2.2.
Alternatively, the Contractor may choose to use control method B as outlined in Sub-
clause 2.3.2.3. In such a case, the mean density shall be LLs + 4% and the lower limit for
individual values shall be LLs + 2%.
Measurement of sub-grade shall be done as specified in Clause 3.4.5 and the rates shall
include the costs detailed under (i), (iii), (v), (vi), (vii) and (viii) of the above-mentioned
Clause.
Preparation of existing roadbed in cuttings to a depth of 0.3 m shall be measured by the

square metre of road bed scarified, reshaped and compacted as required for the sub-grade
layer of suitable material. The rate for preparation of existing roadbed shall include the
cost of all labour, equipment, tools and incidentals necessary to complete the works.
When the Bill of Quantities does not contain an estimated quantity for preparation of
existing roadbed, the works shall not be paid for directly but shall be considered as a
subsidiary obligation of the Contractor covered under other items.
Pay Item
Unit of
3.5.-1 Sub-grade, Suitable material Cubic metre

3-5.-2 Sub-grade, Selected material Cubic metre
3.5.-3 Preparation of existing roadbed Square metre
3.5.-4 Overhaul, sub-grade Cubic metre x km
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3.6 EXCAVATION AND FILLING FOR STRUCTURES
3.6.1 General
This section covers all excavation and filling operations to bridges, box culverts,
retaining walls and other major structures as well as the excavation and filling work
required for existing bridges and culverts where these have to be demolished, extended or
modified.
The material from excavations will be classified in accordance with the classification in
Clause 3.1.2 of the Standard Specification.
3.6.2 Excavation of Foundation for Structures
Prior to commencement of any excavation, the Contractor shall notify the Engineer in
good time to ensure that measurements, cross sections and levels of the undisturbed
ground level can be taken in order that an average ground surface from which the
excavation is to be measured can be established and agreed upon between the Engineer
and the Contractor.
The excavations of the foundations for structures shall be kept to a minimum. Where, in
the opinion of the Engineer, the casting of concrete against the excavated earth faces is
not advisable, or where formwork has to be provided, the extremities of the excavation,
for purposes of measurement and payment, shall be deemed to be vertical planes parallel
to and 0.6 m outside the perimeter of the member for which formwork is to be provided,
typically 0.6 m outside footings for structures. The sides of the excavation shall be kept
vertical and shall be properly timbered or sheet piled, shored and strutted as necessary to
prevent subsidence or slipping of the surrounding soil.
Where suitable stable material is encountered during excavation, that part of the trench or
foundation pit shall be excavated to the neat dimensions of the base unless directed
otherwise by the Engineer. Over excavation in hard material shall be backfilled with the
same class of concrete as that in the base or with mass concrete fill as specified or as
directed by the Engineer. Boulders, logs or any unsuitable material excavated shall be
spoiled.
When hard material suitable for foundation is encountered at the foundation level, it shall
be cut and trimmed to a firm surface, either level, stepped or serrated as required.
Where the material at the foundation level is soft material, or hard material that
deteriorates on exposure, excavation to final grade and levels shall not be made until just
before placing of the blinding layer.
If, in the opinion of the Engineer, unsuitable material is encountered at foundation level,
such material shall be removed and replaced with material of suitable quality as directed
by the Engineer.
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The Contractor shall take the necessary precautions to safeguard the stability and safety
of the excavations and adjacent structures and keep the excavations dry throughout the
work.
No concrete shall be placed before the excavation has been inspected and approved by
the Engineer.
3.6.3 Utilization of Excavated Material
Excavated material and material recovered from temporary work shall, so far as it is
suitable, be utilised for backfill. Material unsuitable for use as backfill or in excess of the
quantity required to complete the backfill shall be spoiled or utilised as directed by the
Engineer.
Excavated and stockpiled material shall be deposited so as not to endanger the

uncompleted structure, either by direct pressure or indirectly by overloading the banks
contiguous to the structure, or in any other way.
3.6.4 Backfilling of Excavations and Filling for Structures
Filling and backfilling shall be made with the excavated material, if it is suitable in the
opinion of the Engineer, or with selected material approved by the Engineer. Selected
material shall comply with the Specifications for sub-base material, Class D, Grading
0/60 mm. The filling material shall be brought up in horizontal layers not exceeding 150
mm in compacted thickness. Each layer shall be thoroughly mixed, watered or dried as
necessary, and compacted to a mean dry density of 101 % MDD (AASHTO T99) and the
lower limit for individual values shall be 98% MDD (AASHTO T99) according to
control method B in sub-clause 2.3.2.3.
Timbering and sheeting left in for the purpose of supporting the excavation shall be eased
up 150 mm at a time in steps with the backfill layers, and compaction to the requirement
above shall be obtained under and behind such sheeting.
Where, according to the drawings, a granular filter material shall be placed, a sliding
form shall be used to separate the granular filter material and adjacent fill material. The
selected granular filter material shall be brought up and compacted at least 150 mm
above the general fill.
(a) Excavation
Excavation for structures shall be measured by the cubic metre.
The net volume of the excavations shall be calculated by multiplying the plan area
inside the vertical planes as defined in Clause 3.6.2 by the average depth and no
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allowance will be made for working space. The average depth shall be calculated as
the difference between the initial ground level as agreed between the Engineer and
the Contractor or the formation level, whichever is the lower, and the required
foundation level.
Excavated material not used for backfill or not taken to spoil, but used in the
construction of embankments or other parts of the work, as directed by the Engineer,
will be paid for under excavation for structures as well as under the relevant item for
the purpose for which it is used.
The tendered rate shall include full compensation for all excavation, temporary
stockpiling, timbering, shoring and strutting, for preparing the bottom of the
excavation, for disposal of excavated material unsuitable for backfilling or surplus to
backfilling requirements, for dealing with any surface or subsurface water and for
any other operations necessary to complete the work as specified.
No payment will be made for overhaul of excavated material carried to spoil.
Pay Item
Unit of
3.6-01 Excavation for structures Cubic metre

0-2 m depth, common material
3.6-02 As Item 3.6-01, but for rock etc

in increments of 2.0 metres Cubic metre
(b) Backfilling
The unit of measurement shall be the cubic metre of material in place after
compaction and the quantity shall be calculated from the leading dimensions of the
excavation as specified or authorized by the Engineer. If excavations are made in
excess of the dimensions specified herein, the quantity of backfilling shall
nevertheless be based upon the authorized dimensions.
The tendered rate shall include full compensation for backfilling of structures, for
watering or drying of the material and for compaction to the specified densities.
In addition, the rates tendered for backfilling with selected material shall include full
compensation for supplying selected material from approved sources, including a
free haul of 1.0 km.
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Pay Item
Unit of
3.6-10 Backfilling, using the

Cubic Metre
excavated material
3.6-11 Backfilling, using

Cubic Metre
imported selected material
3.6-12 Overhaul of backfill

Cubic Metre x km
material, for haul in
excess of 1 km free haul
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S E C T I O N No 4
DRAINAGE
4.1 GENERAL
4.1.1 Scope of Section
This Section covers the provision and installation of culverts, such as:
circular concrete pipes

nestable corrugated metal pipes
multi-plate corrugated metal pipes and pipe arches
including any inlet and outlet structure.
This Section covers also provision of
open drains
sub-surface drains
minor drainage structures
protection works
Concrete box culverts are covered in Section 6 of this Standard Specification.
4.1.2 Order of Work
(a) The drawings may give a guide only to the location and size of each culvert. Precise
details of length, skew and invert levels will be issued to the Contractor from time to
time as construction proceeds. The Contractor should allow in his programme a
period of 14 days between his submission of cross-sections and the issue of precise
culvert details.
(b) All culverts and drainage works shall be carefully programmed and the Contractor
shall normally allow in his programme for the completion of all pipe culverts and
drainage works prior to the construction of embankments over or besides them. Such
culverts shall normally be constructed under "embankment conditions" defined in
Clause 4.4.3.
(c) Where drainage conditions are such that it is not necessary to construct a pipe culvert
ahead of the embankment, the Engineer may consent to its installation after
construction of the embankment under "trenched conditions" as defined in Clause
4.4.3 on the following conditions:
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(i) that the Contractor will be responsible for any damage or delays to the culverts or to
the embankment earthworks;
(ii) that the construction of the culvert shall follow immediately upon the substantial
completion of the embankment earthworks.
4.1.3 Excavations
The Contractor shall carry out all excavations for culverts, head and wing walls, drainage
channels, etc., to the lines, levels, inclinations, and dimensions shown on the Drawings or
If the excavations be dug to a greater depth or width than is necessary, then the
Contractor shall at his own expense backfill the excess excavation with approved
materials, compacted to the density of the adjacent ground, to the correct levels and
dimensions to the approval of the Engineer.
When instructed by the Engineer, the Contractor shall carefully set aside the various
materials encountered so that they may be replaced in their original position.
Trenches shall be kept clean and free from water during the excavation, laying of pipes
and backfilling, and the Contractor shall dig diversion channels, erect cofferdams or
otherwise de-water the trench.
Where, in the opinion of the Engineer, any invert has become soft or unsuitable to receive
the culvert or concrete bed due to the Contractor's method of working, the Contractor
shall at his own expense remove and replace the material with non-structural concrete as
specified in Clause 6.1.1 or other approved material as instructed by the Engineer.
The top 150 mm in the trench invert shall be compacted to a dry density of at least 97%
MDD (AASHTO T99) or at least the density of the adjacent ground, whichever is the
greater, unless otherwise specified.
For culverts which are to be constructed under embankment conditions as defined in

Clause 4.4.3, the Contractor shall level the existing ground by excavating and filling. He
shall then compact the ground for 150 mm below invert or underside of bedding material
to a dry density of 97% MDD (AASHTO T99) or to the density of the adjacent ground,
whichever is the greater, such that the foundation for the culvert or bedding is true to
grade and of uniform density over the whole length of the culvert.
The Engineer's approval of all excavation for culverts shall be obtained prior to
commencing any bedding for the culvert or installation of the culvert itself.
The sides of pits, trenches and other excavations shall, where required, be adequately
timbered and supported to the satisfaction of the Engineer, and all such excavations shall
be of sufficient size to enable the pipes and concrete to be laid accurately, and proper
refilling and compaction to be carried out.
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Where instructed by the Engineer, shoring and supporting timber shall be left in trenches
or other excavations.
Excavations carried out in the diversion, enlargement, deepening or straightening of

streams and rivers or in the formation of new water courses shall be performed as shown
on the Drawings or as instructed by the Engineer, and may include trimming of slopes,
grading of beds and disposal of the excavated materials.
Where water courses have to be diverted, the original channels shall be cleared of all
vegetable growth and soft deposits and carefully filled in with approved materials,
deposited and compacted as instructed by the Engineer.
The Contractor shall at his own expense make good any damage caused by prolonged
and/or excessive pumping and shall take all precautions necessary for the safety of
adjoining structures and buildings by shoring or otherwise, during the time the trenches
are open.
4.1.4 Cleaning and Maintenance
Before any drainage channel, culvert or other drainage structure is brought into use, the
Contractor shall ensure that such channel or structure is free from all silt and extraneous
material to the satisfaction of the Engineer, and the removal and disposal of all such
material shall be at the Contractor's expense.
The Contractor shall be responsible for maintaining all drainage structures, culverts,
channels and drains free of silt and extraneous material at his own expense until the issue
of the Certificate of Completion.
4.2 OPEN DRAINS
4.2.1 Scope
This paragraph covers all work in connection with the excavation and construction of
open drains as defined below at locations and to the sizes, shapes, grades and dimensions
as shown on the drawings or as directed by the Engineer.
4.2.2 Definitions
(a) Open-drain excavation shall consist of excavating open drains and channels inside or
outside the road reserve, including channels to direct the course of streams, all as
shown on the Drawings or as directed by the Engineer.
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(b) Open-drain excavation shall include all excavation required to construct a channel
with a bottom width of less than 4 m or V-shaped channels with side slopes steeper
than 1:4 and total width at the top of less than 5 m. Any excavation required to
construct a channel with a bottom width of 4 m or more, or a V-shaped channel with
side slopes equal to or flatter than 1:4 or width at the top more than 5 shall be classed
as "cut" and shall be measured and paid for under earthworks.
Furthermore, drains within the road prism, such as median drains, side drains and
drains on excavation slopes and benches, shall be classed as "cut" and shall be
measured and paid for under earthworks, except, where, due to the shape of such
drains, excavation by bulk excavating equipment would not be feasible and either
hand excavation or special excavating equipment, such as backactors, draglines or
similar, would be required, in which case such excavation shall be paid for as open-
drain excavation.
Open drains shall be constructed true to line, grade and cross section and shall be so
maintained for the duration of the Contract.
Care shall be exercised to avoid excavation below the required grade for drains and any
excavation carried below the required grade shall be backfilled with suitable material and
compacted to at least 97% MDD (AASHTO T99) or to the density of the adjacent
ground, whichever is the greater, at the Contractor's own expense.
Material resulting from the excavation of open drains shall be used in the construction of
fills, banks and dykes, or for other purposes, or be disposed of to spoil, all as directed by
the Engineer.
Excavation for open drains shall be measured by the cubic metre of material excavated,
measured in place before excavation. The quantity shall be calculated from average end
areas determined at intervals not greater than 10 m along the centre line of the drain. The
end areas shall be calculated from ground levels measured prior to commencement of
excavation, after execution of bulk earthworks, and the cross section of the drain as
shown on the Drawings or instructed by the Engineer.
Only open drains as defined in Clause 4.2.2 shall be measured.
In respect of material resulting from open-drain excavation and not taken to spoil but
used elsewhere in the construction of the Works, payments shall be made for open-drain
excavation as well as for any item of permanent construction built from such material.
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Material from open-drain excavation and taken to spoil will be paid as open-drain
excavation only.
The tendered rate shall include full compensation for the excavation of the material to the
required lines, levels and grades and in case of disposal of the material the rate shall
include free haul of 1 km.
For payment purposes a distinction shall be made between rock and material other than
rock as defined in Clause 3.1.2.
Material from rock excavation paid for under this Clause shall if used as fill be measured
and paid for under earthworks as fill of common material.
Pay Item
Unit of
4.2-1 Excavation for Open Drains, Cubic metre

Common Material
4.2-2 Excavation for Open Drains, Cubic metre
Rock
4.2-3 Overhaul on excavated Cubic metre x km
material carted to spoil,
for haul in excess of
1 km free haul
4.3 SUB-SURFACE DRAINS
4.3.1 Scope
This Paragraph covers all work in connection with the materials used for, and the
excavation and construction of all subsurface drains, at locations shown on the drawings
or as directed by the Engineer.
4.3.2 Material Requirements
(a) Pipes
Pipes to be used in subsurface drains shall conform to AASHTO Specifications. The

following list shows types of pipes which shall be used.
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Type of Pipe AASHTO

Specification
Vitrified clay pipe M 65
Non-reinforced concrete pipe M 86
Perforated concrete pipe M 175
Porous concrete pipe M 176
Asbestos - cement
under-drain pipe M 189
Corrugated polyethylene
drainage tubing M 252
Polyvinyl Chloride (PVC)plastic drain M 267
(b) Permeable Material
Permeable filter material for sub-surface drains shall consist of sand and/or crushed
stone or gravel of suitable grading. Use may also be made of synthetic fibre filter
fabrics. Permeable materials shall conform to the following requirements:
(i) Sand shall be clean, hard sand obtained from approved borrow sources.
Depending on the particular conditions of each case, the required sand shall be
either of coarse, medium or fine grade. When suitable sand is not available from
borrow sources, the Engineer may require that it be procured from commercial
sources outside the Site.
(ii) Crushed Stone and Gravel shall be graded conforming to the following
requirements:
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Percentage passing
Sieve Gradings
mm Coarse Fine
25.0 100
16.0 55-90 100
8.0 15-40 40-60
4.0 - 15-40
2.0 0-15 -
1.0 - 0-12
0.075 0-8 0-6
The aggregate shall be evenly graded between these limits. The Los Angeles
abrasion value of the stone shall not exceed 30%.
The Engineer shall indicate the grades of sand and crushed stone to be used to
suit each case.
(c) Synthetic Fibre Filter Fabric
The synthetic fibre filter fabric (geotextile) shall be capable of retaining the soils it is
to be used with, whatever the application, and the fabric/retained soil interface shall
not develop permeability lower than that of the retained soil. In all cases the
geotextile shall exhibit an intrinsic permeability not less than ten times the
permeability of the retained soil.
The Contractor shall submit samples of the geotextiles he proposes to use together
with the manufacturer's specifications for approval by the Engineer before
purchasing such materials.
Trenches for sub-surface drains shall be excavated to the dimensions and gradients
shown on the Drawings or directed by the Engineer.
The specified width of trenches and the width of excavation measured for payment shall
not be less than 0.5 m, but with the Engineer's permission the Contractor may reduce the
actual width.
A layer of permeable material of the class and thickness as shown on the Drawings shall
be placed on the bottom of the trench and be lightly tamped and finished to the required
gradient.
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Pipes of the type and size required shall then be firmly bedded on the permeable material,
true to level and grade, and be coupled where required. Thereafter the trench shall be
backfilled with further permeable material to such height above the pipes as shown on
the Drawings or as directed by the Engineer. The permeable materials shall be lightly
compacted and finished to the required level. Further layers of finer permeable material
shall then be placed, lightly compacted and finished to an even surface, as directed by the
Engineer. The remainder of the trench, if any, shall be backfilled with approved
impermeable material and as required by the Engineer, in layers not exceeding 100 mm
and compacted to at least the same density as the surrounding material. The trench must
be specially protected against the ingress of surface water until the impermeable layer has
been completed.
Permeable material must be placed in layers of not more than 300 mm at a time and be
lightly compacted. The total thickness of each type of permeable material must be
carefully controlled, and when placing the thinner layers suitable spacers must be used.
When placing successive layers, the lower layer must not be walked on and as far as
possible must not be disturbed. Care shall be taken to prevent the contamination of
permeable material during construction of the sub-surface drains and all permeable
material contaminated by soil or silt shall be removed and replaced by the Contractor at
his own expense.
Where spigot and socket pipes are used, the socket end shall be laid upgrade with the
spigot fully entered into the adjacent socket. Where plain butt-joint pipes are used, they
shall be laid firmly together to prevent infiltration of backfill material. Perforated and
slotted pipes shall joined by couplers. Perforated pipes shall be laid with the perforations
at the top or at the bottom, as instructed. The higher end of sub-surface drain pipes shall
be sealed off with a loose concrete cap of non-structural concrete, as shown on the
Drawings, and at the lower end the pipe shall be built into a concrete head wall providing
a positive outlet or connected to storm water pipes or culverts.
Any section of the sub-surface drain constructed from pipes without perforations or slots
shall be backfilled with impermeable backfill material as described in the foregoing.
Where suitable, the excavated material may be used for backfilling.
Polyethylene Lining to Trenches for Sub-Surface Drains
Where shown on the Drawings or directed by the Engineer, trenches for sub-surface
drains shall be lined with approved polyethylene sheeting 0.15 mm thick. The
polyethylene sheet shall cover the bottom of the trench and shall extend upward on both
sides as far as directed by the Engineer in each particular case, in order to form a
waterproof channel. At joints the polyethylene sheeting shall be heat-welded together or
lap by a minimum of 200 mm.
When backfilling the trench with permeable material, care shall be taken not to displace
or damage the polyethylene lining in any way. The use of plastics other than polyethylene
will be considered, provided that the material is of equal quality and is approved by the
Engineer.
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Synthetic Fibre Filter Fabric
Where shown on the Drawings or directed by the Engineer for use in sub-surface drains,
filter blankets and other applications, synthetic fibre filter fabrics shall be procured,
furnished and installed. Filter fabric shall not be exposed to direct sunlight for prolonged
periods and shall be protected from mechanical damage during installation and
construction.
(a) Excavation for Sub-Surface Drains
The unit of measurement shall be the cubic metre of material excavated, measured in
place before excavation.
In respect of material resulting from sub-surface drain excavation and not taken to
spoil but used elsewhere in the construction of the works, payment shall be made for
sub-surface drain excavation as well as for any item of permanent construction built
from such material. Material from sub-surface excavation and taken to spoil will be
paid as sub-surface excavation only.
The tendered rate shall include full compensation for the excavation of the material
to the required lines, levels and grades, all temporary shoring and strutting, and in
case of disposal of the material as directed; including a free haul of 1.0 km. Overhaul
on material carted to spoil shall be paid for as specified in Clause 4.2.4.
For payment purposes, a distinction shall be made between rock and material other
than rock, as defined in Clause 3.1.2.
Material from rock excavation paid for under this Clause shall, if used as fill, be
measured and paid for under earthworks as fill of common material.
Pay Item Unit of

4.3 -10 Excavation for sub-surface Cubic metre

drains, 0-2 m depth,
common material
4.3 -11 As Item No. 4.3.-1, but Cubic metre

for rock
4.3 -12 Excavation for sub-surface Cubic metre

drains, 2-4 m depth,
common material
4.3 -13 As Item No. 4.3.-3, but Cubic metre

for rock
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Etc, in increments of 2 m depth.
(b) Impermeable Backfilling to Sub-surface Drains
The unit of measurement shall be the cubic metre of backfill, measured in place after
backfilling.
The tendered rate shall include full compensation for procuring, furnishing, placing
and compacting the backfilling and for a free haul of 1.0 km.
Pay Item Unit of

4.3 -20 Impermeable Backfilling Cubic metre

for sub-surface Drains
(c) Permeable Material in Sub-Surface Drains
The unit of measurement shall be the cubic metre of approved permeable material in
place in the drains, calculated from the authorized dimensions.
The tendered rate shall include full compensation for procuring, furnishing and
transporting from borrow areas and placing the material as specified.
For payment purposes, a distinction shall be made between the different classes of
permeable material.
A provisional sum may be allowed to cover the cost of authorized additional

expenditure incurred in procuring, transporting and furnishing approved filter sand
from commercial suppliers, including the cost of transporting the material to the Site.
Pay Item Unit of

4.3 -30 Permeable Material in Cubic metre

Sub-surface drains,
Crushed Stone
4.3 -31 Filter Sand obtained from Cubic metre

Borrow Areas
4.3.-32 Allowances for Additional

Cost of Procuring Filter
Sand (Provisional Sum)
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(d) Pipes in sub-surface drains
The unit of measurement for pipes shall be the metre of pipe, measured in place
along its centre line, including the length of fittings. The unit of measurement for fit-
tings shall be the number of fittings, irrespective of the type.
The tendered rate shall include full compensation for procuring, furnishing, laying
and jointing the pipes and fittings as specified.
Pay Item Unit of

4.3.-40 Pipe: Material, Type, Metre

Dimension, Specification
or Description, etc.
4.3.-41 Fitting: Type, Dimension Number

Specification, etc.
etc. for the different pipes and fittings
(e) Polyethylene sheeting and filter fabric
The unit of measurement shall be the square metre, measured net from the specified
dimensions, of polyethylene sheeting or filter fabric supplied and installed as
specified.
The tendered rate shall include full compensation for furnishing, procuring, cutting,
overlap, jointing, placing and protecting the polyethylene sheeting or filter fabric as
specified, as well as for wastage.
Pay Item Unit of

4.3 -50 Polyethylene sheeting

0.15 mm thick, or equal
approved material, for
lining sub-surface drains square meter
4.3 -51 Synthetic fibre filter

fabric (description of
type, grade, etc.) square meter
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4.4 CULVERTS
4.4.1 Scope
For the purposes of this Specification, the term "pre-fabricated culverts" shall mean
culverts constructed from:
(a) Circular pre-fabricated concrete pipes, hereinafter called "concrete pipe culverts";
(b) Pre-fabricated concrete culverts other than pipe culverts, hereinafter called "portal
culverts" or "rectangular culverts";
(c) Pre-fabricated corrugated metal pipes and pipe arches, hereinafter called "metal
culverts".
Other types of pre-fabricated culverts not mentioned above, if required, will be specified
in the Specifications of Particular Applications or in the Bill of Quantities or on the
Drawings.
The pre-fabricated culvert units shall be factory produced by a reputable manufacturer of

these articles and shall comply with the following requirements:
(a) Pre-Cast Concrete Pipe Culvert Units
Pre-cast concrete pipe culvert units shall comply with the requirements of AASHTO
M86.
(b) Rectangular Pre-Cast Concrete Culvert Units
Rectangular pre-cast concrete culvert units shall comply with the requirements of
AASHTO M273.
(c) Corrugated Metal Culvert Units
Corrugated metal culvert units shall comply with the requirements of AASHTO M36
for riveted and nestable pipes and pipe arches, and AASHTO M167 for multi-plate
pipes and pipe arches.
Culvert units of which the gauge is below that specified, or of which the spelter
coating has been bruised or broken, or which show defective workmanship shall be
rejected.
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The following defects are specified as constituting poor workmanship, and the
presence of any or all of these defects, or other defects, in any individual unit or in
general, shall be sufficient cause for rejection:
Uneven laps, distorted shapes, variations from a straight centre line, ragged or
diagonal-sheared edges, loose rivets, unevenly lined or spaced rivets, poorly
furnished rivet heads, illegible brands, lack of rigidity, dents or bends in the metal.
Metal culverts shall be supplied with inlet and outlet ends that have been finished as
follows, whichever is shown on the Drawings or directed by the Engineer:
(i) Where no concrete inlet and outlet structures are required, inlet and outlet units
shall be bevelled to suit the skew angle of the culverts and the slope.
(ii) Where concrete inlet and outlet structures are required, the ends of the culvert
units shall be cut to the required plan skew angle (if any) and be provided with
anchor bolts projecting radially around the edge, as shown on the Drawings, for
securing the metal culvert to the concrete inlet and outlet structures.
The Contractor is warned against the practice of storing nestable culvert units on Site
in such a manner that moisture can accumulate between the contact faces of the
nested units, as this may adversely affect the spelter coating and render the units
liable to rejection. Any units damaged by corrosion shall, if not rejected, be repaired
by cleaning all affected areas and applying at least two coats of an approved zinc-rich
epoxy primer in accordance with the manufacturers instructions or as directed by the
Engineer.
(d) Fine Granular Material
Wherever the use of fine granular material is specified in this Section for the bedding
of culverts, it shall mean sand or other cohesionless material, all of which shall pass a
8 mm square mesh sieve, and not more than 10% shall pass a 0.150 mm square mesh
sieve.
(e) Protective Coating for Metal Culverts
Where corrosive soil or waste conditions are likely to cause excessive corrosion of
metal culverts, the Engineer may order that pre-fabricated units be protected by the
application of a mastic asphalt protective coating before installation. The coating
shall be applied to the inside or the outside, or to both sides of the metal culvert units,
as directed by the Engineer.
The material to be used shall be a proprietary brand mastic asphalt containing

asbestos fibres and mineral filler such as "Bituseal" or equal approved material and
shall be supplied in a spray or brush grade, as specified.
The surfaces to be protected shall be cleaned to remove all moisture, dirt, oil, paint,
grease, alkalis, rust, mill scale or other deleterious matter.
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The material shall be mixed until all asbestos fibres and mineral filler are uniformly
distributed.
Spray-grade mastic shall be applied by means of an airless gun and shall be of

suitable consistency without the addition of excessive amounts of thinner.
Brush-grade mastic shall be applied with an ordinary roofing brush and the second
coat shall be applied at right angles to the first coat.
The final film thickness shall be a minimum of 1.30 mm measured on the crest of
corrugations, or such other thickness as may be specified.
Care shall be taken not to damage the protective coating, which must be allowed to
harden before handling or assembly. All damage to the coating shall be repaired
before assembly.
(f) Skewed Ends
Where culverts are to be constructed at a skew angle of more than 20o, the culvert
units at the inlet and outlet of the culvert shall be supplied with skew ends, if
required.
Skewed units shall be supplied by the manufacturer and cutting of skew ends on Site
shall only be allowed if authorized by the Engineer in writing.
Portal and rectangular units shall not be provided with skewed ends unless specified
in the Special Provisions. These culvert units shall be supplied square and the portion
that would otherwise be cut off shall project outside the culvert head walls.
(g) Defects
All broken, bent, chipped, cracked, dented, corroded or otherwise damaged units
shall be repaired to the Engineer's satisfaction or, where this is not possible, be
removed and replaced with undamaged units.
Pre-fabricated culverts shall be constructed under either:
"Embankment conditions" where the pipes are laid approximately on the existing ground
surface and the embankment fill is then constructed on either side and over the culvert; or
"Trenched conditions" where the pipes are laid in a trench excavated below existing
ground level or in a trench excavated in a previously constructed embankment.
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As a rule, culverts shall be constructed under embankment conditions or in a trench

excavated below existing ground level. Only in cases where the Engineer considers it
advisable may prefabricated culverts be constructed in a trench excavated in a previously
constructed embankment.
4.4.3.1 Excavation
(a) Depth of Excavation
The amount by which the excavation is to exceed the proposed level of the invert of
the culvert shall be sufficient to allow for the type and thickness of bedding material
to be placed as specified or shown on the Drawings.
Where rock is encountered in trenches for concrete pipe culverts, it shall be

excavated so that no rock protrudes above the underside of the pipe barrel. A
regulating layer of non-structural concrete shall be placed and compacted on the
excavated rock surface, the top of which shall be at the level of the underside of the
bedding layer.
Where rock is encountered in trenches for corrugated metal pipe culverts, it shall be
excavated to a depth of 150 mm below the invert level of the culvert and replaced
with 150 mm of fine granular material to provide a firm but flexible bed for the
culvert.
(b) Width of Excavation
The widths of trenches shall be sufficient to allow for proper laying, bedding and
backfilling of culverts. The widths given below are widths based on practical design
and construction requirements, and variation in widths of trenches may only occur
with the written approval of the Engineer.
If the width of any trench is increased by slipping or collapsing of the side of the
trench, the Contractor shall inform the Engineer immediately and shall not proceed
with any further pipe-laying or backfilling until the Engineer has reviewed the
circumstances and has given instructions as to the need for altering the class of pipe
or bedding conditions.
(i) Concrete pipe culverts
The width of excavation shall be equal to the nominal internal diameter of the
pipe plus 0.5 m on each side. Where pipe culverts consist of two or more pipes
next to each other, the minimum spacing between adjacent pipes shall be 300
mm or half the pipe outside diameter, whichever is the greater, up to a
maximum of 900 mm.
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(ii) Portal and Rectangular Culverts
Where backfilling is to be done with soil or gravel material, the width of

excavation shall be the outside width of the portal plus 500 mm on either side
for both single or multiple culverts.
(iii) Metal Culverts
The width of excavation shall equal to the internal diameter of the span of the
metal pipe or pipe arch plus 0.8 m on each side of the culvert.
Where metal culverts consist of two or more units next to each other, the
minimum clearance between adjacent culverts shall be 0.8 m.
4.4.3.2 Bedding and Placing of Pre-fabricated Culverts
(a) Concrete Pipe Culverts on in-situ or Imported Granular Material.
The bottom of the excavation shall be compacted to 97% MDD (AASHTO T99) or
to the density of the adjacent ground, whichever is the greater, and shaped to the
lower part of the pipe such that the barrel of the culvert rests on it over a width of at
least one third of its diameter, and throughout the length of the barrel.
Voids shall be formed under the joints and sockets so that adequate space is provided
under the pipe to form the joint. When the joint has been formed the void shall be
packed hard with bedding material. The underside of the barrel shall be packed hard
with fine granular material and rammed solid.
(b) Concrete Pipes on a Concrete Bed.
Where pipes are laid on a concrete bed the pipes shall be bedded on class
1:3:6concrete at least 150 mm thick, 1.5 m wide and extending the full length of the
barrel.
After the joints have been formed, class 1:3:6 concrete shall be packed hard under
the barrel and sockets of the culverts, and extending upwards on each side of the pipe
to the height shown on the Drawings.
(c) Concrete Beds, Surrounds and Haunches
The floor of the trench shall be thoroughly cleaned, trimmed and compacted before
any bed, surround or haunch is placed and shall be subject to approval by the
Engineer before concreting is commenced.
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All concrete for beds, surrounds and haunches shall be Class 15/20 complying with
Section 6 of this Standard Specification formed to the dimensions shown on the
Drawings or instructed by the Engineer.
Unless otherwise instructed by the Engineer, 150 mm of concrete surrounding shall

be provided to concrete pipes in the following circumstances:
concrete pipes up to and including 600 mm diameter with less than 0.60
m cover or more than 3.0 m of cover;
concrete pipes over 600 mm diameter and not exceeding 900 mm

diameter with less than 1.0 m of cover or more than 3.0 m of cover;
concrete pipes over 900 mm diameter, at any depth.
(d) Metal Culverts.
All pipes shall be laid, bedded and jointed in accordance with the manufacturers
recommendations.
Where indicated on the Drawings the excavation shall be trimmed to the contour of
the base of the culvert and a bed of fine granular material not less than 75 mm thick
shall be placed, compacted and shaped to enable the culvert to be bedded as shown
on the Drawings.
When indicated on the Drawings or required by the Specifications of Particular

Applications, the pipes shall be painted with one coat of bitumen paint, approved by
the Engineer, prior to assembly. During assembly both areas of pipe sections in
contact shall be painted with a second coat of bitumen paint immediately prior to
fixing. After assembly all pipes shall be painted over the exposed area outside with a
further coat of bitumen paint, and all pipes of 1.22 m diameter and over shall also be
painted internally.
The placing of pipe shall be started at the inlet and with the separate sections firmly
jointed together and with outside laps of circumferential joints pointing upstream.
With the permission of the Engineer pipes may be assembled out of the trench and
lowered in, in which case particular care shall be taken to ensure that the barrels are
properly bedded along the whole length.
Multiple installations shall be laid with centre lines parallel. Unless otherwise
instructed or shown on the Drawings, the clear distance between barrels of adjacent
pipes shall be at least equal to 0.8 m or one half the diameters of the pipes whichever
is the greater.
Where instructed by the Engineer the grade-line shall be cambered to allow for future
settlement.
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4.4.3.3 Jointing Concrete Pipes
(a) Rigid Joints
When placing rigid jointed concrete pipes with integral sockets, before entering a
pipe spigot into its socket both spigot and socket shall be clean from mud, oil, grease
or other deleterious matter. A gasket of tarred hemp yarn, cut to lengths so that it
forms a butt joint at the crown of the pipe, shall be wrapped round the spigot which
shall then be fully entered in to the socket and the gasket caulked up hard into the
joint. The joint shall then be filled completely with a plastic mortar composed of one
part of cement to two parts of sand and finished off with a fillet at an angle of 45o.
Rigid jointed sleeves used to join two spigots shall be jointed in the same manner as
integral sockets.
If the Drawings require ogee jointed pipes to be laid with a mortar joint, the joint
shall be made at the time of laying. Mortar as described above shall be applied to the
lower semi-circumference of the socket and to the upper semi-circumference of the
spigot and the pipe shall be drawn hard into the socket. The outside of the joint shall
be pointed up with a fillet of 1:2 cement : sand mortar, 75 mm wide and 25 mm
thick, all the way round and central over the joint.
All pipes shall be saturated with water before jointing and shall be scraped, cleaned
inside and the joint flushed up with 1:2 cement : sand mortar.
All joints shall be protected from the wind, sun and rain by a covering approved by
the Engineer, and shall be kept constantly damp for a period of at least three days.
The pipes shall not be disturbed in any way for at least 48 hours after jointing.
(b) Flexible Joints
Flexible joints between concrete pipes having integral sockets may be formed by a
shaped rubber gasket fitted within the socket or by a rubber ring of circular cross
section (O-ring) placed on the pipe spigot. The type of flexible joint to be used shall
be subject to the approval of the Engineer.
Before any joint is made all parts of the joint shall be clean and free from mud, oil,
grease or other deleterious matter.
Fixed gaskets shall be lubricated strictly in accordance with the manufacturers’

recommendations. O-ring gaskets shall not be lubricated. Components of flexible
joints from different manufacturers shall not be used together.
The spigot of the pipe to be laid shall be entered into the socket of the previous pipe
with the two pipes in line, and a firm steady pressure exerted on the end of the pipe
being laid. If necessary a jack anchored round the collar of the previous pipe shall be
used to pull in pipes. The spigot shall be pulled hard into the socket and then eased
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back the distance recommended by the manufacturer to provide flexibility in the

joint.
After jointing, the position of O-rings shall be tested with a feeler to ensure that they
are correctly positioned. If any ring shows a significant departure from a line fol-
lowing a pipe circumference, the joint shall be broken and remade using a new ring.
Where plain ended pipes are connected by a sleeve incorporating flexible joints, the
joints shall be made as described for pipes with integral sockets. The joint between
the first pipe and the sleeve shall be completed before the second pipe is inserted into
the sleeve.
The annular space inside the socket of each pipe or sleeve, but outside the gasket,
shall be filled with puddled clay, uncaulked yarn or other suitable material approved
by the Engineer to prevent the entry of stones.
(c) Pipe Ends
Unless otherwise specified pipe ends shall be left square.
4.4.3.4 Backfilling of Prefabricated Culverts
After the culverts have been firmly laid in the required bedding as specified, backfilling
shall be carried out as follows:
The material used for the backfilling of those portions of culverts subjected to traffic
loads shall be selected material of at least sub-base quality or such other lower quality as
the Engineer may permit. Where the excavated material is not of adequate quality,
selected material shall be imported for this purpose. The Contractor shall ascertain in
advance from the Engineer over which portions selected-quality material will be required
for backfilling.
In the case of concrete pipe culverts on granular bedding and metal culverts, the
backfilling material shall be thoroughly tamped in under the flanks of the culverts to
provide a uniform bedding, all to the Engineer's satisfaction. Metal culverts shall be tem-
porarily ballasted during backfilling to prevent them from lifting.
Backfilling alongside and over all culverts shall be watered, mixed, placed and
compacted, in layers not exceeding 150 mm after compaction, to a density of at least the
density required for the material in adjoining layers of fill, sub-grade and sub-base. The
density of backfilling in excavations made in natural ground shall be at least 97% of
standard AASHTO density (AASHTO T99).
Backfilling shall be carried out simultaneously and equally on both sides of a culvert to
avoid any unequal lateral forces.
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For culverts constructed under embankment conditions as defined in Clause 4.4.3, the
backfilling shall be carried out to the same standard as described above, simultaneously
and equally on both sides of the culvert and over the culvert until the minimum specified
cover is obtained. After completion the width of backfill on each side of the culvert shall
be at least equal to the diameter (or span) of one of the openings of the culvert.
Metal culverts shall be backfilled symmetrically to prevent distortion of the units and the
Contractor shall also ensure that the required cover as specified or shown on the
Drawings is provided over the culvert before routing his construction equipment across
the culvert.
Timbering and sheeting left in for the purpose of supporting the excavation shall be eased
up 150 mm at a time in step with the backfill layer and compaction of the backfill shall
be obtained under and behind such timber and sheeting.
(a) Excavation
The unit of measurement shall be the cubic metre of material excavated within the
specified width over the lengths and depths authorized by the Engineer in each case.
Excavation in excess of the widths specified or authorized by the Engineer shall not
be measured for payment.
When measuring excavation for the removal of existing culverts, the volume
occupied by the culvert shall not be subtracted from the calculated volume of
excavation.
In the case of manholes and catch pits the dimensions for determining the volume of
the excavation shall be the neat outside dimensions of the structure plus an allowance
of 0.5 m working space around the structure.
The tendered rate shall include full compensation for all excavation, temporary
timbering, shoring and strutting, for preparing the bottom of the excavation for the
culvert beds, for disposal of excavated material unsuitable for backfilling or surplus
to backfilling requirements, for keeping excavations safe, for dealing with any
surface or subsurface water and for any other operations necessary to complete the
work as specified.
In respect of material resulting from excavation for culverts, payment shall be made
as specified in Clause 4.3.4 (a) for sub-surface drain excavation.
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Pay Item Unit of

4.4 -10 Excavation for prefabricated Cubic

metre
culverts, 0-2 m depth,
common material
4.4 -11 As Item 4.4 -10, but for Cubic metre

rock
etc., in increments of 2 m depth
(b) Backfilling
The unit of measurement shall be the cubic metre of material in place after
compaction and the quantity shall be calculated from the leading dimensions of the
backfilling as specified or authorized by the Engineer.
If excavations made are in excess of the dimensions authorized by the Engineer, the
quantity of backfilling shall nevertheless be based on the authorized dimensions. The
volume occupied by the culvert shall be subtracted when calculating the volume of
backfilling.
The tendered rate shall include full compensation for backfilling under, alongside
and over conduits, for watering and compaction the backfill material to the specified
densities. In addition the rates tendered for backfilling with selected material shall
include full compensation for supplying selected material of sub base quality from
approved sources, including a free haul of 1.0 km.
Pay Item Unit of

4.4 -20 Backfilling, using Cubic metre

the excavated material
4.4 -21 Backfilling, using Cubic metre

imported selected
material
4.4 -22 Overhaul of backfill Cubic metre x

material, for haul in kilometre
excess of 1 km free haul
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(c) Pre-fabricated Culverts
The unit of measurement for pre-fabricated culverts (concrete pipes, metal culverts
and portal or rectangular culverts) shall be the metre of culvert laid as shown on the
Drawings or as directed by the Engineer.
The length shall be measured along the soffit of the culvert. In the case of metal
culverts with bevelled ends, the bevelled portions extending beyond the soffit shall
be measured separately per unit for each size of culvert.
The tendered rate shall include full compensation for supplying, testing, loading,
transporting and off-loading of all culverts, for the provision and placing of the fine
granular material where required for bedding of culverts, and for the installation,
laying and jointing of culverts as specified, including cutting on site and waste.
For payment purposes, a distinction shall be made between the different sizes and
types of culverts.
Pay Item Unit of

4.4 -30 Concrete Pipe Culverts Metre

(type and diameter indicated)
4.4 -31 Metal Culverts

(Size, wall thickness Metre
and type indicated)
4.4 -32 Bevelled ends for metal Number

culverts, (size and type indicated)
4.4 -33 Portal and Rectangular Metre

Culverts (size and type
indicated)
(d) Cast in-situ Concrete Beds, Surrounds and Haunches
The unit of measurement shall be the cubic metre of cast in-situ concrete and the
quantity shall be calculated from the dimensions on the Drawings or authorized by
the Engineer.
The tendered rate shall be full compensation for supplying, casting, finishing and
curing the concrete including all formwork and steel reinforcement.
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Pay Item Unit of

4.4-40 Cast in-situ concrete Cubic metre

for beds, surrounds and
haunches (Class of concrete
indicated)
(e) Protection Mastic Asphalt Coating
The unit of measurement shall be the square metre of protective coating applied as
specified and directed by the Engineer. When both inside and outside surfaces are
treated, both surfaces shall be measured.
The tendered rate shall include full compensation for procuring and furnishing the
mastic asphalt, applying the material and for all other incidentals required to provide
the protective coating as specified.
Pay Item Unit of

4.4.-50 Protective Asphalt Square metre

Mastic Coating for
Corrugated metal
Culverts
4.5 MINOR DRAINAGE STRUCTURES
4.5.1 Type of Structures
Minor drainage structures shall include culverts, headwalls and wing-walls, scour checks,
catch pits, cascades, spillways and the like.
4.5.2 Material and Construction Requirements
Inlet and outlet structures for pre-fabricated culverts, as well as catch pits and manholes,
shall be constructed in accordance with the details shown on the Drawings.
(a) Excavation and Backfilling
The Specifications given elsewhere in this section for the excavation and backfilling
of culverts shall apply mutatis mutandis for inlet and outlet structures, catchpits and
manholes.
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(b) Concrete Work
Concrete work shall be carried out in accordance with the provisions of Section 6 of
these Specifications. Unless otherwise specified, all concrete shall be structural
concrete, Class 20/40.
(c) Brickwork
Bricks shall be engineering bricks conforming to the requirements AASHTO M91

and M114.
The limit for water absorption in the 24 hour immersion test shall be 8%.
Brickwork shall be built in English bond with a 1:3 cement:sand mortar or in

stretcher bond where the thickness does not exceed 115 mm. It is to be well and
regularly bonded with no false headers. All bricks are to be whole except where
required as closers. Bricks are to be wetted well before laying and each brick must be
pressed into its bed so as to leave a finished joint not exceeding 10 mm in thickness.
All joints are to be filled solid with mortar and joints for exposed faces shall be
pointed as the work proceeds.
Where pipes enter brickwork, they shall be thoroughly caulked into the wall and
rendered with mortar.
(d) Plaster and Mortar
Where plastering of brickwork is required, all joints shall be well raked out and the
brick face thoroughly wetted before plaster is applied. Plaster shall not be less than
12 mm nor more than 20 mm thick. Plaster finish shall be smooth and even and not
show any trowel marks. Unless otherwise specified, all plaster shall be finished with
a steel trowel. Plaster and mortar shall consist of one part cement to three parts
approved fine sand.
(e) Manhole Covers, Grid Inlets, Etc.
Manhole covers and frames, grid inlets and other metal accessories shall be supplied
and/or manufactured in accordance with the details shown on the Drawings and
conforming Specifications of Particular Applications.
Before fixing, manhole covers and frames shall be dipped in an approved

preservative and gratings and frames shall be painted with two coats of bituminous
paint. Manhole frames shall be set firmly in cement mortar so that the covers are
flush with the final surface.
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(f) Pre-Cast Concrete Chambers and Shafts
Pre-cast concrete chambers and shafts shall be constructed from non-pressure

concrete pipes complying with the requirements of AASHTO M86M, Class 1. The
diameters of the pipes shall be as specified. The pipes shall be cast in lengths of 150
mm, 300 mm and 600 mm so that chambers and shafts of different lengths can be
constructed. All chambers and shafts shall be installed with the spigot ends pointing
upwards and bedded in mortar and properly caulked to ensure watertight joints.
(g) Benching
All benching shall be rendered in 20 mm granolithic plaster and be finished smooth

and true with a steel trowel. Corners shall be rounded to the dimensions shown on
the Drawings.
(h) Pre-Cast Inlet and Outlet Structures
Where the use of pre-cast inlet and outlet structures is specified, they shall be
manufactured in accordance with the dimensions shown on the Drawings. These
units shall be laid and jointed generally as specified for pre-cast concrete pipe
culverts.
(a) Excavation and Backfilling
Excavation and backfilling for minor drainage structures shall be measured by the
cubic metre. Measurement and payment shall be made as specified in Clause 4.4.4
(a) and 4.4.4 (b) for culvert excavation and backfilling.
(b) Cast in-situ Concrete
Cast in-situ concrete in minor drainage structures including culvert headwalls, and
wing-walls, catch pits, scour checks, cascades, spillways and the like shall be
measured in accordance with Section 6, Clause 6.1.7, of this Standard Specification.
No separate measurement and payment will be made for shuttering or reinforcement

and the rates for concrete shall include for all costs associated with this work.
(c) Brickwork
The unit of measurement shall be the square metre of brickwork built, calculated
from the leading dimensions of the brickwork. Areas in walls occupied by conduits
shall not be included in the areas measured, and corners and intersections common to
more than one brick wall shall be measured only once.
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The tendered rate per square metre shall include for full compensation for brickwork
complete as specified, including pointing and building in conduits.
(d) Plaster
The unit of measurement shall be the square metre of plasterwork provided.
The tendered rate shall include full compensation for raking out joints in the
brickwork and applying a 1:3 plaster as specified to all surfaces required.
(e) Manholes, Catch pits and Pr-cast Concrete Chambers and Shafts
The unit of measurement shall be the complete unit as shown on the Drawings,
including all concrete, brickwork, covers, frames, grids and other accessories.
The tendered rate shall include full compensation for procuring, furnishing and
installing and laying where applicable, the complete units, except for excavation and
backfilling which shall be measured separately. The tendered rate shall also include
compensation for connecting up and building any conduits into the walls of the
various structures.
(f) Pre-cast Inlet and Outlet Structures
Pre-cast concrete inlets and outlets to concrete culverts shall be measured per inlet or
outlet complete in position.
The tendered rate shall include full compensation for providing, loading,
transporting, off-loading and installing the inlets or outlets as specified.
4.6 PROTECTION WORKS
4.6.1 Banks and Dykes
Mitre banks, catch water banks and dykes shall be constructed of approved soil or gravel
obtained from open-drain excavation or, if no suitable material can be obtained from that
source, from suitable alternative sources, and be placed in such a way that the water will
flow on the natural ground and against the bank.
The banks and dykes shall be properly compacted in layers not exceeding 150 mm in
thickness, true to the lines, levels and cross-sections shown on the Drawings or directed
by the Engineer.
The density obtained of the compacted material shall not be less than 97% MDD
(AASHTO T99).
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If the Contractor prefers and the Engineer approves, mitre banks may also be constructed
of hand-packed stone, provided that the interstices are filled with an approved cohesive
soil.
4.6.2 Top-soiling and Grassing
Where specified or instructed by the Engineer, the Contractor shall be required to provide
protection to embankment slopes or cut faces by one of the following means:
(a) Grassing
(b) Top-soiling and grassing.
Where grassing is required, the Contractor shall plant sprigs of approved indigenous
"runner" type grass at 200 mm centres. The Contractor shall care for and water the grass
until it is firmly established.
Where top-soiling is required prior to grassing, the minimum thickness of topsoil shall be
50 mm and the quality of the topsoil shall be to the approval of the Engineer. Light
compaction shall be carried out to the approval of the Engineer.
4.6.3 Slope and Bed Protection
(a) Rip-rap
Stone for rip-rap shall consist of well shaped hard dense durable rock. At least 50 per
cent of the pieces shall have a volume greater than 0.03 m3 and not more than 5 per
cent shall have a volume of less than 0.01 m3. The stones shall be laid with close
joints from the bottom of the slope of embankment or existing ground upward, the
largest of the stones being laid at the bottom. The surface shall be hand packed,
carefully bedded and tightly wedged with suitable spalls to form an even surface.
(b) Stone Pitching
Stone pitching shall be formed of hard stone, roughly dressed square. The least
dimension of any stone shall not be less than 200 mm, and the volume not less than
0.01 m3. No rounded boulders shall be used.
The stones shall be set on edge and securely bedded with the largest dimensions at
right angles to the flow of water, fitted closely together so as to leave only a
minimum of voids between the stones which shall be fitted in with suitably shaped
and tightly wedged spalls. The top of the pitching shall be finished flush with the
adjacent material.
Where grout is specified, a 1:4 cement : sand mortar shall be rammed into the wetted
interstices and smoothed off flush with the pitched face.
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(c) Gabions
Gabions shall be made of galvanized steel weld mesh, galvanized rolled wire
mattress, or galvanized chain link fencing. The maximum mesh size shall be 100 mm
x 120 mm. Wire for the weld mesh, mattress or chain link construction shall have a
minimum diameter of 4.0 mm (8 gauge). The weight of galvanized coating shall be
not less than 460 g/m2.
The binder wire shall be galvanized annealed iron wire with a diameter of at least 2.0
mm. The weight of galvanized coating shall be not less than 335 g/m2.
The galvanizing shall comply with the requirements of BS 443.
The gabion boxes shall be constructed to the shapes and dimensions as shown on the
Drawings or given in the Specifications of Particular Application.
The surface upon which the gabions are to be laid shall be compacted to a minimum
dry density of 98% MDD (AASHTO T99) and trimmed to the specified level or
shape.
Joints in gabion boxes shall be stitched together with 600 mm minimum lengths of
binder wire, with a least one stitch per 50 mm, and each end of the wire shall be
fixed with at least two turns upon itself.
Adjacent boxes shall be stitched together with binder wire along all touching edges
as specified for binding the box itself. Boxes shall be laid with broken bond
throughout to avoid continuous joints both horizontally and vertically. Pre-tensioning
of gabion boxes shall be subject to the approval of the Engineer.
The boxes shall be hand-packed with broken rock of 150 mm minimum dimension
and 300 mm maximum dimension. The sides shall be packed first in the form of a
wall, using the largest pieces, with the majority placed as headers with broken joints
to present a neat outside face. The interior of the box shall be hand packed with
smaller pieces and the top layers shall be packed tight and hammered into place.
At the top and bottom edges and ends of completed gabion work, the existing soil
shall be backfilled, thoroughly compacted against the sides of the gabions and
finished flush with the top surface of the gabion.
4.6.4 Masonry Walls
(a) General
Masonry wall may be plain with dry joints or be constructed with stones set in
cement mortar, as indicated on the Drawings, specified or ordered.
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The minimum mass of stone shall be 10 kg. The minimum dimension of stone shall
be 75 mm.
(b) Plain Masonry Walls
A foundation trench shall be excavated down to rock or to material of adequate

bearing capacity, and the minimum depth shall be 300 mm below ground level.
Large selected stones shall be used in the foundation layer. Flat and stratified stones
shall be laid with the flat surfaces in the horizontal plane. Stones shall be individually
placed to break joints and to provide a minimum of voids, and shall be firmly bedded
against adjoining stones. the spaces between the larger stones shall be filled with
spalls securely rammed into place. The larger stones shall not bear on the spalls used
to fill the voids. The top and ends of the wall shall be neatly finished with selected
coping stones.
The resulting appearance of the wall shall present an even, right surface.
(c) Cement Masonry Walls
The walling shall be constructed as specified in (b) above, with the exception that the
stones shall be wetted and set in a 3:1 sand:cement mortar. Exposed stones on the
wall faces shall be cleaned of mortar by washing or wire brushing. The mortar shall
flush pointed to the approval of the Engineer, who may require a capping and end
treatment in the same mortar.
Weep holes shall be provided as ordered and shall be cleaned of mortar and any other
clogging material that may have entered during construction.
The walling shall be protected from the elements and be kept moist for a minimum
period of four days after completion.
4.6.5 Concrete Kerbing, Channelling and Lining
Scope
This section covers the construction of concrete kerbing and channelling, open concrete
chutes and concrete lining of open drains at the locations and to the details shown on the
Types of Structures
Kerbing shall include barrier kerbs, mountable and semi-mountable kerbs. All these
elements may be pre-cast units or may be constructed in a continuous operation using slip
forms. Channelling may be cast in situ, be constructed with pre-cast units or slip forms.
Chutes may be either pre-cast units or cast in situ. The concrete lining of open channels
shall be cast in situ only, except that side slabs may be pre-cast.
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4.6.5.1 Materials
(a) Concrete
All concrete work shall be carried out in accordance with the requirements of Section
6 of these Specifications.
(b) Kerbing and Channelling
Pre-cast kerbing and channelling and kerbing and channelling cast in situ shall be of
the class of concrete indicated in the Drawings or specified in the Specifications of
Particular Applications.
(c) Joint Sealant
Cold-poured joint sealant shall be a two-part poly-sulphide sealing compound

conforming to the requirements of BS 4254. Alternatively, polyurethane based
compounds may be used with the approval of the Engineer provided they are of equal
quality.
(d) Bedding Material
The material on which concrete kerbs and channels are to be bedded shall consist of
crushed stone, cinders, slag, sand or other approved porous material with a maximum
particle size of 13.2 mm.
Concrete may also be prescribed as bedding material, in which case it shall comply
with the requirements of Section 6 of these Specifications for non-structural
concrete.
4.6.5.2 Construction
(a) Excavation and Bedding
Trenches for kerbs and channels shall be excavated to the required depth and all
unsuitable material shall be removed and replaced with a layer of approved bedding
material at least 75 mm thick. The bedding shall be compacted and accurately shaped
to the required grade. No concrete shall be placed on un-compacted or disturbed
material. Excavation for open drains shall be executed and paid for in accordance
with the provisions of Section 4.2.3. Thereafter the excavations shall be neatly
trimmed to the lines and levels specified so as to permit accurate construction of the
concrete linings. All loose material shall be compacted to a density of not less than
97% MDD (AASHTO T99).
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Where the in-situ material is unsuitable, the Engineer may order that it be removed to
the depth required and be replaced by selected material compacted to a density of not
less than 97% MDD (AASHTO T99).
Where open-drain excavation is in rock, over break shall be backfilled as ordered,

either with mass concrete or with selected natural gravel or soil compacted to at least
97% MDD (AASHTO T99).
Excavations for chutes shall be neatly trimmed. All loose material shall be
thoroughly compacted and where over break occurs in hard material the excavations
shall be backfilled with mass concrete. If required by the Engineer, the excavations
shall be taken deeper to accommodate a concrete screed cast to act as a working
platform for the construction of the chutes.
(b) Pre-Cast Concrete Kerbing and Channelling
Pre-cast concrete kerbing and channelling shall be laid with close joints of 3:1
sand:cement mortar at the ends. The joints may not exceed 10 mm in thickness and
must be neatly pointed with a pointing trowel. Guide lines and straight-edges shall be
used to ensure that the exposed faces of kerbs and edgings are set true to line and
elevation. Kerbing around curves shall be laid along the full curve length before the
joints are made, unless otherwise allowed by the Engineer.
(c) Pre-Cast Concrete Chutes on Side Slopes of Fills and Cuts
Pre-cast concrete chutes shall be manufactured in accordance with the dimensions

shown on the Drawings, and the units shall fit neatly into each other as shown.
The bottom unit that is at the toe of the fill or the bottom of the cut slope, shall rest
against the outlet structure or footing as shown on the Drawings.
The units shall be neatly laid to line and grade from the bottom upwards so that each
consecutive unit fits neatly into the previous one.
A transition section shall be constructed at the inlet to lead the water into the chute as
shown on the Drawings.
(d) Cast In Situ Kerbs and Channels
Kerbs, channels and edgings shall be cast in alternate sections. The lengths of
sections shall be uniform throughout and shall be equal to 2 m for every 100 mm
average thickness or depth of concrete measured perpendicular to the bed, except
where shorter sections are necessary for closures or where otherwise shown on the
Drawings or required by the Engineer.
Forms shall be accurately set to line and elevation and shall be firmly held in position
during the placing of the concrete. Stops at the ends of sections shall be placed
accurately so as to ensure that the joints between adjacent sections are truly
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perpendicular to the surface of the concrete and at right angles to the edge of the
road. After concrete has been placed in the forms, it shall be tamped and spaded until
the exposed surfaces are entirely covered with mortar. Exposed faces shall then be
finished to smooth and even surfaces and edges shall be rounded to the radii shown
on the Drawings.
The forms of concrete surfaces that will be exposed shall be removed within a period
of 24 hours after the concrete has been placed. Minor defects shall be repaired with a
2:1 sand:cement mortar. Plastering shall not be permitted on exposed faces and all
rejected portions shall be removed and replaced at the Contractor's expense. Exposed
surfaces shall be finished while the concrete is still green, by wetting a soft brick or a
wooden block and rubbing the surfaces until they are smooth. When the concrete has
been smoothed by using water, it shall be rubbed with a thin paste of 1:1
sand:cement mortar until a uniform colour is obtained. When completed, the sections
shall be cured in accordance with the requirements specified in Section 6 of these
Specifications.
After the concrete in alternate sections has set, the intermediate sections shall be cast
and finished off in accordance with all the requirements specified hereinbefore for
alternate sections. The exposed end surfaces of the alternate sections cast first shall
be painted with a coat of approved bituminous emulsion containing 60% net bitumen
by mass, and the emulsion must be allowed to set and dry before the intermediate
sections are cast.
Guidelines and straight-edges shall be used to ensure that the exposed faces of kerbs,
channels and edging are formed true to line and elevation.
The Contractor may use an approved machine which is capable of placing cast in situ
kerbs and channels in one continuous operation by means of slip-forms. He must,
however, be able to obtain at least the same standard of finish, in respect of both
appearance and line, which can be obtained by the methods described above. The
concrete strip shall also be provided with neat joints at the intervals described above.
(e) Cast in Situ Chutes on Cut Slopes
Cast in situ concrete chutes on cut slopes shall be constructed in accordance with the
Drawings together with the inlet and outlet structures. The class of concrete shall be
as indicated on the Drawings.
Where required by the Engineer, a concrete screed shall first be cast on excavations
that cannot be trimmed accurately and the screed shall be accurately finished to the
level of the underside of the chute invert slab and be allowed to set before the invert
slab is cast. Where the material being excavated cannot be accurately trimmed or
where chute sides have to extend above the surface of cut slopes, the outer faces of
the sides shall be cast against formwork.
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(f) Concrete-Lined Open Drains
The exposed surfaces of the concrete linings of open drains shall be given a Class U2
(Sub-clause 6.1.4.3) surface finish. Concrete shall be cured in accordance with the re-
quirements of Section 6, Sub-clause 6.1.4.4 of this Standard Specification.
Sealed joints in concrete shall be in accordance with the details indicated on the
Drawings and the provisions of Section 6.1.5. The cast in situ concrete lining shall be
cast in alternate panels and cold joints shall be painted as specified for cast in situ
concrete kerbing and channelling before adjoining slabs are cast.
Where required, the surface on which concrete lining is to be cast shall, after being
trimmed, be covered with polyethylene sheeting 0.15 mm thick and all joints in the
sheeting shall overlap by at least 150 mm. Care shall be taken not to damage this
sheeting during concreting or the placing of reinforcement.
(g) Transition Sections
Transition sections for kerbing, kerbing-channelling combinations and concrete-lined

open drains shall be constructed to the same standards and using the same methods
as described for the uniform sections, but with the required modifications. Sections
may be either pre-cast or cast in situ units.
(h) Backfilling
After completion of concrete work, the spaces at the back of kerbs shall be refilled
with approved material to pavement or shoulder level. Spaces adjoining chutes shall
be backfilled level with the side slope. Such backfill shall be placed in layers not
exceeding 150 mm and each layer shall be watered and thoroughly compacted before
the succeeding layer is placed thereon.
Where kerbs and channels are laid after construction of the base, the spaces between
the concrete and adjoining base shall be backfilled with pre-mixed bituminous
material.
(i) Protection
Care shall be taken to protect all pre-cast units against chipping or breakage during
transportation and placing. Broken or badly chipped sections may not be used and
shall be removed and replaced by undamaged units.
Concrete kerbing and channelling as well as any other structures adjacent to the road
shall be protected from discolouration by bitumen that are being sprayed or pre-mix
being placed. Where bitumen is to be sprayed, all such work shall be completely
covered by polyethylene sheeting at least 0.25 mm thick and weighted down by
packed stones and sand to prevent the sheeting from lifting during windy conditions.
Any work discoloured by bitumen shall be broken down and replaced, unless all such
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bitumen is completely removed so that no discolouration is visible at all. Painting

over discoloured sections will not be allowed.
4.6.5.3 Tolerances and Surface Finish
(a) Concrete Kerbing and Channelling
Concrete kerbing and channelling shall be constructed to within the following

dimensional and alignment tolerances:
(i) Horizontal Alignment
The maximum deviation of edges, centre line or vertical surfaces from the
specified position shall be 25 mm.
Maximum deviation of edges, centre line or vertical surfaces from the specified
alignment shall be 1:500 when taken over any section more than 10 m in length.
(ii) Vertical Alignment and Level
The inside edge of channelling shall nowhere be above the finished road level
nor more than 10 mm below the finished road surface. The invert level of
channels and drains and the top of kerbing shall nowhere deviate more than 10
mm from the required level and nowhere shall channels or drains have any
adverse grade.
(iii) Trueness of exposed surfaces
When tested with a 3 m straight-edge, no surface irregularities shall exceed 6

mm.
(iv) Cross-Sectional Dimensions
All cross-sectional dimensions shall be within 6 mm of the specified dimen-

sions, except that the underside of channelling may extend up to 25 mm below
the level at which it would have the required thickness.
(b) Concrete-Lined Open Drains and Concrete Chutes
Concrete-lined open drains and concrete chutes shall be constructed to within the
following tolerances:
(i) Horizontal Alignment
The maximum deviation from the true position of the edges or centre line shall
be 25 mm.
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(ii) Vertical Alignment
The invert level of concrete-lined open channels shall nowhere deviate more
than 25 mm from the required level and nowhere shall the open-drain inverts
have an adverse grade.
(iii) Trueness of Exposed Surfaces
When tested with a 3 m straight-edge, no exposed surface shall show surface

irregularities of more than 10 mm.
(iv) Cross-Sectional Dimensions
All cross-sectional dimensions shall be within 10 mm of the specified dimen-

sions and the average thickness of any invert of side slab shall not be less than
the specified thickness when considering any complete slab or any slab section
having a surface area of 10 m2 or more and disregarding any thickness of more
than 10 mm in excess of the specified thickness.
All unformed exposed concrete surfaces shall have Class U2 surface finish and
all formed exposed concrete surfaces shall have Class F2 surface finish (sub
clause 6.1.4.3).
4.6.6 Asphalt Berms
Scope
This section covers the construction of asphalt berms at the outer edge of surfaced
shoulders. Berms shall be cast in situ in moulds or by means of a suitable extruding
machine to the shapes as shown on the Drawings or as directed by the Engineer.
4.6.6.1 Materials
(a) Bituminous Binder
Bituminous material shall comply with the following specifications:
Penetration grade bitumen: AASHTO M20

Bituminous emulsion: AASHTO M140
Tars: AASHTO M52
Cut-back (rapid and medium curing): AASHTO M81 & M82
Bituminous binder shall consist of 80/100 or 60/70 penetration grade bitumen as

directed by the Engineer.
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Bituminous prime coats shall be either cutback asphalt or tar. Their grade shall be
specified in the Specifications of Particular Applications.
(b) Fine Aggregate
The fine aggregate shall be crushed stone and shall have the following grading:
SCREEN SIZE PERCENTAGE

(SQUARE MESH) PASSING
mm BY MASS
4.750 100
1.180 65 - 95
0.075 5 - 12
The grading may be varied at the discretion of the Engineer.
The mixing equipment for asphalt shall consist of an approved pug-mill, paddle or pre-
mix type mixing equipment.
(a) Mixing and Transporting of Asphalt
(i) Mixing
Prior to introducing into the mixer, the mineral aggregate shall be dried and
heated to a temperature that will ensure that the mixed material is within the
temperature range 125oC to 140oC when discharged from the mixer.
The method of heating shall be subject to the approval of the Engineer.
The bituminous binder shall be heated in bitumen boilers and the temperature
shall be maintained within the following limits:
80/100 penetration grade bitumen: 120oC - 140oC

60/70 penetration grade bitumen: 130oC - 150oC
The hot, dry aggregate shall be charged in to the mixer and the correct quantity
of bituminous binder shall be added to the aggregate and mixing shall be
continued until the mixture has a uniform colour.
The percentage of bituminous binder shall be 7% by mass of dry aggregate.
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(ii) Transporting
The asphalt shall be transported from the mixer to the site of the works in
vehicles with metal bottoms. The inside of truck bodies shall be cleaned of all
foreign material and shall be oiled slightly to prevent the mixture from adhering
and to facilitate discharge.
The loads shall be covered to prevent excessive loss of heat and to protect the
mixture from the weather.
The loads shall be dispatched from the mixer in such a way that each load will
be fully placed and compacted with the minimum delay after arrival at the site
and that the placing can take place at a sufficiently high temperature to ensure
satisfactory workability. The Engineer may reject any material which he consi-
ders to be at too low a temperature for satisfactory placing and compaction.
(b) Preparation of Berm Foundation
The portion of the base extending beyond the edge of the surfaced shoulder shall be
cleaned thoroughly. The shoulder material adjacent to the base shall be compacted
and trimmed to the level of the top of the base and all loose material shall be
removed.
The portion of the berm foundation falling outside the primed surface of the road
shall be provided with a prime coat of tar prime or cutback asphalt at a rate of 0.75
l/m2. The whole berm foundation shall be given a tack coat of bituminous emulsion
applied at a rate of 0.75 l/m2 after the prime coat has dried. The tack coat must be
allowed to dry before the berm is placed.
(c) Placing
When placing the berms, proper care shall be taken at all times to ensure that the toe
of the berm does not encroach more than 20 mm on the width of the carriageway or
shoulder.
(i) Placing by Hand
The mixture shall be placed and shaped in situ in a rigid portable mould to form
a trapezoidal kerb of a size and shape as indicated on the Drawings.
The mixture shall be thoroughly compacted to form a hard, unyielding berm,

true to level, shape and line, within the specified tolerances. Forms may be
removed as soon as the material has cooled to air temperature.
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(ii) Placing by Extruding Machine
An extruder of approved design may be used for placing the berm. In general,
machine-placed work will require no additional compaction. In areas where, in
the opinion of the Engineer, the compaction is inadequate, the machine shall be
provided with additional mass, or other measures shall be taken to ensure that
adequate compaction is obtained.
In order to prevent damage to the newly placed berm due to vibration of the
machine, the machine shall not be kept running while waiting for material to be
delivered.
(iii) Placing under Guard Rails
Should the berm be placed first, the holes for the guard rail posts shall be
excavated with care and all damage to the berm shall, after erection of the posts,
be made good by the Contractor. Where chutes are required on the fills, the
berm shall be discontinued for the width of the top of the chute and finished to
form a proper inlet for the water into the chute, as indicated on the Drawings.
(d) Protection
The newly laid berm shall be protected from damage by effective methods until it has
hardened.
4.6.6.3 Tolerances
The berms shall be placed true to level, shape and line. All berms deviating more than 10
mm from the specified line when measured at the inner edge of either the crest or the
base, or those of which the height or width, measured at the crest, varies more than 5 mm
from that specified, shall be rejected and shall be removed and replaced at the
Contractor's own expense.
(a) Banks and Dykes
The unit of measurement shall be the cubic metre of material in place, measured in
the banks or dykes.
The tendered rate shall include full compensation for procuring, furnishing, placing,
watering, compacting, shaping and trimming the material in the banks and dykes and
for a free haul of 1.0 km.
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(b) Top soiling and Grassing
Top soiling and grassing shall be measured and paid for as specified in Clause 8.6.7.
(c) Slope and Bed Protection
(i) Rip-rap
The unit of measurement for rip-rap shall be the square metre of actual rip-rap
constructed and accepted.
The tendered rate shall include full compensation for preparation of areas to
receive rip-rap and for furnishing, transporting, handling, and placing the rip-rap
as specified. Bulk and/or trench excavation in connection with the works is
separately measured and paid for.
(ii) Stone Pitching
The unit of measurement for pitching shall be the square metre of plain pitching
or grouted pitching in place.
The tendered rate for each type of stone pitching shall include full compensation
for furnishing all materials, excavations, excluding trench and bulk excavations,
compaction and trimming of excavated areas, forming and cleaning of weep
holes, placing of stones, grouting where applicable, and for all other work
necessary to complete the pitching as specified.
(iii) Gabions
Gabions or gabion mattress shall be measured as their constituent parts as

follows:
Chain link fencing, weld mesh and the like for the manufacture of gabions shall
be measured by the square metre calculated as the superficial area material
required constructing the boxes as shown on the Drawings or instructed by the
Engineer. No separate measurement will be made of internal separation panels,
laps or wastage.
The rate for gabion or gabion mattress shall include for the cost of:
all operations required to manufacture the gabions including pro-

vision of materials, cutting, welding, binding, fixing and transporting
to any position on Site;
excavation as necessary, trimming and compaction of the under-

surface, disposing of arisings and placing of gabions;
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binding adjacent units and pre-tensioning boxes;
filling behind or in front of gabions;
transport of materials from source to Site and thence to place of

deposition or use on Site;
Rock-fill used in gabions shall be measured by the cubic metre calculated from
the volume of the boxes shown on the Drawings or instructed by the Engineer.
The rate for rock-fill in gabions shall include for the cost of:
providing, blasting and selecting rock or boulders, crushing if

necessary;
hand packing and compacting inside boxes;
(d) Masonry Walls
The unit of measurement for masonry walls shall be the square metre of plain
walling or cement mortared walling constructed and accepted.
The tendered rate for each type shall include full compensation for furnishing all
materials, trimming of areas, placing of stones, cement mortared where necessary,
and for all other work necessary to complete the walls as specified. Excavation of
foundation trenches shall be paid separately.
(e) Concrete Kerbing, Channelling and Lining
(i) Concrete Curbing or concrete kerbing-channelling combination
The unit of measurement shall be the metre of concrete kerbing or kerbing-

channelling combination complete as constructed, measured along the front face
of the kerb.
The tendered rate for each metre of concrete kerbing and/or kerbing-channelling
combination shall include full compensation for the necessary excavation, bed-
ding, backfilling, formwork and finishing, and for procuring, furnishing and
installing all materials, kerbing and channelling as specified.
(ii) Concrete chutes
The unit of measurement shall be the metre of completed chute as constructed,

including any overlap, measured along the slope as laid, but excluding tran-
sitions, inlet and outlet structures, which are measured separately by the number
of complete units of each type of structure.
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The tendered rate per metre or per unit shall include full compensation for
procuring, furnishing and installing the completed chutes as specified, and for
all excavation, bedding, backfilling, formwork and finishing required.
(iii) Cast in-situ Concrete Lining for Open Drains
The unit of measurement shall be the metre of concrete lining complete as

constructed, measured along the centre line of the lined drain. The tendered rate
per metre shall be full compensation for all trimming of excavation, furnishing
and installing all materials, formwork, finishing and sealing of joints as re-
quired.
(f) Asphalt berms
The unit of measurement shall be the metre of asphalt berm placed as specified.
The tendered rate shall include full compensation for procuring, furnishing, mixing
and placing the materials, including the prime and tack coats, and for all other work
necessary to complete asphalt berms as specified.
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SECTIONNo 5
PAVEMENT
5.1 GENERAL
5.1.1 Setting Out
The Contractor shall set out the lines and levels of the edges of the carriageway by means
of wooden pegs or steel pins to the width and level shown on the Drawings or as directed
by the Engineer.
The Contractor shall use boning rods or a string line to achieve the correct levels at
intermediate points across the cross section.
The distance between pegs shall not be more than 25 m where the road is straight and the
gradient uniform and not more than 12.5 m where the road is on horizontal or vertical
curvature.
5.1.2 Preparation of Working Surface
The layer on which the sub-base or base is to be laid shall be cleaned of all foreign
matter, and any potholes, loose material, ruts, corrugations, depressions and other defects
which have appeared due to improper drainage, traffic or any other cause shall be
corrected, and if directed by the Engineer, the Contractor shall scarify, water, grade and
re-compact the layer to line and level at his own expense.
5.1.3 Construction
The pavement layers shall be constructed to the dimensions, levels and grades shown on
the drawings or as directed by the Engineer.
The material shall be placed, spread, watered, mixed, shaped and compacted by methods
which shall not disturb the previous layer, and such methods shall be to the approval of
the Engineer.
The material shall not be spread over the area on which it has been tipped but shall be
spread away from that area. Spreading shall proceed from the centre to the sides of the
pavement on normal cross fall and from the high side to the low side on super-elevation.
Hauling of material shall not take place over un-compacted material.

The sub-base material shall be spread without segregation uniformly to the full width in
one operation.
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The base material shall be spread without segregation in lanes of uniform thickness.
Where the material is to be laid in more than one layer, the full width of base shall be
completed before the second layer is commenced.
Storage or stockpiling shall not take place on partially completed sub-grades or

pavement.
Specified thickness of 100 mm to 200 mm for granular and stabilized courses shall be
laid in one layer. Thickness exceeding 200 mm shall be laid in two or more layers.
The compaction equipment and method of compaction shall be approved by the

Engineer.
Compaction shall progress from the sides to the centre of the carriageway under
construction or from one side towards previously compacted work.
The compaction equipment shall follow a regular route such that each track shall slightly
overlap the adjacent previous track until the entire area of each layer has been covered.
The surface of each finished layer shall be smooth and free from irregularities to the
approval of the Engineer.
Any weak spots in a layer which become apparent during compaction shall be cut out and
repaired with sound material before the next layer commences.
5.1.4 Tolerances
The construction tolerances with respect to horizontal alignment, thickness, surface levels
and surface regularity of the pavement layers shall be determined as outlined in Sub-
clause 2.3.2.3 of section 2 of this standard specification and the tolerances shall not
exceed the limits specified in Clause 2.2.3 or any tolerances specified in the relevant
sections for each layer.
5.1.5 Rectification of Pavement Layers Outside Permitted Tolerances
Where any tolerances are exceeded, the Contractor shall determine the full extent of the
area which is out of tolerance and shall make good the surface of the pavement course in
the manner described below.
(a) Formation Level
If the surface is too high, it shall be re-trimmed and re-compacted in accordance with
Clause 3.5.3 of Section 3 of this Standard Specification. If the surface is too low, the
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deficiency shall be corrected by the addition of suitable material of the same

classification and moisture content or other approved material laid and compacted to
Specification.
Where an existing gravel layer is to be improved by the addition of a layer of

material less than 100 mm in thickness, the existing surface shall be scarified to the
depth instructed by the Engineer, mixed with the imported material to form a
homogeneous layer of minimum 100 mm depth, re-compacted to the dry density
specified and formed to the lines and levels shown on the drawings or as ordered by
the Engineer.
Any surplus existing material shall be bladed off and removed to spoil or
incorporated elsewhere in the sub-grade as directed by the Engineer.
(b) Bases and Sub-bases
Where these consist of unbound material, the top 75 mm shall be scarified, reshaped,
with material added or removed as necessary, and re-compacted to the Specification.
The area treated shall be not less than 30 m long and 2 m wide or such area to be
determined by the Engineer as necessary to obtain compliance with the Specification.
Where the courses consist of cement or lime treated material, the method of
correction will depend on the period which has elapsed between detection of the
error and the time of mixing of the material. If this is less than 2 hours, in the case of
cement treated materials, or 4 hours in the case of lime treated materials, the surface
shall be scarified to a depth of not less than 50 mm, supplemented with freshly mixed
material as necessary and re-compacted all to Specification. If the period is more
than 2 or 4 hours respectively, the full depth of the layer shall be removed from the
pavement and replaced to Specification. In either case, the area treated shall be at
least 5 m long and the full width of the paving laid in one operation. If areas are
corrected within 7 days of laying, no construction traffic or compaction equipment
shall use the surrounding satisfactory areas.
For asphalt courses where the surface is too high, the full depth of layer shall be
removed and replaced with fresh material laid and compacted to Specification. Any
area so treated shall be at least 5 m long and the full width of the paving laid in one
operation. Alternatively for low areas the Contractor may make up with the material
of the layer immediately above the one being rectified when the subsequent layer is
laid, provided that the subsequent layer is a bituminous premix.
(c) Wearing Courses
These shall have the full depth of the layer removed and replaced with fresh material
laid and compacted to Specification. The area rectified shall be the full width of the
paving laid in one operation and at least 15 m long.
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Asphalt and concrete wearing courses exceeding tolerances might be rectified by

grinding if approved by the Engineer. This procedure is not applicable if a thinner
than specified layer will be obtained.
5.2 GRANULAR COURSES
5.2.1 Scope
This paragraph covers the construction of sub-base, base, wearing course and shoulder
from unbound natural or partly crushed gravel and graded crushed stone.
Granular courses shall be classified according to their constituent materials and to their
position and function in the pavement system.
5.2.2 General Requirements
5.2.2.1 Materials
(a) Definitions:
The term "gravel" used throughout this paragraph means any natural or crusher run
material used in a granular course, and shall include lateritic gravel, quartzitic gravel,
calcareous gravel and decomposed rock.
The term "crushed stone" used throughout this paragraph refers exclusively to
materials obtained from crushing hard sound rock.
A "gravel wearing course" means a top surfacing course constructed from one or a
combination of the materials defined above and shall include a course placed on the
formation of a new road where no bound surface is included in the pavement.
(b) Sources of Material:
Materials for granular courses may be obtained from excavations, cuttings, borrow
pits or quarries.
In all cases the Engineer will instruct the Contractor as to the source of material to be
used and the location in which it is to be placed.
Where a source of material is available for inspection before tendering the Contractor
shall satisfy himself as to the nature and amount of work involved particularly in
respect of the volume of overburden, the quality of material, the degree of selection
necessary, the method of extraction, and access to the source.
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The Contractor shall comply with all the requirements of Clause 3.1.4 of this
Standard Specification in respect of Quarries and Borrow Pits.
5.2.2.2 Processing of Materials
(a) Grid Rolling
For the purpose of this Specification, normal grid rolling shall be taken to mean the
following:
(i) The material shall be evenly spread over the whole width of the layer being
prepared.
(ii) The grid roller, which shall have a minimum mass of 13,500 kg per metre width
of roll, shall make two complete passes of the material, each pass consisting of
rolling with the grid roller in a longitudinal direction over the whole width of
the layer so that each roll laps over half the previous roll.
(iii) Then the material shall be bladed to windrow on one side of the road, re-spread
and subjected to two more grid roller passes.
The above procedure shall be applicable to a compacted layer thickness of up to 150

mm. Where the actual layer thickness is in excess of 150 mm, the number of passes
of the grid roller shall be increased proportionally.
(b) Crushing and Screening
Where the materials intended for use in the pavement layers cannot be suitably
broken down by the method described above, or requires modification by screening
out certain fractions, the Engineer may direct that the material be crushed or
screened, or crushed and screened.
Single stage crushing shall consist of passing the material through a single stage
crusher capable of breaking down oversize material to the maximum size specified
for the layer concerned.
Crushing and screening shall consist of passing the material through a multiple stage
crusher and screening the material so that after crushing and screening the material
conforms to the grading for the layer concerned.
Screening only shall consist of screening the material using one or more screens, the
smallest of which shall be the 8 mm screen, so that the material shall be separated at
this size and any specified proportion of the minus 8 mm material added back if
required.
5.2.2.3 Placing and Compacting
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(a) Spreading of Materials
The materials shall be evenly spread over the whole of the designated area for the
layer concerned and in such quantity that the compacted thickness of the layer
complies with the specified requirements.
Any new layer of less than 75 mm compacted thickness shall be bonded to the
previous layer by scarifying the previous layer to a depth so that the total compacted
thickness of the new layer plus the scarified portion of the previous layer will not be
less than 100 mm.
The compacted thickness of any base layer shall not be less than 3 times maximum
particle size of the base material and the compacted thickness of any sub-base layer
shall not be less than 2 times the maximum particle size of the sub-base material.
(b) Breaking Down and Preparation of the Material
The material placed on the road shall be thoroughly broken down throughout the
layer by means of equipment suited to this purpose to a size not exceeding two-thirds
of the compacted layer thickness.
When normal grid rolling cannot effectively break down the material to the required
size, the Engineer may order that the material be crushed, screened or crushed and
screened as described in Sub clause 5.2.2.2 (b) or he may order the Contractor to use
specialized equipment, such as heavy vibrating grid rollers and self-propelled
tamping rollers, in order to break down the material. The use of such equipment shall
not be paid for separately unless payment for its use is provided for in the special
specifications and the Bill of Quantities.
Any oversize material which cannot be broken down to the required size shall be
bladed off the road, loaded, transported and disposed of or utilized as directed by the
Engineer.
Where the coarse and fine fractions of the material are not uniformly distributed or
have been allowed to become segregated, the material shall be thoroughly mixed on
the road by blading in successive cuts over the full depth of the layer with a motor
grader, after the required amount of water has been added as described below. Such
mixing shall continue until a uniform mixture of the various size fractions of the
material has been obtained.
(c) Watering and Mixing
Any water required before material is compacted shall be added to the material in
successive applications by means of water sprinklers fitted with sprinkler bars or by
means of pressure distributors all capable of applying the water evenly and uniformly
over the area concerned.
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The water shall be thoroughly mixed with the material to be compacted by means of
soil mixers or other suitable equipment. Mixing shall continue until the required
amount of water has been added and until a uniform mixture is obtained. Thereafter
compaction may proceed.
The amount of water to be added shall be sufficient to bring the material to the
optimum moisture content for the compaction equipment used.
(d) Compaction
Compaction shall be carried out in a series of continuous operations covering the full
width of the layer concerned and the length of any section of a layer being compacted
shall, where ever possible, be not less than 150 m nor more than can be properly
compacted with the available equipment. The Engineer reserves the right to order the
Contractor to reduce the length of any layer compacted in any single operation if the
proper compaction of such a layer is not being achieved.
The types of compaction equipment to be used and the amount of rolling to be done
shall be such as to ensure that specified densities are obtained without damaging
lower layers or structures. During compaction the layer shall be maintained to the
required shape and cross-section. All holes and lamination shall be removed.
If at any time after compaction the layer is damaged by drying out or is damaged by
rain, it shall be scarified, aerated or watered and re-compacted as specified above, all
at the Contractors expense.
(e) Disposal of Oversize Material
The Engineer will direct that oversize material be disposed of or utilized elsewhere in
one of the following ways:
(i) The material is bladed off the road and utilized in the uniform widening of fills
outside the road prism.
(ii) The material is bladed off the road, loaded, transported and taken to spoil.
(iii) The material is bladed off the road, loaded, transported to the point of use and
utilized in any other item of construction.
The Contractor shall exercise all reasonable care not to bring onto the road material
which cannot be broken down to the required size by processing on the road.
5.2.2.4 Protection and Maintenance
The compacted layers shall be adequately drained and shaped to prevent water from
standing on or scouring the finished work. Windrows shall be removed to facilitate
drainage of water from surface.
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No material for a succeeding layer shall be placed if the underlying layer is softened by
excessive moisture.
The Contractor shall protect and maintain the completed layer at his own expense.
Maintenance shall include the immediate repair of any damage or defects which may
occur and shall be repeated as often as it is necessary to keep the layer continuously
intact. Repairs shall be done in a manner that will ensure restoration to an even and
uniform surface.
5.2.2.5 Tests and Compliance with Specified Quality
(a) The relevant tests listed in Paragraph 2.4 shall be performed at the frequency shown
in Table 2.4.10/1 if not otherwise indicated in the Specifications of Particular
Application.
(b) Compliance with the specified compaction requirements shall be determined on the
basis of statistical control as outlined in Sub-clause 2.3.2.2, Control Method A.
5.2.3 Gravel Sub-base and Base Course
5.2.3.1 Materials
(a) Quality
The material shall consist of natural or partly crushed gravel and the quality shall
conform to one of the sets of requirements given in table 5.2.3.1/1.
Table 5.2.3.1/1
Material Class A B C D
Los Angeles Abrasion, Max. % 40 45 45 50

Sodium Sulphate Soundness, Max. % 12 12 20 20
Flakiness Index, Max. 30 30 35 35
Crushing Ratio, Min. % 80 60 30 -
Plasticity Index, Max. % 6 6 8 10
The Specifications of Particular Applications shall specify the class of material to be

used for each layer. For base course class A or B shall be preferred.
(b) Grading
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The grading of the material, after processing, placing and compaction shall be a
smooth curve within the grading envelopes given in table 5.2.3.1/2.
Table 5.2.3.1/2
Sieve Size - Percentage by weight passing -

Base Sub base
mm 0/30 0/40 0/40 0/60
75 100
63 100 100 95-100
37.5 100 90-100 90-100 75- 95
31.5 95-100 80- 95 80- 95 65- 90
25 80- 95 - - - - - -
16 62-85 52- 80 50- 80 40- 75
8 42- 70 35- 65 30- 67 25- 60
4 30- 55 26- 50 22- 55 18- 50
2 22- 40 20- 40 15- 45 12- 40
1 15- 30 15- 30 8- 35 7- 30
0.5 10- 23 10- 23 6- 27 5- 25
0.25 7- 17 7- 17 3- 22 2- 20
0.125 5- 13 5- 13 2- 16 1- 13
0.075 4- 10 4- 10 0- 12 0 -10
The Specifications of Particular Applications shall specify the grading to be used for
each layer.
(c) California Bearing Ratio (CBR)
For sub-base the soaked CBR shall be not less than 25% at 96% MDD (AASHTO T
180).
For base the soaked CBR shall be not less than 90% at 98% MDD (AASHTO T
180).
In addition to the methods specified in Sub-clause 5.2.2.3, compaction shall be carried

out to reach a dry density, which can be accepted, when tested and evaluated in
accordance with control method A outlined in Clause 2.3.2 and applying the following
values of the Specification Limit, LLs, for the relative compaction.
Sub-base Course: LLs =94% MDD (AASHTO T180)

Base Course: LLs = 95% MDD (AASHTO T180)
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Unless otherwise instructed by the Engineer, the moisture content at the time of
compaction shall be between 80% and 120% of the Optimum Moisture Content
(AASHTO T180).
The surface of the material shall, on completion of compaction, be well closed, free from
movement under the compaction equipment and free from compaction planes, ridges,
cracks or loose material. All loose, segregated or otherwise defective areas shall be dug
out and made good with new material to the full thickness of the layer and re-compacted.
5.2.3.3 Construction Tolerances
The completed gravel sub-base and base course shall conform to the dimensional
tolerances required in Clause 2.2.3 of this Standard Specification as well as the tolerances
stated below.
(a) Level
Sub-base Base
H90 = ± 20 mm H90 = ± 15 mm
Hmax = ± 25 mm Hmax = ± 20 mm
(b) Thickness
The thickness tolerances referred to in Sub-clause 2.3.2.3 shall be as follows:
Sub-base and base
D90 = 21 mm
Dmax = 27 mm
Dave = 5 mm
5.2.4 Crushed Stone Base Course
5.2.4.1 Materials
(a) Quality
The aggregate used for crushed-stone base or sub-base shall be derived from a parent
rock that is hard, sound, durable and un-weathered. It shall contain no deleterious
material such as decomposed rock, clay, shale or mica. The crushed aggregate shall
comply with one of the sets of requirements given in table 5.2.4.1/1.
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Table 5.2.4.1/1
Stone Class I II
Los Angeles Abrasion Max.% 30 40

Sodium sulphate soundness Max. % 12 12
Flakiness Index Max 25 30
Crushing Ratio Min. % 100 100
Material passing the 0.425 mm sieve shall be non-plastic.
The Specifications of Particular Applications shall specify the class of material to be

used.
(b) Grading
After processing, placing and compaction, the material in the pavement shall be a
smooth curve within the grading envelopes given in Table 5.2.4.1/2.
Table 5.2.4.1/2 Grading for Crushed Stone Base Material
Sieve Size Percentage by weight passing

(mm) 0/30 0/40
63 100
37.5 100 90-100
31.5 95-100 80- 95
25 80- 95 - -
16 68- 85 60- 80
8 48- 65 40- 60
4 35- 48 28- 43
2 26- 36 20- 32
1 19- 27 15- 25
0.5 14- 20 10- 18
0.25 10- 15 7- 14
0.125 7- 11 5- 10
0.075 6- 9 3- 6
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The Specifications of Particular Applications shall specify the grading to be used for base
course.
(c) California Bearing Ratio (CBR)
The soaked CBR of crushed stone base material shall not be less than 100% at 98%
MDD (AASHTO T 180).
(d) Production
Unless otherwise instructed, crushing shall be carried out in at least two stages.
Fine aggregate (passing the 2 mm sieve) to be added to the graded crushed stone to
achieve the specified grading, shall consist of approved hard durable particles. Such
fines may be produced from the approved grades of crushed stone or rock by
additional crushing using a crusher, purpose built for fines production. Such crushing
fines shall be non-plastic, free from organic materials, clay or other deleterious
substance and shall in all respect be to the approval of the Engineer.
Where the addition of fine aggregate is necessary to achieve the specified grading, it
shall be thoroughly mixed in with the crushed stone. The percentage of fine
aggregate to be added to the crushed stone will be agreed with the Engineer and shall
in any case not exceed 15 per cent by weight of the mixture.
Proportioning and mixing shall be carried out using such methods and machines as
shall be acceptable to the Engineer. To avoid segregation, graded crushed stone shall
be moistened when being handled and shall be stockpiled in layers not exceeding 2.5
m thickness.
(a) Placing
In addition to specified methods in Sub-clause 5.2.2.3, the Contractor shall take

appropriate measures to prevent segregation during dumping and spreading
operations.
Graded crushed stone shall be transported in damp condition and in such a way that
no segregation occurs.
Crushed stone base material shall be loaded to the site in ready mixed condition.
Water shall be added at the mixing equipment or during the spreading operation in
such quantities as to ensure that additional watering will not be necessary during the
compaction of the layer.
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The crushed stone base shall be spread by means of a self propelled paver to the
required width and such thickness that no supplementary spreading, shaping or
finishing will be required to obtain the tolerance requirements after final compaction.
The compacted thickness of any layer laid, processed and compacted at any time
shall not exceed 200 mm, and where a greater thickness is required, the graded
crushed stone shall be laid in two or more layers.
The compacted thickness of any base layer shall not be less than 3 times the
maximum size of the graded crushed stone.
(b) Compaction
compaction shall be between 80 and 120% of the Optimum Moisture Content as
determined by the vibrating hammer method in BS 1377 -Test 14.
All rolling shall be longitudinal and shall commence at the outer edges of the
pavement and progress towards the centre, except that on super-elevated curves,
rolling shall progress from the lower to the higher edge.
Crushed stone material shall be compacted to achieve a dry density which can be
accepted, when tested and evaluated in accordance with control method A outlined in
Clause 2.3.2 and applying the following values of the Specification Limit, LLs, for
relative compaction.
Crushed Stone Base Course: LLs = 96% MDD (BS1377-14)
On completion of the compaction the surface shall be well closed, mechanically

stable, free from visible movement under compaction equipment and free from
compaction planes, ridges, cracks or loose material. If the surface fails to meet the
requirements of this Specification, the Contractor shall take the action set out in
Clause 5.1.5 of this Section.
The completed crushed stone base course shall conform to the dimensional tolerances as
required in Sub-clause 5.2.3.3 for gravel base course.
5.2.5 Gravel Wearing Course
5.2.5.1 Materials
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Gravel wearing course material shall conform to one of the material classes specified in
table 5.2.3.1/1 and to one of the grading specified in table 5.2.3.1/2. the Engineer may
order plastic fines to be added to the material.
In addition to the methods specified in Sub-clause 5.2.2.3, the gravel wearing course shall
be compacted to reach a dry density which in accordance with Control Method A,
outlined in Clause 2.3.2 can be accepted when applying the following value of the
Specification Limit, LLs, for relative compaction:
Gravel Wearing Course: LLs = 96% MDD(AASHTO T180)
compaction shall be between 80% and 100% of the Optimum Moisture Content
(AASHTO T180).
The surface of the material shall, on completion of compaction, be well closed, free from
movement under the compaction equipment and free from compaction planes, ridges,
cracks or loose material. All loose, segregated or otherwise defective areas shall be dug
out and made good with new material to the full thickness of the layer and re-compacted.
The completed gravel wearing course shall conform to the dimensional tolerances as
required in sub-clause 5.2.3.3 for gravel base course.
5.2.6 Shoulders
5.2.6.1 Materials
Materials for construction of shoulders shall be as shown on the Drawings or instructed

by the Engineer. It may consist of gravel or crushed stone as defined in this Paragraph for
sub-base and base course. Grading for the shoulder material shall be selected as to
produce a material at least as permeable as the pavement layer adjacent to it at each level
in the pavement system.
Shoulders shall be constructed concurrently with or subsequent to construction of the

adjacent pavement layers. Shoulders shall not be constructed ahead of adjacent pavement
layers and the Contractor shall ensure that the method of construction is such that at no
time is water prevented from draining off any of the pavement layers.
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Granular shoulders shall be constructed to the same compaction requirements and to the
same tolerances as the adjacent granular pavement layers.
The top 100 mm of granular shoulders shall be constructed at least to the requirements as
for base course.
Granular courses shall be measured by the cubic metre placed and compacted upon the
road. The volume of material shall be calculated as the product of the area specified to
be laid and the specified compacted thickness.
Granular course materials shall be classified according to quality and grading as specified
in the special specifications.
The rates for granular courses shall include full compensation for procuring, furnishing,
placing and compaction all materials and shall include for the cost of:
(i) Opening up the borrow area including site clearance, removal of top soil and
overburden, fencing and drainage and making good on completion and leaving
neat and tidy;
(ii) Constructing and maintaining access roads, complying with conditions of

access, traffic control, safety and public health requirements, fencing, drainage
and making good on completion and leaving neat and tidy;
(iii) Drilling, blasting and crushing material, screening and stockpiling.
(iv) Submission of samples, laboratory and Site Trials, setting out and preparation of
formation.
(v) Transporting for the free haul distance of 1.0 km for gravel materials and
transporting for any distance from the materials source for crushed stone base
material.
(vi) Completing, control testing, protecting and maintaining the works.
(a) Gravel Sub-base
Measurement and payment shall be as described above with a distinction between

classes of materials encountered in cut.
The rate shall include for a free haul of 1.0 km.
Pay Item Unit of

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5.2-1 Gravel sub-base constructed from

material obtained from borrow
or cut in common material Cubic metre
5.2-2 Gravel sub-base constructed

from material obtained from
cut in rock Cubic metre
5.2-3 Overhaul on sub-base material Cubic metre x km

hauled in excess of 1.0 km
(b) Gravel Base
Measurement and payment shall be as described above with a distinction between

classes of materials encountered in cut.
The rate shall include for a free haul of 1.0 km.
Pay Item Unit of

5.2-4 Gravel base constructed from

material obtained from borrow
or cut in common material Cubic metre
5.2-5 Gravel base constructed

cut in rock Cubic metre
5.2-6 Overhaul on base material Cubic metre x km

hauled in excess of 1.0 km
(c) Crushed Stone Base Course
Measurement and payment shall be as described above, but in addition the rate for
crushed stone material shall include full compensation for haul from the materials
source, whether it is a cut in rock or a quarry.
Pay Item Unit of

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5.2-7 Crushed Stone Base Cubic metre
(No overhaul on crushed stone base material)
(d) Gravel Wearing Course
Measurement and payment shall be as described for gravel base course.
Pay Item Unit of

5.2-8 Gravel wearing course constructed

borrow or cut in common material Cubic metre
5.2-9 Gravel wearing course constructed

from material obtained from cut
in rock Cubic metre
5.2-10 Overhaul on gravel wearing Cubic metre-

course material hauled in kilometre
excess of 1.0 km
(e) Shoulder
Where shoulders are constructed from the same material as for the adjacent
pavement layer, no separate items will be included in the Bill of Quantities for
shoulder construction.
Separate items for shoulder construction will only be included if the type of
construction differs from that of the adjacent pavement layer in which case
measurement and payment as described in this Clause for sub-base and base course
shall apply mutatis mutandis for the construction of shoulders.
5.3 STABILIZED COURSES
5.3.1 Scope
This paragraph covers the stabilization of materials used in the construction of the sub-
grade, fill or pavement layers by the addition of a chemical stabilizing agent to them. It
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includes the furnishing, spreading and mixing in of the stability agent and curing and
protection of the stabilized courses.
Stabilized courses shall be classified according to the position and function of the layers
in the pavement system and to the stabilizing agent used in them.
5.3.2 Lime and Cement Treated Sub-grade, Sub-base and Base Courses
5.3.2.1 Materials
(a) Chemical Stabilizing Agents
For the purposes of this Contract, the stabilizing agent shall be either one or more of
the following agents, whichever is specified on the Drawings, in the Bill of
Quantities, the Specifications of Particular Application or ordered by the Engineer.
(i) Road Lime
Road lime shall comply with the requirements of AASHTO M 216 "Lime for
Soil Stabilization", but the use of un-slaked lime will not be permitted.
(ii) Portland Cement
Ordinary Portland cement shall comply with the requirements of BS 12,

AASHTO M 85 or national specifications as specified in the Specifications of
Particular Applications.
(iii) Milled Blast-Furnace Slag
Milled blast-furnace slag shall have a specific surface of not less than 3 500 cm2
and the residue on the 0.075 mm sieve shall not exceed 10% by mass.
Milled blast-furnace slag shall not be used on its own as a stabilizing agent, but
shall be mixed either with Portland cement to form a cement-slag mixture or
with lime to form a lime-slag mixture. The ratio by mass of the ingredients of
each mixture shall be indicated by the Engineer.
Cement-slag and lime-slag mixtures shall be mixed thoroughly by means of

approved mixers and/or spreaders prior to application on any layers to be
stabilized, or they may be mixed on the road.
(iv) Other Chemical Stabilizing Agents
Other chemical stabilizing agents may be used if specified in the Specifications

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From the time of purchase to the time of use, all stabilizing agents shall be kept
under proper cover and be protected from moisture.
Consignments on these materials shall be used in the same sequence as that in

which they are delivered at the Works. Stocks which may have been stored on
the Site for periods longer than three months shall not be used in the work,
unless otherwise authorized by the Engineer.
(b) Soil and Gravel to be stabilized
The soil or gravel shall be taken from within the limits of an approved source and
shall be subject to such requirements regarding grading, plasticity or other properties
as may be required by the special specifications or ordered by the engineer.
5.3.2.2 Mixing and Laying of Materials
(a) Mix in Place Method of Construction
The mix in place method may be used for the addition and mixing in of stabilizer to
natural materials to produce low strength stabilized layers by a reduction of the water
susceptibility and increase of the stability.
(i) Mixing Equipment
The equipment for pulverizing the material and mixing in the stabilizer shall be
purpose-built equipment, capable of pulverizing the materials and mixing in the
stabilizer to the full depth of the loose layer necessary to give the specified
thickness of compacted material mixed and compacted in accordance with this
section of the Specification.
The equipment may be either single or multi-pass machines and shall only be
acceptable if, during the Site Trials carried out in accordance with Clause 2.3.1
of this Standard Specification, it can produce material to specified requirements.
If single-pass equipment is used for plastic soils, the degree of pulverization as

determined in accordance with BS 1924 - Test 17 shall not be less than 80
percent.
The mixers shall be equipped with a device for controlling the depth of
processing and mixing blades shall be maintained or reset periodically so that
the correct depth of mixing is obtained at all times.
Mixing by grader will not be permitted.
(ii) Preparation of the layer
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Before the stabilizer is applied, the material to be treated shall be spread and
broken down and oversize material removed so that the maximum size of the
particles is not more than specified. If multi-pass processing is employed, the
material shall first be pulverized to the required tilth by successive passes. The
material shall then be shaped true to line, grade and cross-section and, if
required, lightly compacted. The loose thickness shall be such as to give the
specified thickness after full compaction has been carried out.
The moisture content of the layer before the addition of the stabilizer shall be
adjusted to within the range 70% - 85% of the Optimum Moisture Content for
compaction (AASHTO T180).
(iii) Spreading the stabilizer
The amount of cement or lime to be added to natural materials shall be

determined by the Engineer following laboratory trials and site trials carried out
by the Contractor in accordance with Clause 2.3.1 of this Standard
Specification.
After the layer to be treated has been prepared to the satisfaction of the
Engineer, the stabilizer shall be uniformly spread over the width to be worked at
the specific rate. If a spreader is used to spread the stabilizer ahead of the mixer,
it shall be fitted with a device to ensure a uniform and controllable rate of spread
both transversely and longitudinally.
Only sufficient stabilizer for immediate use shall be spread ahead of the mixing
operation and any stabilizer which, in the opinion of the Engineer, becomes
defective, shall be replaced at the Contractors expense.
Only equipment actually used in the spreading or mixing operation shall be

allowed to pass over the stabilizer, when so spread, before it has been mixed
into the material to be treated.
(iv) Mixing and watering
Immediately after the stabilizer has been spread, it shall be thoroughly and
intimately mixed into the material for the full depth of the layer. Mixing shall
continue until the resulting mixture forms a fine and homogeneous tilth.
Full width working, without longitudinal joints, will generally be required. Half-
width working may be instructed by the Engineer to pass traffic. When forming
longitudinal joints, with a width of at least 100 mm of the adjoining first laid
half-width layer shall be re-treated and mixed in with the second half-width
layer.
When forming transverse joints at least 1.0 m length of the previously laid
treated work shall be incorporated into the new treated layer and the Engineer
may instruct that the percentage of stabilizer be increased at these places.
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Care shall be taken that the underlying layer is not disturbed and that no material
from the underlying layer or shoulders is mixed with that being processed.
If watering is necessary to bring the mixture to the required moisture content,

then this shall be done after spreading and mixing in the stabilizer. Water shall
be added in a uniform and controllable manner and, where necessary, in
successive increments. Each increment shall be mixed in as a separate mixing
operation. Care shall be taken to avoid a concentration of water at any point or a
flow of water over the surface.
Any part of the mixture which becomes too wet after the stabilizer has been
added and before the mixture is compacted will be rejected and any such part
shall be allowed to dry out until its moisture content is satisfactory and shall be
retreated with fresh stabilizer and finished off in accordance with this Sub-
clause.
Throughout the process of mixing in the stabilizer and water, a uniform

thickness of the mixture shall be maintained and, if necessary, the mixture shall
be graded to maintain the correct un-compacted thickness and shape. Any part
of the mixture that becomes segregated shall be removed and replaced.
(b) Ready Mix Method of Construction
The ready mix method shall be used to produce material for stabilized layers of a
specified strength, related to the structural load carrying capacity of the layer.
(i) Stationary mixing equipment shall be of the power driven paddle or pan type
and may be of the batch or continuous type.
If batch mixers are used, the appropriate measured amounts of material and
stabilizer shall first be placed in the mixer, water being then added as necessary
to bring the moisture content of the resulting mixture within the range
determined by the laboratory and Site Trials. Special care shall be taken with
batch type paddle mixers to ensure that the stabilizer is spread uniformly in the
loading skip so that it is fed evenly along the mixing trough and that with both
paddle and pan mixers the stabilizer is proportioned accurately by a separate
weighing or proportioning device. Mixing shall be continued until the mixture
has the required uniformity and for not less than 1 minute unless a shorter
minimum period is permitted by the Engineer after satisfactory preliminary
trials.
If continuous mixing is used, the paddles, baffles and rate of feed of materials
shall be adjusted to give uniformly mixed material.
If a spray is used for distributing water into the mixer, it shall be adjusted to give
uniformity in moisture content throughout the mix.
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(ii) Transporting:
Mixed material shall be transported to the road in suitable vehicles. Material

that becomes segregated or is affected by weather shall be removed and replaced
at the Contractors expense.
(iii) Laying:
The mixed material shall be spread by means of a mechanical paver to the

required width and such thickness that the tolerance requirements are obtained
after final compaction. Segregation shall be avoided and the layer shall be free
from pockets of coarse or fine material.
(c) Joints Between New and Existing Work:
The forming of construction joints and the protection of previously treated materials
shall be carried out so as to produce a uniformly compacted and homogeneous layer
free from ridges or other irregularities.
When forming longitudinal or transverse joints, previous work shall be cut back to
expose fully treated and compacted material.
5.3.2.3 Compaction and Finishing
For cement treated materials final compaction and finishing shall be completed within 2
hours after the cement comes into contact with the material to be treated.
For lime treated materials, final compaction and finishing shall be completed within 4
hours after the lime comes into contact with the material to be treated.
(a) Thickness limitations:
The compacted thickness of any treated layer laid, processed and compacted at one
time shall not exceed 200 mm. Where a greater thickness is required, the material
shall be laid in two or more layers; each of them at least 100 mm in thickness.
The compacted thickness of any base layer shall not be less than 3 times the
maximum particle size of the material and the compacted thickness of any sub-base
layer shall not be less than twice the maximum particle size of the material.
(b) Compaction requirements:
Stabilized layers shall be compacted to a dry density, which in accordance with

Control Method A in Sub-clause 2.3.2.2 can be accepted when applying the
following values of the specification limit, LLs, for relative compaction:
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Treated sub-grade: LLs = 94% MDD (AASHTO T 180)

Treated sub-base : LLs = 95% MDD (AASHTO T 180)
Treated base : LLs = 96% MDD (AASHTO T 180)
compaction shall be between 80% and 100% of the corresponding Optimum
Moisture Content.
(c) Finishing:
The surface finish after compaction shall be free from ridges, compaction planes,
laminations, loose material and other surface irregularities and shall be to line and level
and within the tolerances specified.
All defective areas shall be made good to the full thickness of the layer and re-
compacted. If this cannot be done within the specified time limits for compaction, the
defective material shall be broken out to the full thickness of the layer, removed and
replaced with freshly mixed material compacted to specification.
5.3.2.4 Curing and Protection
a) Curing
The stabilized layer shall be protected against rapid drying out for at least seven days
following the completion of the layer:
The methods of protection may be any one or more of the following:
(i) The stabilized layer shall be kept continuously wet or damp by spraying with
water at frequent intervals. This method shall be used for a period of 48 hours
after which time one of methods (ii), (iii) or (iv) may be applied. The Contractor
is warned that work which is not kept continuously wet or damp but is subjected
to wet-dry cycles may be rejected by the Engineer in his sole discretion.
(ii) The stabilized layer shall be covered with the material required for the following
layer whilst the stabilized layer is still in a wet or damp condition. The material
forming the protective layer shall be watered at such intervals as may be
required to keep the stabilized layer continuously wet or damp, and these
intervals shall not exceed 24 hours in dry weather.
(iii) The layer shall be covered with a curing membrane consisting of a spray grade
emulsion or cutback bitumen, applied at the rate directed by the Engineer. The
provisions of Clause 5.5.2 shall apply mutatis mutandis to the application of a
curing membrane.
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(iv) Where prime coat is specified on top of the stabilized base or sub-base, the
prime coat may be utilized as a curing membrane and shall be applied as
specified in Clause 5.5.2.
No additional payment shall be made for curing as described above, except that
the application of a curing membrane when ordered by the Engineer shall be
paid for separately and the application of a prime coat shall be paid for under
Paragraph 5.5.
(b) Traffic
Traffic or equipment, other than actually engaged in the various treatment processes,
shall not run over the layer being processed and compacted.
No traffic or equipment will be allowed on a treated layer earlier than 7 days after
completion of compaction, and subsequently only that traffic necessary for
construction of the next layer will be permitted on the treated layer.
The completed stabilized sub-base and base course shall conform to the dimensional
tolerances required in Clause 2.2.3 of this Standard Specification as well as the tolerances
stated below.
(a) Level
Sub-base Base Course
H90 = ± 20 mm H90 = ± 15 mm
Hmax = ± 25 mm Hmax = ± 20 mm
(b) Thickness
Sub-base and Base Course
D90 = 21 mm
Dmax- = 27 mm
Dave- = 5 mm
5.3.2.6 Tests and Compliance to Specified Quality
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Tests listed in paragraph 2.4 shall be performed at the frequency shown in Table 2.4.10/1,
if not otherwise indicated in the Specifications of Particular Application.
Compliance with the specified compaction shall be determined according to Control

Method A in Clause 2.3.2.
(a) Mix-in-Place Method
The unit of measurement shall be the cubic metre of chemically stabilized material
measured in place after compaction in the manner specified for the particular layer
under the various Clauses of this Specification. All measurements shall be neat and
any stabilization in excess of the authorized dimensions shall not be measured and
shall not be paid for.
Chemical stabilization shall be paid for as extra over the rates tendered for
constructing the layers un-stabilized. The tendered rates for chemical stabilization
shall, therefore, include spreading and mixing of the stabilizing agent, curing of
stabilized sections, any extra water required and all material, supervision, labour,
equipment, tools and incidentals (extra over that provided for in the rates tendered
for constructing the layer un-stabilized) necessary to complete the work prescribed,
but excluding the cost of furnishing the stabilizing agent. No distinction shall be
made in respect of the type of stabilizing agent used, the time for completion and the
specific layer being stabilized, and the extra-over rate tendered shall apply to any
combination of these.
The Engineer reserves the right to vary the thickness of the layer to be stabilized
without varying the Contractors rate for this work. The Contractor will, however, not
be called upon to stabilize any layer less than 100 mm or more than 200 mm in
thickness.
Pay Item Unit of

5.3-1 Extra over un-stabilized compacted

layers for chemical stabilization
(indicate layer to be stabilized) Cubic metre
(b) Ready Mix Method
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The unit of measurement shall be the cubic metre of chemically stabilized material
measured in place after compaction in the manner specified for the particular layer
under the various Clauses of this Specification. All measurements shall be neat and
any stabilized material spread in excess of the authorized dimensions shall not be
measured and shall not be paid for.
The tendered rates for ready mix stabilization shall include furnishing all materials
except the stabilizing agent, mixing, transporting, placing and compacting the
stabilized material, finishing, curing and protection of stabilized sections, testing,
mix design, laboratory and site trials and all labour, equipment, tools and incidentals
necessary to complete the work prescribed.
The cost of furnishing the stabilizing agent will be paid for under separate item.
No distinction shall be made in respect of the type of stabilizing agent used, the time
for completion and the specific layer being constructed and the tendered rates shall
apply to any combination of these.
The Engineer reserves the right to vary the thickness of the layer to be constructed
without varying the Contractors rate for this work. The Contractor will however not
be required to place any layer less than 100 mm or more than 200 mm in thickness.
Pay Item Unit of

5.3-2 Chemically stabilized layer using

ready mix method of construction
(indicate layer to be constructed) Cubic metre
(c) Chemical Stabilizing Agent
The unit of measurement shall be the metric tonne of stabilizing agent. For
measurement purposes a distinction shall be made between the various agents used.
When mixtures of slag and cement or lime are used, the quantity of each constituent
agent shall be measured separately and not the mixture as a whole.
The quantity shall be the actual quantity of stabilizing agent specified or ordered by
the Engineer or actually provided within the layer concerned, whichever is the lesser
quantity, provided, however, that any tests for stabilizer content below that specified,
but within the tolerance allowed, shall not be construed as an indication of
insufficient stabilizer quantity.
The right of the Engineer to accept work not containing the full quantity of stabilizer
specified or ordered, subject to payment of only the actual amount of stabilizer
provided, shall not mean that he waives the right to condemn such work.
The tendered rates shall include full compensation for the provision of the stabilizing
agent within the Works, irrespective of the rate of application specified or ordered by
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the Engineer, but shall allow for the variations in mixing and compaction times for
the various stabilizing agents. The rate for milled blast-furnace slag shall include
premixing with other stabilizing agents in the required proportions.
Pay Item Unit of

5.3-3 Portland Cement Metric tonne

5.3-4 Road Lime Metric tonne
5.3-5 Milled Blast-Furnace Slag Metric tonne
5.3-6 Other Stabilizing Agents
(specify the type) Metric tonne
(d) Application of a Curing Membrane
The unit of measurement shall be the litre of bituminous curing membrane applied in
accordance with the Engineer's instructions.
The tendered rates shall include full compensation for procuring, furnishing and
applying the curing membrane within the time specified and all incidentals
necessary, including the maintenance of the curing membrane for a period of at least
fourteen days after it has been applied.
Pay Item Unit of

5.3-7 Bituminous material for curing Litre

membrane (indicate type)
5.4 LEAN CONCRETE BASE COURSE
5.4.1 Materials
(a) Aggregates
Unless otherwise specified in the Specifications of Particular Applications aggregates

for lean concrete shall comply with the following requirements:
(i) Grading
Sieve Size % by weight

mm passing
37.5 100
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31.5 90 - 100
16 55 - 85
8 35 - 65
4 25 - 50
2 18 - 40
1 13 - 32
0.5 9 - 25
0.25 6 - 18
0.125 3 - 12
0.075 2 - 10
(ii) Combined aggregate
Sodium Sulphate Soundness : Maximum 12%

Fines (passing 0.425 mm) : non-plastic
Sand Equivalent : Minimum 30%
Organic Matter : Maximum 0.3%
(by weight)
(iii) Aggregate retained on a 2 mm sieve:
Flakiness Index : Maximum 25%

Los Angeles Abrasion : Maximum 35%
(b) Cement
Unless otherwise specified cement shall be ordinary Portland cement complying with
the requirements of BS 12 or AASHTO M 85.
(c) Water
Water shall comply with Clause 6.1.2 of this Standard Specification.
5.4.2 Lean Concrete Mix Proportions
The ratio of cement to aggregate by weight (including any absorbed moisture but
excluding free water in the aggregate) shall be not less than 1:25 and shall be such as to
produce average crushing strengths to the requirements of this Clause. The ratio of
cement to aggregate by weight shall not, however, be more than 1:20 except with the
approval of the Engineer.
The water content of the mixed concrete shall be such as to ensure that the degree of
compaction specified below can be achieved under all normal working conditions.
5.4.3 Crushing Strength
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The average 28-day strength of three cubes shall be regarded as one sample.
In any consecutive five samples not more than one sample shall be less than 10 MPa.
If, however, the average of any five consecutive samples falls below 12 MPa or if one
sample is less than 5 MPa or more than 20 MPa, the Engineer may require the use of
different materials, mix proportions, equipment or methods notwithstanding any approval
which may have been previously given to such materials, mix proportions, equipment or
methods.
Furthermore, in order to ensure a high probability at an early stage that the above
requirements will be met, the average 7 - day strength of groups of three cubes shall not
be less than 7 MPa and if more than one of the 7 - day strengths in any consecutive five
fall below 7 MPa, the cement content shall be increased to such a value as may be
approved by the Engineer and the making of cubes shall be continued at the same rate as
at the start of the work until the results show that a satisfactory material is being
produced.
5.4.4 Construction
(a) Site Trials
The Contractor shall carry out Site Trials in accordance with Clause 2.3.1 of this
Standard Specification at least one month before he intends commencing full
construction of any lean mix layer. Should the trial show that the specified strength
and compaction requirements cannot be achieved, the Contractor shall amend the
mix proportions or the laying and compaction techniques in order to achieve the
required result.
(b) Mixing, Transporting and Laying
Lean mix concrete shall be mixed, transported and laid in accordance with Clause
5.3.2.2 (b) of this Standard Specification (Ready Mix Method of Construction).
(c) Compaction
Immediately after laying, the mix shall be compacted by vibratory and smooth wheel
rollers to 96% of the Target Dry Density. Compaction shall be completed within 2
hours of the cement being added to the aggregates at the batching equipment.
The Target Dry Density shall be determined daily as follows:
From three separate batches of the mix, two 150 mm test cubes shall be prepared in
accordance with BS 1881 except that the cubes shall be compacted to refusal in three
layers using a vibrating hammer as described in BS 1377-Test 14, but with a square
flat plate head with an area of between 10,000 and 15,000 mm2. As soon as the cubes
can be handled without damage, their density and moisture content shall be
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determined in accordance with BS 1881. The average dry density of the six cubes
shall be the Target Dry Density.
The density of the compacted base shall be determined for each 1,000 m2 laid. The
Contractor shall provide a portable coring rig capable of cutting acceptable cores of
minimum diameter 150 mm and to a depth of at least 250 mm. The density and
moisture content of each core shall be measured in accordance with BS 1881.
Following the determination of the density each core shall be crushed and the
minimum equivalent cube strength shall be 7 MPa at 7 - days.
The compacted thickness shall not exceed 250 mm.
(d) Finishing
The surface finish after compaction shall be free from ridges, compaction planes,
laminations, loose material and other surface irregularities and shall be to line and
level and within the tolerances specified for base course in Sub-clause 5.3.2.5 of this
Standard Specification.
All defective areas shall be made good to the full thickness of the layer and re-
compacted. If this cannot be done within the specified time limits for compaction,
the defective material shall be broken out to the full thickness of the layer, removed
and replaced with freshly mixed material compacted to specification.
(e) Joints
At the end of each days work the lean concrete shall be compacted against a securely
fixed vertical temporary stop and if compaction is being done with a vibratory roller,
this shall be transversely close to the stop end. In addition, the material in the corners
adjacent to the stop end shall be compacted by means of a small power-operated
compactor. When the stop end is removed any poorly compacted material adjacent to
it shall be removed and a 1:1 cement:sand grout shall be applied to the exposed face
to a thickness of 5-10 mm before proceeding with the laying of further adjoining lean
concrete. Such fresh lean concrete shall be thoroughly compacted against the joint
and where a vibratory roller is employed this shall be used transversely close to the
joint again using the small power-operated compactor in the corners of the new
work. None of the compacting equipment shall be allowed to bear directly on the
hardened or partially hardened lean concrete previously laid.
Where the full width of the layer cannot be placed by one pass of the paver, work
shall be arranged so that at longitudinal joints a free edge of spread material is not
exposed for more than one hour before placing the adjacent layer. Where a free edge
is exposed for more than one hour, it shall be cut back to expose fully compacted
material before laying the adjacent layer, all at the Contractors expense.
(f) Curing
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Unless otherwise specified, the compacted layer shall be protected by application of

bituminous seal coat or a prime coat within one hour of completion. The type of
bituminous binder and the rate of application shall be instructed by the Engineer. If
the seal or prime coat is to be trafficked before the binder or wearing course is
placed, it shall be covered with approved sand or crusher dust. The seal or prime coat
shall be maintained until the next layer is placed.
(a) Lean Concrete Base Course
Lean concrete shall be measured by the cubic metre placed and compacted upon the
road as the product of the net area specified to be laid and the specified compacted
thickness.
The tendered rates for lean concrete shall include furnishing all materials except
cement, mixing transporting, placing and compacting the lean concrete mix,
finishing, curing and protection of the layer, testing, mix design, laboratory and site
trials and all labour, equipment, tools and incidentals necessary to complete the work
prescribed. The cost of furnishing the cement will be paid for under separate item.
The rates shall additionally include for the cost of the following if required for the
execution of the works.
(i) Opening up a quarry including site clearance, removing top soil and over
burden, fencing and drainage and making good on completion and leaving neat
and tidy;
(ii) Constructing and maintaining access roads, complying with conditions of

access, traffic control, safety and public health requirements, fencing, drainage
and making good on completion and leaving neat and tidy;
(iii) Drilling, blasting and crushing aggregate, provision of fine aggregate, screening,
re-combining if necessary, providing and mixing water, stock-piling, loading
and transporting to the mixing equipment;
(iv) Provision of coring machine, and cutting of cores from completed work for
determination of crushing strength and in-situ density.
The Engineer reserves the right to vary the thickness of the layer to be constructed
without varying the Contractors rate for this work. The Contractor will however not
be required to place any layer less than 150 mm or more than 250 mm in thickness.
No payment will be made for haul.
Pay Item Unit of

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5.4-1 Lean concrete base course Cubic metre
(b) Cement
Measurement and payment as described in Clause 5.3.4 (c) shall apply mutatis
mutandis for furnishing Portland cement for lean concrete.
Pay Item Unit of

5.4-2 Portland cement Metric tonne
5.5 BITUMINOUS SURFACE TREATMENTS AND DRESSINGS
5.5.1 General
This Clause comprises specifications related to materials and construction which apply to
all subsequent clauses of this Paragraph.
Requirements stated in other sections of the Specification as listed below apply to

Clauses throughout this Paragraph and shall be read in conjunction therewith.
Section 2: The whole section
Section 3: Paragraphs 3.1, Clause 3.1.4, Materials Sources and Spoil Areas
5.5.1.1 Aggregates and Filler
If not otherwise specified in the Specifications of Particular Application, aggregates and

filler shall as a minimum conform to AASHTO Standards as follows:
(a) Coarse aggregate
(i) Coarse aggregate shall consist of crushed stone, crushed air-cooled blast furnace
slag, gravel or other approved inert materials of similar characteristics, or
combinations thereof, conforming to this specification.
(ii) Coarse aggregate shall have a Los Angeles Abrasion of not more than 40%
when tested in accordance with AASHTO T 96.
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(iii) When subjected to five cycles of the soundness test (AASHTO T 104), the
coarse aggregate shall have a weighted loss of not more than 12% when sodium
sulphate is used or 18% when magnesium sulphate is used.
(b) Fine Aggregate
(i) The fine aggregate shall consist of natural sand, or of sand prepared from stone,
air-cooled iron blast furnace slag, or gravel, or combinations thereof. It shall
consist of hard, tough grains, free from injurious amounts of clay, loam, or other
deleterious substances.
(ii) The gradation of fine aggregate from any one source shall be made upon
representative samples of fine aggregate from such sources as are proposed for
use. Fine aggregate having a variation in Fineness Modulus greater than + 0.25
from the Fineness Modulus of the representative sample may be rejected.
(iii) The fine aggregate, when subjected to five cycles of the soundness test, shall
have a weighted loss of not more than 15 mass percent when sodium sulphate is
used or 20 mass percent when magnesium sulphate is used (AASHTO T104).
(c) Filler
(i) Mineral filler shall consist of finely divided mineral matter such as rock dust,
slag dust, hydrated lime, hydraulic cement, or other suitable mineral matter. It
shall be free from organic impurities, and at the time of use, shall be sufficiently
dry to flow freely and shall be essentially free from agglomerations.
(ii) Mineral filler shall be graded within the following limits when tested in
accordance with AASHTO T37:
Sieve Size Percent by weight passing

mm
_____________________________________________
0.600 100
0.300 95-100
0.075 70-100
_____________________________________________
(iii) The mineral filler shall have a Plasticity Index not greater than 4.
NOTE: Plasticity Index limits are not appropriate for hydrated lime and cement.
5.5.1.2 Bituminous Binders
The appropriate binder shall, if not otherwise specified in the Specifications of Particular
Application, be selected from one of the types conforming to AASHTO standards as
described below.
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(a) Penetration Graded Asphalt Cement (AASHTO M 20)
Penetration graded asphalt cement shall conform to the requirements of table

5.5.1.2/1.
The asphalt cement shall be homogeneous, free from water, and shall not foam when
Table 5.5.1.2/1
Penetration Grade
40- 50 60- 70 85- 100 120- 150 200- 300
Test Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
(AASHTO)
T49 Penetration at 25oC

1/10 mm 40 50 50 70 85 100 120 150 120 300
T48 Flash point, Cleve-
land Open Cup oC 235 ... 235 ... 235 ... 220 ... 180 ...
T44 Solubility in trich-
loroethylene, % 99 ... 99 ... 99 ... 99 ... 99 ...
T179 Loss on heating,
(5 hrs. at 163 oC), % ... 0.8 ... 0.8 ... 1.0 ... 1.3 ... 1.5
T49 Penetration, after
heating, % of orignl. 58 ... 54 ... 50 ... 46 ... 40 ...
_______________________________________________________________________________
Table 5.5.1.2/1a
Viscosity Grades
Test (AASHTO)
AC-2.5 AC-5 AC-10 AC-20 AC-30 AC-40
Min Max Min Max Min Max Min Max Min Max Min Max
T202 Viscosity at 60ºC 200 300 400 600 800 1200 1600 2400 2400 3600 3200 4800
- poises
T201 Viscosity at 125 - 175 - 250 - 300 - 350 - 400 -
135ºC - CS
T49 Penetration at 220 - 140 - 80 - 60 - 50 - 40 -
25ºC (
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T48 Flash, Point, 163 - 177 - 219 - 232 - 232 - 232 -

Cleveland Open Cup,
ºC
T44 Solubility in 99 - 99 - 99 - 99 - 99 - 99 -
trichloroethylene, %
T179 Loss on heating - - - 1.0 - 0.5 - 0.5 - 0.5 - 0.5
(5hrs at 163ºC) %
T2020 Viscosity at 60º - 1000 - 2000 - 4000 - 8000 - 12000 - 16000
after heating, poise
b) Cut Back Asphalt (AASHTO M 81 and M 82)
(i) This specification covers liquid petroleum products, produced by fluxing an

asphaltic base with suitable petroleum distillates, to be used in the treatment of
road surfaces.
The cut-back asphalt shall show no separation or curdling prior to use and shall
not foam when heated to the application temperature.
(ii) Cut-back asphalt of the grade designated shall conform to the requirements shown
in Table 5.5.1.2/2a for rapid curing (RC) types and in Table 5.5.1.2/2b for medium
curing, (MC) types.
Table 5.5.1.2/2a
RC-70 RC-250 RC-800 RC-300
Test Min. Max. Min. Max. Min. Max. Min Max.

(AASHTO)
T201 Kinematic Viscosity at 60 70 140 250 500 800 1600 3000 6000
centistokes
T79 Flash point (Tag, open-cup),oC .. .. 27 .. 27 .. 27 ..
T55 Water .. 0.2 .. 0.2 .. 0.2 .. 0.2
T78 Distillation test:

Distillate, % by volume of
total distillate to 360 oC
to 190 oC 10 .. .. .. .. .. .. ..
to 225 oC 50 .. 35 .. 15 .. .. ..
to 260 oC 70 .. 60 .. 45 .. 25 ..
to 315 oC 85 .. 80 .. 75 .. 70 ..
Residue from distillation to
360 oC, % by volume of
sample 55 .. 65 .. 75 .. 80 ..
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distillation:
T202 Absolute viscosity at 60 oC,

poises 600 2400 600 2400 600 2400 600 2400
T51 Ductility (50 mm/min. at

25 oC), cm 100 .. 100 .. 100 .. 100 ..
T44 Solubility in trichloroety-

lene, % 99.0 .. 99.0 .. 99.0 .. 99.0 ..
Table 5.5.1.2/2b
MC-30 MC-70 MC-250 MC-800 MC-3000
Min.Max. Min.Max. Min.Max. Min.Max. Min. Max.
Test
T201 30 60 70 140 250 500 800 1600 3000 6000

centistokes
T79 Flash point (Tag, open- 38 .. 38 .. 66 .. 66 .. 66..
T55 Water .. 0.2 .. 0.2 .. 0.2 .. 0.2 .. 0.2
T78 Distillation test:

Distillate, % by volume of
.. 25 0 20 0 10 .. .. .. ..
40 70 20 60 15 55 0 35 0
15
75 93 65 90 60 87 45 80 15
75
Residue from distillation to
sample 50 .. 55 .. 67 .. 75 .. 80
..

distillation:
T202
Poises 300/1200 300/1200 300/1200 300/1200 300/1200
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T51
cm 100 .. 100 .. 100 .. 100 .. 100 ..
T44 Solubility in trichloroethylene,

% 99.0 .. 99.0 .. 99.0 .. 99.0 .. 99.0 ..
(c) Emulsified Asphalt (AASHTO M 140)
(i) The emulsified asphalt shall be homogeneous. Within 30 days after delivery and
provided separation has not been caused by freezing, the emulsified asphalt shall be
homogeneous after thorough mixing.
(ii) Emulsified asphalt shall conform to the requirements prescribed in Table 5.4.1.2/3.
Guidance for selection of the appropriate grade is given under "Typical Applications".
(iii) The properties of the emulsified asphalt given in Table 5.4.1.2/3 shall be determined in
accordance with AASHTO T59, Testing Emulsified Asphalt.
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Table 5.5.1.2/3
MISSING TABLE INSERT
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Table 5.5.1.2/3
MISSING TABLE INSERT
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5.5.1.3 Adhesion Agent
The adhesion agent shall be of an approved type and shall be used in accordance with the
manufacturer’s instructions and as instructed by the Engineer.
5.5.1.4 Storage and Handling of Bituminous Binders
Before any bituminous binder is delivered to the Site, the Contractor shall provide the
Engineer with a certificate from the manufacturer that the material to be supplied complies
in all respects with the relevant specification.
(a) Transport and Storage
When carried in bulk containers, records of binder temperature and time in a manner
acceptable to the Engineer shall be kept.
Any bituminous binder delivered in leaking or deteriorated containers may be rejected.
The bitumen storage area and heating station shall be kept neat and tidy.
The storage area shall be cleared of vegetation and the drums stacked on their sides only in
small quantities with gaps between each stack to reduce fire risk.
Bitumen distributors and boilers shall be kept clean, at all times. When changing the grade
of bitumen and at the end of each days work, all boilers and distributors shall be thoroughly
cleaned out with a solvent.
The flushing from boilers and distributors shall not be poured over the area
indiscriminately, but shall be led by drainage channels to disposal pits, care being taken that
flushing do not find their way into storm water ditches or streams.
All boilers, pre-heating pits, tools, and equipment shall be kept scrupulously clean.
When filling the bitumen distributor from the boilers or bulk containers, the bitumen shall
be passed through a filter of fine wire gauze.
On completion of the Works, the disposal pits and drainage channels shall be filled in and
the Site left clean and tidy.
During storage the temperature of the bituminous binder shall be kept as low as possible,
consistent with reasonable pumping ability.
(b) Heating
The bituminous binder shall be heated in boilers or bulk storage containers, equipped with
adequate pumps and accurate thermometers. No bitumen shall be heated in a boiler when
the thermometer is broken or inaccurate.
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The minimum pumping temperatures, the range of spraying temperatures and the maximum
heating temperatures of cut-backs and penetration-grade bitumen are given in the Table
5.5.1.4/1.
Table 5.5.1.4/1
Temperature (oC)
Binder
Minimum Spraying Maximum
Pumping Heating
Slot-jets Atomizing jets
Cut-back RC 30 10 35 - 45 - 50
" RC 70 25 55 - 65 - 70
" RC 250 45 80 - 90 - 90
" RC 800 60 100 - 115 - 120
" RC 3000 80 125 - 135 - 135
Cut-back MC 30 10 35 - 45 50 - 60 65
" MC 70 25 55 - 65 70 - 85 85
" MC 250 45 80 – 90 90 - 100 110
" MC 800 60 100 - 115 120 - 135 135
" MC 3000 80 125 - 135 135 - 150 150
" 8000/4000
(France) 90 135 - 145 145 - 160 160
Bitumen 400/500 95 140 - 150 160 - 170 170

" 280/320 100 150 - 150 160 - 17 170
" 180/200 105 155 - 165 160 - 170 175
" 80/100 115 160 - 170 170 - 180 180
The pumping and spraying temperatures are for guidance only, since the optimum spraying
temperature depends on the temperature viscosity relationship of the bitumen.
For slot-jets the viscosity for spraying shall be 70 to 100 centistokes and for atomizing jets
35 to 60 centistokes.
No bitumen or cut-back bitumen shall be heated above the maximum temperature given
above and any that is overheated shall be removed from the Site and disposed of by the
Contractor.
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The rates of application of binder specified or instructed by the Engineer refer to volumes of
binder corrected to 15.6oC using the Standard Petroleum Management Table (ASTM D
1250).
(c) Safety Precautions
The Contractor shall take every precaution to avoid fire or health hazards. He shall always
ensure that;
(i) bitumen is heated only to the temperature required for the particular application;
(ii) hot bitumen never comes in contact with water;
(iii) suitable protective clothing and gloves are used when handling hot bitumen;
(iv) dust is reduced to a minimum
Great care is required when using rapid-curing cut-back, because of the highly flammable
nature of the solvent.
(d) Production and Handling Aggregates
The equipment provided and the methods of operating shall be such as will produce
aggregates which meet the requirements specified throughout this Paragraph. This may
require washing the coarse aggregates to meet the cleanness requirements.
The Contractor shall comply with Section 3 of this Standard Specification when stockpiling
aggregates and no production of bituminous pavement materials will be allowed until the
Engineer is satisfied with the handling and storage of aggregates. If required the stockpile
area shall be surfaced with 100 mm thickness of gravel or other material, acceptable to the
Engineer. Any contaminated aggregate shall not be used in the work. After use the stockpile
area shall be cleared and left neat and tidy.
(a) Preparation of Surface
Immediately before placing the bituminous material in the pavement, the existing surface
shall be cleaned of all loose material and foreign matter with mechanical brooms or other
approved method. The debris shall be deposited well clear of the surface to be covered.
Any defect of the surface shall be made good as instructed by the Engineer and no
bituminous material shall be laid or sprayed until the surface has been approved by the
Engineer.
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(b) Equipment
The Contractor shall submit to the Engineer in accordance with Paragraph 1.5 of this
Standard Specification, full details of the equipment he proposes to use and the procedures
he proposes to adopt for carrying out the permanent works.
The Engineer shall have access at all times to the equipment for the purposes of inspection.
The Contractor shall carry out regular calibration checks in the presence of the Engineer
and shall correct forthwith any faults which are found.
All equipment used in the mixing, laying and compacting of bituminous mixes shall be of
adequate rated capacity, in good working condition, and shall be acceptable to the Engineer.
Obsolete or worn-out equipment will not be allowed on the work.
(i) Bitumen Distributors
Bitumen distributors shall be truck mounted and shall have sufficient power to maintain
uniform speeds for the proper application of the binder. The truck shall be equipped
with an accurate tachometer showing the speed in metres per minute. The truck shall be
fitted with a gauge bar and chain or any other acceptable device clearly visible to the
driver to enable him to follow the required edge. The distributor tank shall have a
capacity of at least 4.000 litres and shall be fitted with a device for indicating the
quantity in the tank at any time. It shall be equipped with heaters capable of maintaining
temperatures up to 200 oC and be fitted with an accurate thermometer.
The circulation system shall permit pumping around the tank and around the spray bar
without actually spraying. Spray bars shall be available for spraying in widths varying
from 1 m to 4 m and shall be adjustable transversely so that the operator can follow the
required edge independently. The spray nozzles shall be arranged to give a uniform
spray and the shut-off shall be quick acting with an anti-drip device. The pressure in the
spray bar shall be sufficient to give a good distribution and spraying of the binder.
Distributors shall be capable of applying bituminous binder within the limits of 10% of
the specified rate of application over any portion of the surface.
Distributors shall be checked and calibrated before starting any work or when required
by the Engineer. This shall include the calibration of all the metering devices and
checking the uniformity of the transverse distribution of spray.
All distributors shall be furnished with their "rate of spray-machine speed" chart.
(ii) Chipping Spreaders
Chipping spreaders shall be capable of spreading the chipping uniformly over variable
widths, from 0.5 to 4.0 m, at the rates specified.
The number and output of chipping spreaders shall be sufficient to ensure that chippings
are spread immediately after the bituminous binder has been applied.
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Chipping spreaders shall be checked and calibrated before starting any work or when
required by the Engineer.
(iii) Rollers
The main rolling shall be carried out with self-propelled pneumatic tyre rollers, having a
wheel-load of more than 2 tonnes. The tyres shall be smooth and their pressure shall be
more than 0.4 MPa.
Steel-wheeled rollers shall not be used for surface dressings.
The number and output of rollers shall be sufficient to ensure that rolling does not lag
behind laying or spreading bituminous materials.
(iv) Miscellaneous Equipment
Sufficient trucks and loading machinery shall be employed to ensure an adequate,

prompt and continuous supply of chippings.
Rubber tyre mechanical rotary brooms towed by or mounted on rubber tyre vehicles
shall be provided.
All labour working with or on bitumen shall be provided with protective clothing and
footwear.
(c) Traffic Control and after care
The road shall not be opened to traffic until the binder has attained sufficient viscosity to
prevent any damage to the bituminous surfacing.
The Contractor shall erect temporary restriction signs, barriers and removable bumps or any
other device, as instructed by the Engineer, to prevent vehicles travelling too fast over the
newly laid surface course. Vehicle speed shall be restricted to ensure that material will not
be dislodged by faster vehicles.
(d) Tolerances
The final average overall width of the surfacing measured at six equidistant points over a
length of 100 m shall be at least equal to the width specified or instructed. At no point shall
the distance between the centre-line of the road and the edge of the surfacing be narrower
than that instructed by more than 20 mm.
The rate of application of binder along and across the lane width shall not vary by more
than + 10% of the rate ordered and for each length of lane sprayed in a single pass the
average rate of binder application shall be not less than the rate ordered.
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The average rate of application of aggregates along and across the lane width for each
single pass of the spreader shall not vary by more than + 10% of the rate ordered.
5.5.2 Prime Coat and Tack Coat
(a) Definition
A prime coat means an application of low viscosity bituminous binder to an absorbent non-
bituminous surface. If the prime coat is to be trafficked, it shall be covered with blinding
material.
A tack coat shall mean a light application of bituminous binder to a bituminous or concrete
surface.
(b) Materials For Prime Coat and Tack Coat
For prime coat, the binder shall be a medium-curing cut-back unless otherwise instructed by
the Engineer.
For tack coat, the binder shall be a rapid-curing cut-back, a medium-curing cut-back, a
quick-breaking emulsion or a slow setting emulsion diluted with water.
The blinding material shall consist of fine aggregate, or sand, or crusher dust and shall
contain not more than 15 per cent retained on a 6.3 mm sieve. The blinding material shall
be specified in detail in the Specifications of Particular Application.
(c) Preparation of Surface
In addition to Sub-clause 5.5.1.5 (a):
Where required by the Engineer, immediately prior to the application of prime coat, the
surface of the layer shall be lightly sprayed with water, but in no case saturated.
In order to bring the surface to be primed to the condition required, water shall be applied in
small increments by a distributor. Any water on the surface after spraying shall be brushed
off or allowed to drain away before the prime coat is applied.
(d) Spraying of Prime Coat and Tack Coat
Spraying shall not be carried out later than 12 hours after the surface has been prepared. The
bituminous material shall be sprayed at the temperature specified, in Table 5.5.1.4/1, or to
the temperature ordered by the Engineer.
The spraying width shall normally be one lane width so that construction traffic may run
over the other lane.
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The quantity of binder used shall give complete coverage of the surface with a slight trace
of run-off in places. Should the specified rate of spray appear to be incorrect, the Contractor
shall immediately stop spraying, inform the Engineer and change the spray rate as
instructed.
The edge of the area shall be marked out with a line of string or wire pegged down at
intervals not exceeding 15 m on straights or 7.5 m on curves.
Bitumen shall be sprayed from a pressure distributor and no hand spraying shall be
permitted except in small areas, or to make good a defective area caused by a blocked
nozzle.
The nozzles shall be arranged to give a uniform spray and shall be tested prior to spraying
by discharging on to suitable material (such as building paper, metal sheets, etc.,) or into
purpose made troughs. Testing shall not take place on the road, and any bitumen spilt on the
ground shall be cleaned off.
If during spraying, a nozzle becomes blocked or develops a defect, the spraying shall be
immediately stopped, any area incompletely sprayed shall be made good with a hand spray
and the machine repaired before further spraying is commenced.
When commencing and stopping spraying, sheets of building paper or metal at least 2 m
long shall be spread across the full width to be sprayed to give a clean sharp edge.
Metal sheets or troughs used for testing and the metal sheets used for stopping and starting
work shall be cleaned at the end of each days work.
During spraying, all kerbs, road furniture, culvert headwalls, tree bowls and the like which
are liable to be disfigured by splashing of bitumen shall be protected, and any such feature
which is accidentally marred by bitumen shall be cleaned off with a suitable solvent or
made good.
(e) Curing and Blinding
If, after the application of the prime coat, the road must be used by traffic, blinding material
may be spread in the amount required to protect the primed surface.
Blinding material shall be spread only if permitted by the Engineer.
Unless the Engineer permits otherwise, all loose material on the sprayed surface, including
any blinding material, shall be removed before any further layer of the pavement is laid.
(f) Tolerances shall conform to Sub-clause 5.5.1.5(d).
5.5.3 Surface Dressing
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(a) Definition
A single surface dressing means an application of bituminous binder to any kind of road
surface followed immediately by a single layer of uniform uniformly graded chippings.
A multiple surface dressing means two or more surface dressings placed one on the other.
(b) Materials for Surface Dressing
(i) Bituminous Binder
The binder shall be penetration grade asphalt cement, cationic quick-breaking emulsion
or a medium-curing cut-back unless otherwise instructed by the Engineer.
(ii) Chippings
Chippings shall as a minimum meet the requirements for coarse aggregate defined in
Sub clause 5.5.1.1 (a).
For roads with medium and high traffic, the chippings shall comply with one of the
following sets of requirements as shall be specified in the Specifications of Particular
Applications.
Chipping Class 1 2 3 4
Los Angeles Abrasion, max.% 20 25 30 35
Sodium Sulphate Soundness, max.% 12 12 12 12

Flakiness Index, max. % 20 20 25 25
Crushing ratio, min. % 100 100 100 100
The minimum size of the stone or pebbles crushed to produce the chippings shall be at
least 4 times the maximum size of the chippings.
The polished-stone value of chippings when determined in accordance with BS 812,

shall not be less than 55 unless otherwise approved by the engineer.
(iii) Grading
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The grading of chippings shall be within one of the grading envelopes shown in Table
5.5.3/1. The Specifications of Particular Applications shall specify the nominal size of
chippings to be used.
Table 5.5.3/1
Sieve Percentage by weight passing

Size
-Nominal Sizes-
mm
25 16 12.5 8
28 100 - - -
20 85-100 100 - -
14 0-30 85-100 100 -
10 0-5 0-30 85-100 100
6.3 - 0-5 0-25 80-100
5 - - 0-7 0-30
3 - - - 0-4
0.5 0-0.5 0-0.5 0-0.5 0-0.5
(c) Rate of Application of Binder and Chippings
The rate of spray of binder and the size and rate of spread of chippings shall be as specified
in the Specifications of Particular Application or as instructed by the Engineer.
The correct rate of spread of aggregate is generally estimated visually, as providing

complete coverage. Should the coverage appear to be incorrect, the Contractor shall
immediately inform the Engineer, who will amend the rate of spread accordingly. Any
excess of aggregates shall be removed by hand and any insufficiently covered area shall be
spread over by hand, so that adequate coverage is obtained. Brooming of the material to
effect redistribution will not be permitted.
Tray tests shall be carried out at least once per day during surface dressing operation to
check spray and spread rates calculated using the dip-stick spray truck. This must be done
more frequently when there are a number of short lengths being surface dressed.
(d) Precoated Chippings
The bituminous binder used for pre-coated chippings shall be a medium curing cut-back or
a semi-stable or stable emulsion such as anionic or cationic unless otherwise instructed by
the Engineer. The amount of bituminous binder used to pre-coat chippings shall be as
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specified in the Specifications of Particular Application or shall be as instructed by the

Engineer.
Pre-coating shall be carried out in a mixing machine acceptable to the Engineer.
The pre-coated chippings shall not be tacky and liable to agglomerate. The chippings pre-
coated with cut-back or emulsion shall be stockpiled for the lapse of time required by the
solvents or water to evaporate.
The pre-coated chippings shall be kept free of contamination by dust or other deleterious
matter.
(e) Application of Surface Dressing
The spaying width shall normally be one lane width so that construction traffic may run on
the other lane.
Immediately after the binder has been sprayed, clean dry aggregate shall be uniformly
applied at the specified rate by the use of as many mechanical sprayers as necessary to
match the rate of spraying. The elapsed time between the spraying of binder and the
spreading of aggregates shall in no case exceed one minute.
Should it become apparent that the supply of aggregate is about to fail, the binder spraying
shall be immediately stopped and shall not resume until an adequate supply is assured.
Rolling with pneumatic tired rollers shall begin immediately after the aggregate has been
spread and, in no case, later than two minutes after the application of binder.
Rolling shall continue until all chippings are firmly embedded into the binder. The number
of passes shall be as agreed with the Engineer. Usually, each point shall receive at least 6
passes but excessive rolling, resulting in the crushing of chippings, shall be avoided.
The roller speed shall not exceed 8 km/h, unless otherwise directed by the Engineer.
Additional rolling on a previously completed section shall be given later by pneumatic tyre
rollers in the heat of the day if instructed by the Engineer.
After traffic has been permitted to run on a surface dressing for a period of at least two days
and when instructed by the Engineer, all loose aggregate shall be swept and taken away.
Windrows of loose aggregate shall not be allowed to accumulate at the sides of the road.
(f) Tolerances
Tolerances shall conform to Sub-clause 5.5.1.5 (d).
5.5.4 Sand Seal
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(a) Definition
A sand seal means an application of bituminous binder covered with sand or fine aggregate.
(b) Material for Sand Seal
(i) Binder
The binder shall be a medium-curing cut-back or an emulsion unless otherwise

(ii) Sand
Sand shall meet at least the requirements for fine aggregate in Sub-clause 5.5.1.1 (b).
The grading shall be as follows
Sieve % by weight
(mm) passing
6.3 100
5 95 - 100
4 90 - 100
2 50 - 95
1 20 - 80
0.6 10 - 50
0.425 3 - 25
0.3 0 - 15
0.150 0-8
0.075 0-5
(c) Rate of Application of Binder and Fine Aggregate
The rate of spray of binder and the rate of spread of the fine aggregate shall be as specified
in the Specifications of Particular Application or as instructed by the Engineer.
During the Sand Sealing operation tray tests to determine spray and spread rate shall be
carried out at least once per day.
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(d) Application of Sand Seal
The surface to be covered shall be prepared in accordance with Sub-clause 5.5.1.5 (a).
The binder shall be uniformly sprayed at the specified rate, the fine aggregate shall be
uniformly spread and rolled, all as described in Clause 5.5.3(e) for surface dressing except
that the fine aggregate shall be spread in excess of that required to cover the binder.
(e) Tolerances
Tolerances shall conform to Sub clause 5.5.1.5 (d).
5.5.5 Gravel Seal
(a) Definition
A gravel seal means an application of bituminous binder covered with graded granular
material.
(b) Material for Gravel Seal
(i) Binder
The binder shall be a medium curing cut-back unless otherwise instructed by the
Engineer.
(ii) Gravel
Gravel shall meet at least the requirements for coarse and fine aggregates in Sub-clause
5.4.1.1 (a) and (b).
The cover aggregate shall consist of graded gravel or graded crushed stone or a mixture
of these and shall have a grading within and approximately parallel to the following
envelope:
Sieve % by weight
mm passing
20 100
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14 65 - 95
10 45 - 95
6.3 25 - 80
4 15 - 65
2 10 - 50
1 5 - 40
0.425 3 - 30
0.075 0 - 10
(c) Rate of Application of Binder and Gravel
The rate of spray of binder and the rate of spread of gravel shall be as specified in the
Specifications of Particular Application or as instructed by the Engineer. Tray tests shall be
carried out at least once per day during gravel sealing operations.
(d) Application of Sand Seal
The binder shall be uniformly sprayed and the gravel shall be uniformly spread and rolled in
accordance with Sub-clause 5.5.3 (e).
(e) Tolerances
Tolerances shall conform to Sub-clause 5.5.1.5 (d).
5.5.6 Emulsion Slurry Seal
(a) Definition
An emulsion slurry seal means a mixture of bitumen emulsion, fine aggregate, mineral filler
and water prepared in a mixer and then spread on the road surface.
(b) Materials for Slurry Seal
(i) Emulsion
The emulsion shall be either an anionic emulsion (slow setting or rapid-setting) or a

slow-acting cationic emulsion unless otherwise instructed by the Engineer.
(ii) Aggregate
Sand shall be produced from stone that meets requirements for fine aggregate in Sub
clause 5.5.1.1 (b). It shall have a Sand Equivalent of at least 40.
The grading curve shall be within one of the following envelopes, as specified in the
Specifications of Particular Application:
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Sieve Percentage by weight passing

Size
Type I Type II Type III
mm (Fine) (Normal) (Coarse)
10 - - 100
6.3 - 100 80 - 95
5 - 90 - 100 70 - 90
2 100 60 - 87 40 - 65
1 60 - 85 40 - 67 25 - 45
0.425 30 - 48 22 - 38 15 - 28
0.3 25 - 40 18 - 30 12 - 25
0.150 15 - 27 10 - 20 7 - 18
0.075 10 - 20 5 - 15 4 - 13
(iii) Mineral Filler
The type shall conform to requirements in Sub-clause 5.5.1.1 (c), and the amount of
filler shall be as specified in the Specifications of Particular Application.
(c) Preparation of the Slurry Mixture
The respective amounts of the various materials shall be as specified in the Specifications
of Particular Application or as instructed by the Engineer.
The slurry mixture shall be prepared in a slurry mixer acceptable to the Engineer. The
mixer shall be charged with materials in the proportions specified.
The mixing cycle shall be sufficient to produce a uniform coating of the aggregate and a
uniform consistency of the slurry. It shall continue until the slurry mixture is discharged
into the spreader box or onto the road surface. The entire batch shall be discarded if there is
evidence that the emulsion has broken. The slurry, ready for application, shall be a smooth,
free flowing mixture throughout.
(d) Rate of Application of Slurry Mixture
The rate of application of the slurry mixture shall be as specified in the Specifications of
Particular Application or as instructed by the Engineer.
Tray tests shall be carried out at least once per day during slurry seal operations.
(e) Construction
Where a slurry seal is to be applied to a surface dressing, the surface dressing shall be
trafficked for a period of at least two weeks prior to application of the slurry.
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The slurry mixture shall be evenly spread at the specified rate by a slurry machine, except in
restricted areas where hand spreading may be permitted.
The surface immediately ahead of the spreader shall be slightly dampened, unless otherwise
instructed by the Engineer. Where required by the Engineer, slurry seal shall be rolled with
smooth tyre pneumatic rollers acceptable to the Engineer. Rolling shall commence as soon
as the slurry has set sufficiently to ensure that there is no rutting, nor any pick-up will occur.
When the slurry is applied in two layers, the first layer of slurry shall be struck off level
with the tops of the stones in the aggregate layer so that the tops of the stones will be just
visible after application of the slurry.
The second layer of slurry shall not be applied until the first layer has dried. Before the
second layer of slurry is applied, the road shall, wherever possible, be opened to traffic for
as long as possible and as directed by the Engineer. On sections of the road where this is
not possible, the surface shall be well-rolled with a pneumatic-tyre roller and the second
layer applied after sufficient time has been allowed for the first layer to cure. The Engineer
shall decide on the time necessary for proper curing, which will in any case be not less than
24 hours.
The surface shall be thoroughly cleaned of all dust, dirt and foreign materials before the
second layer of slurry is applied.
The tops of the stone chips shall not be exposed after the second layer of slurry has been
applied and the emulsion has cured and set.
The finished slurry shall be of uniform surface texture and colour throughout the work. The
finished surface shall be free from blow-holes and irregularities.
(f) Curing and Control of Traffic
All traffic shall be kept off the slurry seal until it has cured to a firm condition that will
prevent pick-up of the mixture. Where two applications of slurry are required, the initial
treatment shall be cured thoroughly prior to placing the succeeding application.
(g) Tolerances
Tolerances shall conform to Sub-clause 5.5.1.5 (d) applied to the mix.
(a) Bituminous Binder
Application of bituminous binders for prime coat, tack coat, surface dressing, sand seal, and
gravel seal shall be measured by the square metre at the application rate specified in the Bill
of Quantities.
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Binder sprayed over areas outside the specified area to be sprayed shall not be measured or
paid for.
Items are included in the Bill of Quantities for variation in the binder application rates
instructed by the Engineer over or under the nominal application rates specified in the Bill
of Quantities. Measurement shall be per kg of binder more than or less than the nominal
quantity specified, and the amount calculated by extending this quantity and the rate shall
be added to or deducted from the total value of work certified.
The rates for the various grades or bituminous binder prime and tack coats shall include for
the cost of:
testing, preparation of surfaces including watering where necessary and

application;
setting up, maintaining and dismantling of bitumen heating equipment;
provision of binder, heating, transporting any distance (no overhaul will be

paid), spraying at the rate instructed, spraying in large or small areas, waste,
provision of protective clothing;
Protecting road furniture and exercising traffic control.
(b) Chippings and Blinding Material
Chippings and blinding material shall be measured by the cubic metre placed and
compacted upon the sprayed surface of the road calculated as the product of the area
instructed to be laid and the rate of application instructed by the Engineer.
Separate items are included in the Bill of Quantities for each nominal size of chipping
specified in the Specifications of Particular Application, and for blinding material, if
specified.
The rates for chippings and blinding material shall include for:
provision of the material on the Site including drilling, blasting, crushing,

stockpiling, loading, access roads, transport and compliance with this Standard
Specification;
washing, if necessary;
spreading at the application rate instructed by the Engineer;
rolling, back rolling;
sweeping and disposal of surplus material, wastage;
traffic control.
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Chippings or blinding material spread over areas outside the specified area to be covered
shall not be measured or paid for.
(c) Adhesion Agent
Adhesion agent shall be measured by the kilogram for the quantity instructed by the
Engineer to be used.
The rate for adhesion agent shall include the cost of diluting and spraying onto the
aggregate or mixing in with the binder.
(d) Pre-coating of Chippings
Pre-coating of chippings with bituminous binder shall be measured as follows:
Binder shall be measured by the litre for the quantity instructed by the
Engineer to be used.
The rate for binder shall include the cost of diluting and spraying onto the
aggregate and mixing as required to obtain complete cover of the
aggregate.
(e) Sand Seal Aggregate
Sand seal aggregate shall be measured by the cubic metre placed and compacted upon the
sprayed surface of the road as the product of the area instructed to be laid and the rate of
application instructed or agreed by the Engineer.
The rate for sand seal shall include for the cost of the items detailed in 5.5.3 (b) above and
for brooming the whipped off sand back onto the road as many times as are necessary for it
to adhere fully to the binder.
(f) Gravel Seal Aggregate
Gravel seal aggregate shall be measured by the cubic metre placed and compacted upon the
sprayed surface of the road as the product of the area instructed to be laid and the rate of
application instructed or agreed by the Engineer.
The rate for gravel seal aggregate shall include for the cost of the items detailed in 5.5.3 (b)
above.
(g) Emulsion Slurry Seal
Emulsion slurry seal shall be measured by the tonne of dry aggregate placed, calculated as
the product of the rate of application of dry aggregate instructed by the Engineer and the
area specified to be covered.
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No adjustment to the measurement shall be made for variations of application rate within
the tolerance specified in the Specifications of Particular Applications.
Slurry seal spread over areas outside the specified area shall not be measured or paid for.
The rate for emulsion slurry seal shall include for the cost of the following:
preparing and cleaning the surface prior to laying;
providing the dry aggregate on Site including drilling, blasting, crushing,

stockpiling, loading, access roads transport and compliance with this Standard
Specification;
providing on Site mineral filler of the type and at the nominal proportion by
weight of the mix specified in the Specifications of Particular Application;
providing on Site bitumen emulsion of the type and at the nominal proportion
by weight of the mix specified in the Specifications of Particular Application;
of water;
mixing the dry aggregates, filler, emulsion and water in the proportions
specified;
transporting, laying and rolling the mixture at the application rate instructed by
the Engineer;
signs, barriers and traffic control measures.
Variation in Filler Content
An item shall be included in the Bill of Quantities for variation in the filler content
instructed by the Engineer over or under the nominal proportion specified in the
Measurement shall be per tonne of filler more than or less than the nominal proportion
specified, and the amount calculated by extending the quantity and the rate shall be
added to or deducted from the total value of work certified.
Variation in Emulsion Content
An item shall be included in the Bill of Quantities for variation in the emulsion content
instructed by the Engineer over or under the nominal proportion specified in the
Measurement shall be per kg of the emulsion more than or less than the nominal
proportion specified, and the amount calculated by extending the quantity and the rate
shall be added to or deducted from the total value of work certified.
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5.6 BITUMINOUS COURSES
5.6.1 General
Clause 5.6.1 comprises specifications related to materials, construction and test methods
which apply to all subsequent clauses of this Paragraph.
Furthermore, the requirements stated in other sections of the Specification as listed below
apply to Clauses throughout this Paragraph and shall be read in conjunction therewith.
Section 2: The whole section
Section 3: Paragraph 3.1, clause 3.1.4, Materials Sources and Spoil Areas
5.6.1.1 Aggregates and Filler
(a) Coarse and Fine Aggregates
Supplementary requirements to specifications in Sub-clause 5.5.1.1 shall be specified for

coarse and fine aggregates in correspondence to their use in the pavement.
Tables 5.6.1.1/1 and 2 show minimum requirements. The limits for pavements exposed to
light traffic are in brackets. The Specification of Particular Application shall normally
specify a higher quality according to availability of materials on Site.
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Table 5.6.1.1/1 Coarse Aggregate
Coarse Aggregate Class A1 A2 A3 B1 B2

Los Angeles Test LAA max. 25 35 40 45 45
Crushing Ratio CR min. 90 75 60 75 50
Flakiness Index FI max. 15 20 25 20 25
Hotmix Asphalt Concrete

Wearing Course X (X) - - -
Binder Course X (X) - -
Base Course X (X) -
Cold Mix Asphalt

Wearing Course X (X) - - -
Base Course X X (X)
Patching X -
Open Graded Asphalt

Drainage Course X (X) - (X)1)
Base Course X -
Dense Bituminous Macadam

Base Course X
1) Only for use as permeable material in subsurface drains off the pavement system.
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Table 5.6.1.1/2 Fine Aggregate
Fine Aggregate Class S1 S2 S3
Los Angeles Test LAA max. 25 35 40

Sand Equivalent SE min. 60 40 35
Plasticity Index PI max. NP 3 6
Hotmix Asphalt Concrete

Wearing Course X (X) -
Binder Course X (X)
Base Course X (X)
Coldmix Asphalt
Wearing Course X (X) -
Base Course X
Patching X
Open Graded Asphalt Base Course X
Dense Bitumen Macadam Base Course X
Fine aggregates shall conform to one of the grading presented in Table 5.6.1.1/3.
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Table 5.6.1.1/3 Grading Requirements for Fine Aggregates
Percent by weight passing

Sieve Size
Grading Grading Grading

No. 1 No. 2 No. 3
mm
9.5 100 ... 100

4.75 95 - 100 100 80 - 100
2.36 70 - 100 95 - 100 65 - 100
1.18 40 - 80 85 - 100 40 - 80
0.600 20 - 65 65 - 90 20 - 65
0.300 7 - 40 30 - 60 7 - 40
0.150 2 - 20 5 - 25 2 - 20
0.075 0 - 10 0 - 5 0 - 10
Note: It is recognized that for certain purposes satisfactory results may be obtained with materials
not conforming to the grading requirements of this specification. In such cases the use of
fine aggregates not conforming to the grading requirements of this specification may be
authorized only based on field experience or laboratory studies of the possibility of
designing a mixture of materials to be used on the job that will yield bituminous paving
mixtures equivalent in quality to the job mix requirements.
(b) Filler
Added mineral filler shall consist of Portland cement, hydrated lime, limestone dust, or
other suitable filler complying with the requirement of Sub-clause 5.5.1.1 (c) of this
Standard Specification. The approved type shall be separately added directly to the pugmill
from the filler silo.
5.6.1.2 Bituminous Binders
If not otherwise specified in the Specifications of Particular Application or ordered by the

Engineer, the binder grades stated in Table 5.6.1.2/1 shall be used in the mixes for the
different layers.
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Table 5.6.1.2/1 Bituminous Binders
Type of
Bituminous Asphalt Cement Cutback Emulsion
Binder Pen. Graded MC & SC Anionic & Cationic
Grade 60/70 85/100 250 800 3000 MS-2h SS-1 SS-1h
Hotmix Asphalt
Concrete
Wearing Course (X) X - - - - - -
Binder Course X X - - - - - -
Base Course X (X) - - - - - -
Coldmix Asphalt
Concrete
Wearing Course - - - X X X - X
Base Course - - X X - - X -
Patching - - X - - - X
Open Graded Asphalt

Concrete
Drainage Course X - X - - X - -
Base Course X (X) - X X - X X
Dense bitumen
Macadam
Base Course X (X) - - - - - -
The standard specifications for penetration graded asphalt cement; cutback and emulsion
are contained in Tables 5.51.2/1, 5.5.1.2/2b and 5.5.1.2/3 respectively.
The maximum Viscosity Index

be specified for the penetration graded binder in the Specifications of Particular
Applications.
5.6.1.3 Adhesion Agent
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An approved adhesion agent shall be used in mixes where aggregate fails to retain at least
70% of the coating when tested according to the "Dynamic Immersion Test" described
hereunder.
Test Procedure for Dynamic Immersion Test:
A sample of 115 grams of aggregate fraction 9.5-12.5 mm is rinsed with distilled water and
dried for at least 5 hours at 150
The sample is mixed for 1 minute at 3 revolutions per sec. with 4 grams bitumen, and anti-
stripping agent if required, at a temperature which gives the bitumen a viscosity of 150 cSt.
Before mixing the aggregates and bitumen the samples must be kept at mixing temperature
for minimum ½ hour and maximum 1 hour.
Place the coated aggregate on a steel lid and let cool for 15 hours at room temperature.
Add 100 ml distilled water to a glass bottle with a 100 mm steel lid. Transfer the coated
aggregates one by one by means of wet fingers into the glass bottle. Insert a glass rod
through the sample. The length of the rod shall be fit to enable the rod to be fixed tightly
between the bottom edge of the bottle and the lid.
Screw on the lid and put the bottle on a rotating machine.
Let the bottle roll at 40 rpm at a temperature of 30 +/-
Report the percentage of stone surface still coated.
Each test shall be made in duplicate.
5.6.1.4 Design of Working Mix
At least two months prior to commencing work using a bituminous mix, the Contractor
shall, having demonstrated that he can produce aggregates meeting the grading
requirements of the Specification, submit samples of each constituent of the mix to the
Engineer.
The Engineer shall decide on the constituent proportions for the initial design mix or mixes
and the Contractor shall carry out Site Trials using these mixes in accordance with Clause
2.3.1 of this Standard Specification.
Following laboratory and Site Trials, the Engineer will determine the proportions of the
working mix and the Contractor shall maintain this composition to the tolerances specified
in Sub clause 5.6.1.7.
Should any changes occur in the nature or source of the constituent materials, the Contractor
shall advise the Engineer accordingly, and submit further samples of each constituent to the
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Engineer who will then decide upon any revisions which may be required to the mix. If any
change is required, the Contractor shall carry out further Site Trials in accordance with
Clause 2.3.1 until a satisfactory mix is obtained.
(a) General Requirements to Equipment
The Contractor shall submit to the Engineer in accordance with Section 1 of this Standard
Specification, full details of the equipment he proposes to use and the procedures he
proposes to adopt for carrying out the permanent Works.
The Engineer shall have access at all times to the equipment for the purposes of inspection.
The Contractor shall carry out regular calibration checks in the presence of the Engineer
and shall correct forthwith any faults that are found.
All equipment used in the mixing, laying and compacting of bituminous mixes shall be of
adequate rated capacity, in good working condition, and shall be acceptable to the Engineer.
Obsolete or worn out equipment will not be allowed on the work.
(i) Mixing Equipment
Bituminous materials shall be mixed in equipment complying with ASTM

designation D995 or which is otherwise acceptable to the Engineer and shall be
located on Site unless otherwise agreed by the Engineer. It shall be equipped with
at least three bins for the storage of heated aggregates and a separate bin for filler.
All bins shall be covered to prevent the ingress of moisture.
The equipment may be either the batch mix type or the continuous mix type and
shall be capable of regulating the composition of the mixture type within the
tolerances specified in Sub clause 5.6.1.7 of this Standard Specification.
For production of asphalt concrete for surfacing a batch mix type mixing
equipment shall be preferred.
The bitumen tank shall be capable of maintaining its contents at the specified
temperature within a tolerance of plus or minus 5oC and shall be equipped with a
thermostat to prevent the temperature rising above 180oC and a fixed thermometer
easily read from outside the tank. Any bitumen which has been heated above
180oC or has suffered carbonization from prolonged heating shall be removed
from the equipment.
(ii) Laying Equipment
Bituminous materials shall be laid by a self-propelled spreader finisher equipped

with a hopper, delivery augers and a heated adjustable vibrating screed. It shall be
capable of laying bituminous materials with no segregation, dragging, burning or
other surface defects and within the specified level and surface regularity
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tolerances. Delivery augers shall not terminate more than 20 cm from the edge
plates.
(iii) Compaction Equipment
The Contractor shall provide sufficient rollers of adequate size and weight to
achieve the specified compaction. Prior to commencing the laying of bituminous
mixes in the permanent Works, the Contractor shall carry out Site Trials in
accordance with Clause 2.3.1 of Section 2 of the Standard Specification to
demonstrate the adequacy of his equipment and to determine the optimum method
of use and sequence of operation of the rollers.
(b) Mixing of Aggregates and Bitumen
The bitumen shall be heated so that it can be distributed uniformly. Care shall be taken
not to overheat it. the temperature shall never exceed 180oC for Pen. 80/100 or Pen.
60/70 bitumen and shall normally be 120-140oC for 80/100 and 130-150oC for 60/70
bitumen unless specified otherwise in subsequent parts of this Section.
The required aggregate fractions shall be of uniform quality and of such gradings that
when combined in proper proportions, with mineral filler if necessary, the resultant
mixture will meet the gradation requirements. The different aggregate sizes shall be
kept separated at the mixing plant until they have been delivered to the cold elevator
feeding the dryer.
The storage yard shall be maintained neat and orderly, and the separate stock piles shall
be readily accessible for sampling. Coarse aggregate (retained on the 2.0 mm sieve)
shall be produced, stored and fed to the cold elevator in at least two separate fractions
of suitable grading.
The aggregates shall be dried and heated so that they are mixed at the following
temperatures:
125 - 165oC when 80/100 bitumen is used

130 - 170oC when 60/70 bitumen is used.
The dried aggregates shall be combined in the mixer in the amount of each fraction
required to meet the requirements established and agreed at the laboratory and Site
trials in Clause 2.3.1 of Section 2 of this Standard Specification. The bitumen shall be
introduced into the mixer in the amount specified. The materials shall then be mixed
until a complete and uniform coating of the aggregate is obtained.
The mixing time shall be the shortest required to obtain a uniform mix and thorough
coating. The wet mixing time shall be determined by the Contractor and agreed by the
Engineer for each equipment and for each type of aggregate used. It shall normally not
exceed 60 seconds.
(c) Transporting the Mixture
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The bituminous mix shall be kept free of contamination and segregation during
transportation. When so instructed by the Engineer, each load shall be covered with
canvas or similar covering to protect it from the weather and dust.
(d) Laying the Mixture
Immediately after the surface has been prepared and approved, the mixture shall be
spread to line and level by the laying equipment without segregation and dragging.
The mixture shall be placed in widths of one traffic lane at a time, unless otherwise
agreed by the Engineer. The compacted thickness of any layer shall be at least 2.5
times the maximum size of the aggregate for wearing course and at least 2 times for
binder course. (The minimum practical thickness is 25 mm).
On areas where irregularities or unavoidable obstacles make the use of mechanical

laying impracticable, the mixture shall be spread, raked and luted by hand.
The temperature of the mixture at the time of spreading shall be at least 90oC where
80/100 bitumen is used and at least 95oC where 60/70 bitumen is used unless specified
otherwise in subsequent parts of this Section.
(e) Compaction
Immediately after the bituminous mixture has been spread, it shall be thoroughly and
uniformly compacted by rolling.
The surface shall be rolled when the mixture is in the proper condition and when rolling
does not cause undue displacement or shoving.
The number, weight and type of rollers furnished shall be sufficient to obtain the
required compaction while the mixture is in a workable condition. The sequence of
rolling operations shall be as directed by the Engineer.
Initial rolling with a steel tandem or three-wheeled roller, vibratory roller or pneumatic-
tyred roller shall follow the laying equipment as closely as possible. The rollers shall be
operated with the drive roll nearest the laying equipment, at a slow and uniform speed.
Intermediate rolling with a pneumatic-tyre roller shall follow immediately. Final

rolling with a steel wheeled roller shall be used to eliminate the marks from previous
rolling.
To prevent adhesion of the mixture to the rollers, the wheels shall be kept lightly
moistened with water.
Rolling shall begin at the side and proceed longitudinally parallel to the centre-line,
each trip overlapping one-half of the roller width. On super-elevated curves, rolling
shall begin at the low side and progress to the high side.
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In areas too small for the roller, a vibrating plate compactor or a hand tamper shall be
used to achieve the specified compaction.
(f) Finishing, Joints and Edges
Any mixture that becomes loose and broken, mixed with dirt or is in any way defective,
shall be removed and replaced with fresh hot mixture, which shall be compacted to
conform with the surrounding area.
Spreading the mixture shall be as continuous as possible. Transverse joints shall be

formed by cutting neatly in a straight line on the previous run to expose the full depth of
the course. When instructed by the Engineer, the vertical face so formed shall be
painted with bitumen just before additional mixture is placed against it.
Longitudinal joints shall be rolled directly behind the paving operation. The first lane
shall be placed true to line and level and have an approximately vertical face. The
mixture placed in the abutting lane shall then be tightly crowded against the face of the
previously placed lane. The paver shall be positioned to spread material overlapping
the joint face by 20-30 mm. Before rolling, the excess mixture shall be raked or luted
and discarded.
When the abutting lane is not placed on the same day, or the joint is destroyed by
traffic, the edge of the lane shall be trimmed to line and painted with bitumen just
before the abutting lane is placed.
Any fresh mixture spread accidentally on the existing work at a joint shall be carefully
removed by brooming it back on to un-compacted work, so as to avoid formation of
irregularities at the joint. The finish at joints shall comply with the surface
requirements and shall present the same uniformity of finish, texture and density as
other sections of the work.
The edges of the course shall be rolled concurrently with or immediately after the
longitudinal joint. In rolling the edges, roller wheels shall extend 50 to 100 mm beyond
the edge.
5.6.1.6 Sampling and Testing of Bituminous Mixture
(a) Samples from Plant
During mixing and laying of bituminous mixtures, control tests on the constituents and
on the mixed material shall be carried out in accordance with Clause 2.4.10 of this
If the results of any tests show that any of the constituent materials fail to comply with
the Specification, the Contractor shall carry out whatever changes may be necessary to
the materials or the source of supply to ensure compliance.
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Samples of the plant mixture shall be taken and tested as frequently as deemed
necessary to determine if grading, asphalt content and all mixing conditions conform to
the job-mix formula requirements.
The number of samples taken from the plant shall be as directed by the Engineer but
there shall be a minimum of one sample for every days run from the mixing plant.
(b) Samples from Roadway
Suitably sized samples for the determination of the air void and compaction rate
(density) of the completed pavement shall be cut from the finished work by the
Contractor at his expense as often as deemed necessary by the Engineer, but not less
than one sample per 100 metres paving lane and two samples for each days run.
Samples shall be taken at equal frequency in the middle of the paving lane and 100 mm
from unconfined edges or cut back edges for cold joints.
In addition, samples shall be taken whenever a substantial change is made in the job-
mix formula. Where samples have been taken, new material shall be placed and
compacted satisfactorily by rolling or tamping.
The samples from the pavement shall be taken by core drilling at a minimum diameter
of 100 mm.
(c) Identification of Samples
Each sample shall be accompanied by a description giving the following information:
1. Date of placing and date of sampling

2. Chainage of point at which the sample was taken
3. The point on the roadway measured transversely from the centre line in
centimetres
(d) Surface Requirements as Specified to be tested
- Profile at 25 metres interval

- Texture depth at 50 metres interval
Or as directed by the engineer
(e) Results
The results shall be judged by the applicable Control Methods in Clause 2.3.2. If they
fail to comply with the Specification, placing shall forthwith cease until the reason for
the failure has been found and corrected. If instructed by the Engineer, the Contractor
shall remove any faulty material laid and replace it by material complying with the
Specification, all at his own expense.
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5.6.1.7 Tolerances
(a) Composition of the mix
The Contractor shall maintain the composition of the mixture as determined from the
laboratory and Site trials within the tolerances per single test, where the bitumen
content is given in per cent by the total weight of mixture and the aggregate content is
given in per cent of the total weight of dry aggregate:
Bitumen Content : + 0.3%
Passing 10 mm sieve and larger : + 6%
Passing 2 mm and 1 mm sieve : + 4%
Passing 0.425 mm sieve : + 3%
Passing 0.075 mm sieve : + 2%
The average amount of bitumen in the total length of any layer, calculated as the
product of the bitumen contents obtained from single tests and the volume represented
by each test, shall not be less than the amount ordered.
The average amount of bitumen for each days production calculated from the checked
weights of mixes shall not be less than the amount ordered.
(b) Construction Tolerances
The completed bituminous surfacing and base courses shall conform to the dimensional
tolerances required in Clause 2.2.3 of this Standard Specification as well as the
tolerances stated below.
(a) Levels
H90 ±10 mm
Hmax ±15 mm
(c) Thickness
D90 = 10 mm
Dmax = 15 mm
Dave = 4 mm
(d) Width
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The final average overall width of the upper surface of a bituminous mix layer
measured at six equidistant points over a length of 100 m shall be at least equal to the
width specified.
At no point shall the distance between the centre-line of the road and the edge of the
upper surface of a bituminous mix layer be narrower than that specified by more than
13 mm.
5.6.2 Asphalt Concrete for Surfacing
Asphalt concrete means a thoroughly controlled, hot-mixed, hot-laid, mixture of well

graded dried aggregate and penetration grade bitumen, which, once compacted, forms a
dense material.
A distinction will be drawn between asphalt concrete Type I (High Stability) and asphalt
concrete Type II (Flexible).
5.6.2.1 Bituminous Mix Requirements
(a) Mix Properties
The mixture shall comply with the appropriate following requirements from Table 5.6.2.1/1
as specified in the Specifications of Particular Application.
Bitumen contents shall be determined in per cent by total weight of mixture.
Table 5.6.2.1/1 Asphalt Concrete
Type I Type I Type II

(Wearing Course) (Binder Course) (Wearing Course)
Marshall Stability
75 blows (N) Min. 9,000 Min. 7,000 5,000-7,000
Flow Value (mm) 2-4 2-4 2-5
Voids in total
mix (%) 3-5 3-7 3-8
(b) Grading Requirements
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The grading of the mixture of coarse and fine aggregate, (and if required, the filler),
shall be within and approximately parallel to the appropriate envelope in Table
5.6.2.1/2.
Table 5.6.2.1/2 Grading Envelopes
Sieve Type I Type II

Size
mm
Wearing Course Binder Course Wearing Course
0/14 0/10 0/6 0/20 0/14 0/10 0/14 0/10
28 - - - 100 - - - -
20 100 - - 90-100 100 - 100 -
14 90-100 100 - 75-95 90-100 100 90-100 100
10 70-90 90-100 100 60-82 70-90 90-100 70-95 90-100
6.3 55-75 60-82 90-100 47-68 52-75 60-82 55-85 62-90
4 45-63 47-67 75-95 37-57 40-60 45-65 46-75 50-80
2 33-48 33-50 50-70 25-43 30-45 30-47 35-60 35-65
1 23-38 23-38 33-50 18-32 20-35 20-35 25-45 25-50
0.425 14-25 14-25 20-33 11-22 12-24 12-24 14-32 14-33
0.300 12-22 12-22 16-28 9-17 10-20 10-20 11-27 11-27
0.150 8-16 8-16 10-20 5-12 6-14 6-14 6-17 6-17
0.075 5-10 5-10 6-12 3-7 4-8 4-8 3-8 3-8
Should a change in source or grading or quality of materials occur, further laboratory

trials shall be carried out to confirm compliance with the requirements.
Hydrated lime shall normally be added with the filler in such quantities that the content
of hydrated lime in the mix is minimum 1% by weight of total aggregate.
5.6.2.2 Construction Requirements
(a) Mixing and Laying Asphalt Concrete
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The temperature of the bitumen when mixed with the aggregate shall be between 130oC
and 150oC when 60/70 bitumen is used and between 125oC and 140oC when 80/100
bitumen is used.
The minimum temperature of the mixture at commencement of compaction shall be

130oC when 60/70 bitumen is used and 125oC when 80/100 bitumen is used. The
minimum temperature at completion of compaction shall be 100oC when 60/700
bitumen is used and 90oC when 80/100 bitumen is used.
The layer thickness of asphalt concrete Type II shall not exceed 50 mm.
The minimum thickness of the compacted layer shall be 25 mm when 0/10 and smaller
aggregate is used and otherwise 2.5 times the nominal aggregate size
.
(b) Compaction
Rolling shall be continued until the voids measured in the completed layer are within
the ranges 3-7% for wearing courses and 3-9% for binder courses and type II wearing
courses.
The density of 100 mm cores cut from the layer shall be at least 98% of the Marshall
density.
The compaction requirement of 98% Marshall density shall be taken as the mean of one
days production. No single compaction value shall be less than 96% of the Marshall
density.
5.6.3 Cold Asphalt for Surfacing, Base, Levelling and Patching
Cold-asphalt shall mean a hot or cold-mixed, cold-laid pre-mix of graded aggregate and
bituminous binder.
(a) The density and stability of the cold asphalt shall be as specified in the Specifications of
Particular Application or as instructed by the Engineer.
The mixture of aggregates and, if required, filler shall be within and approximately
parallel to the grading envelope specified in the Specifications of Particular Application
or as instructed by the Engineer.

trials shall be carried out to confirm compliance with the requirements of the clause
above.
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(a) When bitumen emulsion is used as the binder, heating and drying of aggregates and
heating of the binder are not required. The moisture content of the mixture shall be
adjusted in the mixing equipment to permit optimum compaction. The aggregate shall
have a moisture content in the range 3% - 5% when the emulsion is added.
When cut-back bitumen is used as the binder, the requirements of Sub-clauses 5.5.1.2
and 5.6.1.2 shall apply but with the following temperature limitations:
Cut back Mixing Heating (Max.)
MC and SC 250 55-80oC 100oC

MC and SC 800 70-100oC 125oC
MC 3000 90-120oC 140oC
The aggregates shall be dried and heated so that they are mixed at the following
temperatures.
60 - 90oC when MC or SC 250 is used

75 - 115oC when MC or SC 800 is used
90 - 130oC when MC 3000 is used.
Cold asphalt may be laid by grader, provided the Contractor can demonstrate in the Site
Trials that he can achieve the geometric tolerances for the base with this method.
(b) Compaction
The density of 100 mm cores cut from the layer shall be at least 97% of the laboratory
density of the mix selected for use in the Site Trials.
The compaction requirement of 97% bulk density shall be taken as the mean of one
days production. No single compaction value shall be less than 955 of the bulk density.
5.6.4 Dense Bitumen Macadam for Base
Dense bitumen macadam means a hot-mixed, hot-laid mixture of well graded aggregate and
of a comparatively low amount of straight-run bitumen.
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(a) The density and stability of the dense bitumen macadam shall be as specified in the
Specifications of Particular Application or as instructed by the Engineer.
The mixture of coarse aggregate, fine aggregate and, if required, filler shall be within
and approximately parallel to one of the following grading envelopes, as specified in
the Specifications of Particular Application:
Sieve Percentage % by weight passing

Size
0/40 0/30
50 100 -
37.5 90-100 100
28 75-95 90-100
20 60-90 65-95
14 50-75 55-80
10 40-65 45-70
6.3 30-55 35-60
2 18-38 20-40
1 12-30 15-30
0.425 7-23 9-23
0.300 6-20 8-20
0.150 4-15 5-15
0.075 2-8 3-8

trials shall be carried out to confirm compliance with the requirements.
(a) Mixing and Laying Dense Bitumen Macadam
The temperature of the freshly mixed dense bitumen macadam shall be between 130oC
and 150oC. The minimum temperature at laying and commencement of compaction
shall be 120oC to 150oC and at completion of compaction shall be 90oC.
The requirements regarding laying as specified in Sub-clause 5.6.1.5 (d) shall be

modified as follows:
Laying equipment capable of spreading the mixture over the full carriageway width
shall be used as much as possible, otherwise the longitudinal joint shall be compacted
before the temperature of the existing lane has dropped to 70oC where 80/100 bitumen
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is used and to 80oC where 60/70 bitumen is used. This temperature limitation may
require the use of at least two mechanical pavers working in echelon.
The minimum thickness of the compacted layer shall be 100 mm when 0/30 mm
aggregate is used and 125 mm when 0/40 mm is used. No compacted layer shall
exceed 200 mm thickness.
(b) Compaction
Rolling shall be continued until the voids measured in the completed layer are within
the range 4% - 10%.
The density of 100 mm cotes cut from the layer shall be at least 98% of the laboratory
bulk density of the mixture. The compaction requirement of 98% bulk density shall be
taken as the mean of one day’s production. No single compaction value shall be less
than 96% of the bulk density.
(c) Sealing of Dense Bitumen Macadam Base
Bitumen macadam base course shall normally be sealed by applying the wearing course
or surface dressing specified within three months of completing any section of the base
course.
5.6.5 Open Graded Asphalt for Base and Drainage Courses
Open graded asphalt means a hot or cold pre-mix of graded coarse aggregate and
bituminous binder.
(a) The mixture shall comply with the following requirements in accordance with the
specified use of the open graded asphalt in the pavement system:
Course Base Drainage

Function Crack Relieving Free draining
____________________________________________________
Bitumen Content
% by weight 3-4 1.5 - 3
Voids in compacted
mix , Total % min. 10 min. 25
_____________________________________________________
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(b) The grading of the aggregates in the mixture shall conform to the appropriate envelope
in Table 5.6.5.1/1. Aggregates shall conform to the class specified in Sub-clause
5.6.1.1.
Table 5.6.5.1/1
Percentage by weight passing

Sieve size mm 2/40 2/28 5/28
40 100 - -
28 85-100 100 100
20 65-90 75-95 65-100
10 30-60 30-60 10-35
5 10-25 10-25 0-10
2 0-10 0-10 0-2
0.075 0-2 0-2 0-1
(a) Mixing and Laying Open Graded Asphalt
Either hot or cold open graded asphalt shall be mixed in a stationary mixing equipment
conforming to Sub clause 5.6.1.5 (a).
The temperatures of the mix shall be the appropriate ones as stated in Sub clause 5.6.1.5
(b)or as instructed by the Engineer.
Open graded asphalt shall be laid by self-propelled spreaders. Care shall be taken to
avoid segregation. Laying temperature shall conform to requirements to hot asphalt
concrete or cold asphalt in accordance with the type of bitumen used in the mix.
(b) Compaction
Compaction requirements shall be established after Site Trials made conforming to

Clause 2.3.1 for each open graded asphalt mix used in base courses.
Compaction of drainage courses shall consist of sufficient passes of a steel roller,

weighing not less than 8t and not more than 13 t, to cover the whole surface and finish
the layer to the required grade tolerances.
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(c) Maintenance and Traffic
No traffic shall be permitted on drainage layers with the exception of the equipment
(hauling, spraying, spreading and compacting equipment) during construction of the
layer covering it.
Open graded asphalt shall be covered by an impervious surfacing.
The Contractor shall plan the construction of open-graded drainage courses in

accordance with the progress of the layer covering it.
All damaged and/or dirtied areas of the drainage courses shall be re-constructed at the
Contractors expense.
5.6.6 Pavement Repairs
5.6.6.1 General
This Section contains the specifications for the pavement repair work to be performed to
improve the surface condition or to prepare the existing surface prior to sealing or
overlaying.
The Section is divided into the following parts:
Part Coverage
A Pothole Repairs
B Edge Repairs
C levelling Works
D Partial Surface Sealing
5.6.6.2 Pothole Repairs
(a) Introduction
The work is divided into the following types of pothole repairs:
Type 1: shallow pothole repair by 30 mm cold-mix 0/12 mm.
Type 1A: As Type 1, but cutting out neat rectangular area enclosing the
pothole.
Type 2 & 3: Deep pothole repair on sections not to be resealed or overlaid.

Sealing of pothole by 30 mm cold-mix 0/12 mm and pothole filling
by either 0/25 mm cold-mix crushed materials /Type 2) or by 0/25
mm cement treated mix (Type 3).
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Type 2A & 3A: As Type 2 & 3 respectively, but including removal of existing
deteriorated pavement material or sub quality soil filling.
Type 4 & 5: Deep pothole repair on sections are to be resealed or overlaid.

Filling in full depth of pothole by 0/25 mm cold-mix crushed
material (Type 4) or by 0/25 mm cement treated mix (Type 5).
Type 4A & 5A: As Type 4 & 5 respectively, but including removal of existing
deteriorated pavement material or sub quality soil filling.
These pothole repair works shall include repair of local damaged pavement areas, such as
alligator or block cracked surfacing and open or tentatively closed potholes and shall
include all costs for preparatory work, materials, priming, tack coating , mixing, placing,
compaction and cleaning in conformance with the following specifications and as shown
on the Drawings or as directed by the Engineer.
(b) Materials
The aggregate to be crushed for cold mix shall consist of crushed hard durable rock as
specified in Sub-clause 5.2.4.
The binder shall be bitumen - emulsion AASHTO Type CMS-1h, CSS-1h or similar
type suitable and used for cold mixtures in Zambia.
Certificate and representative results of testing in accordance with ASTM or BS

standards for emulsion products shall be submitted to the Engineer for approval.
The combined mineral aggregate shall be a well-graded dense 0/25 mm materials as

specified in Sub-clause 5.2.4 for Graded Crushed Rock Base 0/30 mm, except that max.
size shall be 25 mm.
The grading for cold mix to be laid in 30 mm thickness for surfacing of potholes shall,
however, be a 0/12 mm dense well-graded non-segregated material as approved by the
Engineer.
The mixture shall be stable. The mix composition shall be tested at min. 4 different
binder contents, by the Marshall method, modified for cold composition as agreed and
approved by the Engineer prior to use.
Following requirements shall be met:
Marshall stability at 60ºC after 4 days Min 500 kg

Flow 2-4 mm
Marshall density at 2x50 blows at 25ºC Report
Marshall air voids Report
Stripping and coating after 96 hrs in
rolling bottle of the loose coated
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8/12 mm aggregate cured for one week

before testing coating in accordance with
the procedure specified in Clause 5.5 Min. 40%
The unit rate shall be calculated on 5.0% bitumen residue for 0/12 mm and 4.5% by
weight for 0/25 mm mixture. The unit shall include for addition of 1.0% by weight
hydrated lime as stabilizer and anti-stripping agent.
The materials used for 0/25 mm Cement Treated Mixture shall meet all the
requirements specified in Sub clause 5.3.2 (mix-in-place).
(c) Preparations and Placing
The various types of pothole repairs specified in Clause 5.6.6.2 (a) shall include the
following work and procedures:
(i) Shallow pothole repair Type 1
Excavate and remove deteriorated pavement materials or filling in

pothole area to min. depth below surrounding pavement surface as
specified on the drawings.
Remove by hand tools loose cracked surfacing at pothole edge.
Clean and remove dust and fines from pothole by steel type broom
Compact the pothole base by tampers
Prime edges and bottom of pothole with MC-30.
Place 0/12 mm cold mix with sufficient surcharge and compact with
hand operated vibrating roller or heavy vibrating plate compactor. The
compaction degree shall be to the satisfaction of the Engineer.
The finished level shall be min. 2 mm and max. 5 mm above surrounding surfaces,
deviations from this tolerance e.g. due to deformation by traffic within the defects
liability period, will not be accepted.
(ii) Shallow pothole repair type 1A

Procedure as specified for Type 1 except for following additional work
Marking up in neat straight longitudinal and transverse lines with chalk

enclosing the damaged area. Calculate the total patching areas and
obtain the Engineers approval before cutting.
Cut by pneumatic hammer or by saw neat, straight and vertical edges.
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Break up all surfacing materials and excavate to the specified depth

inside the cutting lines and remove the excavated materials to spoil
area.
Moisten and re-compact the exposed by hand operated vibratory roller

or by heavy vibrating plate compactor. The dry density of the
compacted base shall not be less than 96.0% of the MD for BS 1377
Test 13.
(iii) Deep pothole repairs Type 2 and 4 (open holes)
Deep pothole repair procedure shall be applied where the depth of pothole varies and
exceeds the minimum thickness of cold mix surfacing for shallow pothole by more than
50% or where directed by the Engineer to avoid deformations due to non-uniform
thickness of the cold mix surface layer.
The work will include:
Trim the sides and remove all loose mineral aggregate, dirt and foreign
matter from the hole (by hand tools, steel brooms or pressurized air).
Prime edges and bottom of the pothole with MC-30.
Place 0/25 mm cold mix and compact with tampers, hand operated
vibrating roller or heavy vibrating plate compactor. Potholes with
depth exceeding 80 mm shall be made in two lifts.
(iv) Deep pothole repairs Type 3 and 5 (open holes)
The work will include:
Trim the sides and remove all loose mineral aggregate, dirt and foreign
matter from the hole .
Moisten the sides and bottom of the pothole.
Place the cement treated base materials and compact with tampers,
hand operated vibratory roller or heavy vibrating plate compactor.
pot holes with depth exceeding 80 mm shall be made in two lifts wet in wet.
(v) Deep pothole repairs Type 2A, 3A, 4A and 5A (filled holes)
Procedure for Type 2A and 4A respectively Type 3A and 5A shall be as specified above
under (c) and (d) respectively except for following additional work:
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Excavate existing deteriorated pavement material or subquality soil

filling to sound surface as directed and remove excavated material to
spoil area.
5.6.6.3 Edge Repairs
(a) Introduction
The work is divided into the following types of pavement edge repairs:
Type 1 Shallow edge repairs of max. average edge depth not exceeding 50
mm repaired with 0/12 mm cold mix and without longitudinal back
cutting /sawing of irregular edges.
Type 1A As Type 1, but includes a uniform straight longitudinal back

cutting/sawing of irregular edges.
Type 2 Deep edge repair for edge exceeding 50 mm repaired with 0/25 mm
cold mix and without longitudinal back-cutting /sawing of irregular
edges.
Type 2A As Type 2, but includes a uniform straight longitudinal back

cutting/sawing or irregular edges.
The pavement edge repair works shall include all necessary preparatory works,
materials, priming, mixing, placing, compaction and cleaning in conformance with the
following specifications and as shown on the drawings or as directed by the Engineer.
(b) Materials
The materials to be used for edge repair shall be 0/12 mm and 0/25 mm cold mix
consisting of materials as specified in Clause 5.6.6.2 (b).
(c) Preparation and placing
The various pavement edge repairs specified in Clause 5.6.6.3 (a) shall include the
following work procedures.
(i) Edge repair type 1 and Type 2 (no back cutting)
Remove by hand tools, loose, cracked, unsupported bituminous

materials and all loose mineral aggregate, dust, etc. along the damaged
edge. No general back cutting of irregular edges but sound surfacing is
required.
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Determine length and type of repair (Type 1 for max. average edge
step not exceeding 50 mm and Type 2 for edge step above 50 mm).
mark it up on the drawings for the Engineer's approval.
Prime vertical and horizontal surfaces as shown on the drawings.
Place 0/12 mm cold mix for shallow edge repairs (Type 1) and 0/25
mm cold mix for deep repairs (Type 2) with sufficient surcharge and
edge batter not steeper than 60º from horizontal. Compact batter with
tampers and the surface by pneumatic tired roller.
The compaction degree shall be min. 96.0% of the reference (Marshall) density.
The finished cold mix edge shall be straight, uniform, flush to the carriageway
pavement and free of deformations.
(ii) Edge repair Type 1A and Type 2A (incl. back cutting).
The work and procedure shall be as specified for Type 1 and Type 2 except for
following additional work:
Marking up with chalk in neat, straight, longitudinal lines placed

behind the major part of the edge irregularities as directed by the
Engineer.
Cut the edge longitudinal by saw to full edge depth.
Excavate the edge strip and remove materials to spoil.
The placing of cold mix may be made either by manual method or by purpose built
placing/paving equipment.
5.6.6.4 Levelling Works
(a) Introduction
This section contains the specifications for levelling of local deformations, rutting and
minor settlements by cold mix laid by hand. The works shall include all necessary
preparatory works, materials, mixing, tack coating, placing and compaction in
conformance with following specifications and as directed by the Engineer.
(b) Materials
The materials to be used for levelling works shall be 0/12 mm and 0/25 mm cold mix
consisting of materials as specified in Clause 5.6.6.2 (b).
(c) Preparation and placing
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The levelling works for shallow deformations (Type 1) and deep deformations (Type 2)
shall include following preparatory works and construction procedures:
Mark up by chalk the areas to be levelled and estimate quantity and type of
levelling material to be used for elimination of the major deformations on
each relevant subsection for the Engineer's approval.
Clean the surface for dust and dirt by brooming.
Apply emulsion tack coat uniformly at a rate of 200 g/m²
Provide and place by hand the cold mix levelling course and compact to
min. 96.0% of the reference (Marshall) density.
Cold mix type 0/12 mm shall be used for shallow levelling of up to 50 mm depth
(levelling Type 1) and be laid in one layer.
Cold mix type 0/25 mm shall be used for deep levelling with depth exceeding 50 mm
(levelling Type 2) and applied in thicknesses of 40 to 80 mm per layer.
The compaction equipment shall be a heavy pneumatic tired roller having a load of 3
ton on each tyre in fully ballasted condition.
5.6.6.5 Partial Surface Sealing
(a) Introduction
The work for partial surface sealing where needed as directed by the Engineer shall
include all necessary preparatory work, materials, bitumen spraying, dressing, rolling
and sweeping in conformance with the following specifications or as directed by the
Engineer.
(b) Materials
Materials for the sealing works shall be as specified in the relevant parts of clause 5.5.
(c) Application and Finishing
The partial sealing works shall be made as specified in the relevant parts of Clause 5.5.
The sealing works shall be finished in neat, straight rectangular areas of any size down
to 1 m width where and as directed by the Engineer.
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Bituminous mixes shall be measured by the cubic metre compacted on the road calculated
as the product of the length instructed to be laid and the net cross section area shown on the
Drawings or instructed by the Engineer.
No measurement or payment shall be made for bituminous mixes laid in excess of the
thicknesses or widths shown on the Drawings or specified by the Engineer.
The rate for bituminous mixes shall include for the cost of:
submission of samples, testing, mix design, trial mixes, laboratory and Site
trials, submission of Site Trial data, and proposals for laying and compaction;
preparation of surface, alignment and level markers and working to construction

tolerances, traffic control;
provision and transport of aggregates including any mineral filler necessary to

achieve the specified grading;
provision and transport of the nominal proportion of binder specified in the

Specifications of Particular Application;
storage, screening, stockpiling, drying, heating, batching, mixing of aggregates,

mineral filler and binder;
hauling, laying and compacting the mixture, forming joints including cutting
back and priming cut faces, rectification of surface and repairs;
construction control testing including provision and operation of a coring

machine.
Payment shall be made at the rate per cubic metre for bituminous mixes irrespective of the
unit weight of the mixes which payment shall include for the nominal binder content
specified in the Specifications of Particular Application. The actual binder content will be
instructed by the Engineer and will be based on the results of laboratory and Site trials.
Measurement of the variation in binder content shall be by the kg, calculated as the product
of the difference between the nominal binder content and the binder content instructed by
the Engineer, and the volume of compacted mix to which the variation applies, calculated as
described above.
Adjustment of compensation to the Contractor shall be as follows:
As a payment to the Contractor where the binder content is increased above the
specified nominal, but only where such increase has been instructed in writing
by the Engineer.
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As a refund to the Employer where the binder content is reduced below the
specified nominal. The binder content may only be reduced if the Engineer so
instructs.
The rate per cubic metre for bituminous mixes includes for providing any mineral filler
necessary to achieve the grading as specified and to the satisfaction of the Engineer and no
additional payment shall be made if the Engineer may require the addition of mineral filler
to modify a grading curve which already meets the specified requirements.
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SECTION 6
CONCRETE WORKS
6.1 CONCRETE
(a) Scope
This section covers the materials, design of mixes, mixing, transport, placing,
compaction and curing of concrete and mortar required in the Works.
Requirements stated elsewhere in this Standard Specification and listed below, apply
to Clauses throughout this Paragraph and shall be read in conjunction therewith.
Section Paragraph Clause Item

2 2.1 2.1.5 Test Certificate
2 2.2 2.2.1 Routine Testing and
Inspection by the Engineer
2 2.2 2.2.4 Construction and Control
Testing
2 2.3 2.3.1 Trials to Confirm Compliance
with Specifications
2 2.3 2.3.2 Control Methods
2 2.3 2.3.3 Sampling
2 2.4 2.4.2 Stone, Aggregates, Sands and
Fillers
2 2.4 2.4.3 Cement
2 2.4 2.4.6 Concrete
2 2.4 2.4.10 Sampling and Testing
Frequencies
3 3.1 3.1.4 Materials Sources and Spoil
Areas
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(b) Definitions
Structural concrete is any class of concrete which is used in reinforced, pre-stressed

or un-reinforced concrete construction, which is subject to stress and which is
required to comply with a specified concrete quality according to Clause 6.1.2
Non-structural concrete is composed of materials complying with the Specification

but for which no strength requirements are specified and which is used only for
filling voids, blinding foundations and similar purposes where it is not subject to
significant stress.
A formed surface is a face which has been cast against formwork.
An unformed surface is a horizontal or nearly horizontal surface produced by

screeding or trowelling to the level and finish required.
A pour refers to the operation of placing concrete into any mould, bay or formwork,
etc., and also to the volume which has to be filled. Pours in vertical succession are
also referred to as lifts.
6.1.1 Materials for Concrete
6.1.1.1 Cement.
Cement used for concrete shall be as specified in the Specifications of Particular

Applications or indicated on the Drawings and may be any of the following:
(i) Ordinary Portland cement, according to BS 12.
(ii) Rapid hardening Portland cement, according to BS 12.
(iii) Portland - blast furnace cement, according to BS 146, Part 2.
(iv) Low heat Portland cement, according to BS 1370.
(v) Sulphate resisting Portland cement, according to BS 4027.
(vi) Low heat Portland - blast furnace cement, according to BS 4246, Part 2.
Alternatively cement produced to national specifications or to AASHTO M 85 may be

specified.
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6.1.1.2 Aggregates
(a) Fine Aggregate
Fine aggregate shall be clean, hard and durable and shall be natural sand, crushed
gravel sand or crushed rock sand complying with BS 882 and the following
requirements:
(i) The fine aggregate shall not contain iron pyrites or iron oxides. It shall not
contain mica, shale, coal or other laminar, soft or porous materials or organic
matter unless the Contractor can show by comparative tests on finished
concrete as set out in BS 1881 that the presence of such materials does not
adversely affect the properties of the concrete.
(ii) Content passing the 0.075 mm sieve shall not exceed 3 per cent for natural or
crushed gravel sand or 15 per cent for crushed rock sand.
(iii) Chlorides soluble in a 10 per cent solution by weight of nitric acid shall not
exceed 0.05 per cent by weight expressed as chloride ion when tested as set
out in BS 812, subject also to the restriction on total chloride content given
below.
(iv) Sulphates soluble in a 10 per cent solution by weight of hydrochloride acid

shall not exceed 0.4 per cent by weight expressed as SO3, when tested as set
out in BS 1377, subject also to the restriction on total sulphate content given
below.
(v) Soundness: After five cycles of the Sodium Sulphate Soundness test in
AASHTO T104 the aggregate shall not show a weight loss of more than 10
per cent.
(vi) Organic Impurities: If the test described in Clause 2.4.2 of this Standard
Specification shows that more than a trace or organic impurities is present,
the fine aggregate shall not be used in the Works unless the Contractor can
show by tests on finished concrete as set out in BS 1881 that the presence of
organic impurities does not adversely affect the properties of the concrete.
(b) Coarse Aggregate
Coarse aggregate shall be clean, hard and durable crushed rock, crushed gravel or
natural gravel complying with the requirements of BS 882 and the following
requirements.
(i) The material shall not contain any iron purities, iron oxides, flaky or
laminated material, hollow shells, coal or other soft or porous material, or
organic matter unless the Contractor can show by comparative tests on
finished concrete as set out in BS 1881 that the presence of such materials
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does not adversely affect the properties of the concrete. The pieces shall be
predominantly angular rounded or irregular as defined in BS 812 Part 1.
(ii) The proportion of clay, silt and other impurities passing the 0.075 mm sieve
shall be not more than one per cent by weight.
(iii) The content of hollow and flat shells shall not be such as will adversely affect
the concrete quality when tested as set out in BS 812. The total shell content
of aggregates shall not be more than the following:
40 mm nominal size and above 2% of dry weight

20 mm nominal size 5% of dry weight
10 mm nominal size 15% of dry weight
(iv) Chlorides soluble in a 10 per cent solution by weight of nitric acid shall not
exceed 0.03 per cent by weight, expressed as chloride ion when tested as set
out in BS 812 but subject also to the restriction on total chloride content given
below.
(v) Sulphates soluble in a 10 per cent solution by weight of hydrochloric acid

shall not exceed 0.4 per cent by weight expressed as SO3 when tested as set
out in BS 1377 subject also to the restriction on total sulphate content given
below.
(vi) Soundness: After 5 cycles of the Sodium Sulphate Soundness test in

AASHTO T104, the aggregate shall not show a weight loss of more than 12
per cent.
(vii) When tested in accordance with test ASTM C289 the aggregate shall be non-
reactive.
(viii) Flakiness Index when tested in accordance with BS 812 shall be as follows:
For 40 mm stone and above, not more than 40

For 20 mm stone and below, not more than 35
If the flakiness index of the coarse aggregate varies by more than five units
from the average value of the aggregate used in the approved trial mix, a new
set of trial mixes shall be carried out if the workability of the mixes have been
adversely affected by such variation.
(ix) Ten per cent fines value: Not less than 50 kN when tested in accordance with
BS 812.
(x) Shrinkage: When mixed with other ingredients in the approved proportions
for concrete and tested as set out in BS 1881, the shrinkage factor shall not
exceed 0.05 per cent.
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(xi) Organic impurities: If the test described in Clause 2.5.2 of Section 2 of this
Standard Specification shows that more than a trace of organic impurities is
present, the aggregate shall not be used in the Works unless the Contractor
can show by tests on finished concrete as set out in BS 1881 that the presence
of organic impurities does not adversely affect the properties of the concrete.
(xii) Water absorption: The aggregate shall not have water absorption of more than
2.5 per cent when tested as set out in BS 812.
(xiii) Los Angeles Abrasion (LAA): Not more than 50%.
(c) Total chloride and sulphate content
(i) The total chloride content arising from all ingredients in a mix including
cement, water and admixtures shall not exceed the following limits, expressed
as chloride ion and as a percentage of the weight of cement in the mix:-
For pre-stressed concrete, steam cured concrete or concrete containing

sulphate resisting or super-sulphated cement: 0.05 per cent.
For any other reinforced concrete: 0.3 per cent in 95 per cent of all test results
provided no result is more than 0.5 per cent.
(ii) The total sulphate content expressed as SO3 of all the ingredients in a mix
including cement, water and admixtures shall not exceed 0.4 per cent by
weight of the aggregates or 4.0 per cent of the weight of cement in the mix,
whichever is the less.
6.1.1.3 Water for Concrete and Mortar
Seawater or brackish water containing more than 1000 ppm (parts per million) chloride
ion or 2000 ppm sulphate ion shall not be used for mixing or curing concrete.
Water shall be clean and free from harmful matter and shall comply with the
If instructed by the Engineer the Contractor shall carry out tests in accordance with BS
3148 to establish compliance with the Specification.
6.1.1.4 Admixtures
The use of admixtures in concrete may be required under the Contract to promote special
properties in the finished concrete or may be proposed by the Contractor to assist
compliance with the Specification.
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Admixtures shall not be used in concrete without the approval of the Engineer, who may
require tests to be carried out before the approval in order to prove the suitability of the
admixtures.
Admixtures, if allowed, shall comply with the following requirements:
(i) Admixtures shall be used only in liquid form and shall be dispensed to an
accuracy of within 5% of the required amount.
(ii) Any admixture shall comply with the requirements of ASTM C-494or
AASHTO M-154 and shall be of an approved brand and type.
(iii) Air-entraining agents shall comply with the requirements of ASTM C-260 or
AASHTO M-194.
(iv) Admixtures shall not be mixed together without the consent of the Engineer.
(v) The chloride ion content of any admixture shall not exceed 2 per cent by
weight of the admixture nor 0.03 per cent by weight of the cement in the mix.
(vi) Calcium chloride or admixtures containing calcium chloride shall not be used
in pre-stressed concrete.
In all cases the Contractor shall submit to the Engineer full details of the admixture he
proposes to use and the manner in which he proposes to add it to the mix. The
information provided shall include:
(i) The typical dosage, the method of dosing and the detrimental effects of an
excess or deficiency in the dosage.
(ii) The chemical names of the main active ingredients in the admixture.
(iii) Whether or not the admixture contains chlorides, and if so the chloride ion
content expressed as a percentage by weight of admixture.
(iv) Whether the admixture leads to the entrainment of air when used at the
manufacturers recommended dosage, and if so, the extent to which it does so.
(v) Details of previous uses of the admixture in the country.
6.1.1.5 Storage and Handling Materials
(a) Cement
Cement which is stored on Site shall be kept under cover that provides adequate
protection against moisture and other factors that may promote deterioration.
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When the cement is supplied in bags, the bags shall be closely and neatly stacked to a
height not exceeding 12 bags and be so arranged that they can be used in the order in
which they were delivered to the Site.
Storage of cement in bulk in silos or similar containers shall be permitted provided

that the cement drawn for use is measured by mass and not by volume.
Cement shall not be kept in storage for longer than 6 weeks without the Engineer's
permission and different brands and/or types of the same brand shall be stored
separately.
(b) Aggregates
Aggregates shall be delivered to Site in clean and suitable vehicles. Different types or
sized of aggregate shall not be delivered in one vehicle.
Aggregates of different nominal sizes shall be stored separately and in such a way
that segregation is avoided. Intermixing of different materials and contamination by
foreign matter shall be avoided.
Coarse aggregate for concrete with maximum size of aggregate exceeding 20 mm

shall be delivered and stored in at least two different size fractions.
(c) Storage Capacity
The storage capacity provided and the amount of material stored (whether cement,
aggregates or water) shall be sufficient to ensure that no interruptions to the progress
of the work are caused by lack of materials.
(d) Unsuitable Material
Material that has deteriorated or that has been contaminated or otherwise damaged
shall not be used in concrete. Such materials shall be removed from the Site without
delay.
6.1.2 Concrete Quality
6.1.2.1 Structural Concrete
The classes of structural concrete to be used in the Works shall be those shown on the
Drawings and designated in Table 6.1.2.1/1, in which the class designation includes two
figures. The first figure is the characteristic compressive strength at 28 days expressed in
MPa and the second figure is the maximum nominal size of aggregate in the mix
expressed in millimetres.
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Sampling and testing of concrete shall be carried out according to BS 1881.
The requirements of BS 5400, Part 7, shall be adhered to with respect of target mean
strength and trial mixes.
Table 6.1.2.1/1: Classes of Concrete
28 days characteristic Maximum size

Class of compressive strengthof aggregate
concrete (MPa) (mm)
15/20 20
15/40 15 40
20/14 14
20/20 20 20
20/40 40
25/14 14
25/20 25 20
25/40 40
30/14 14
30/20 30 20
30/40 40
40/14 14
40/20 40 20
40/40 40
50/14 14
50/20 50 20
50/40 40
60/14 14
60/20 60 20
60/40 40
The Contractor shall be responsible for the design of the concrete mix and for the
proportions of the constituent materials necessary to produce concrete that complies with
the requirements specified for each class of concrete.
Unless otherwise required by this Standard Specification or the Specifications of

Particular Applications, BS 5400, Part 7 and Part 8, shall be adhered to with respect of:
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(i) Minimum cement content for different categories of exposure to ensure

durability.
(ii) The requirements for the durability of concrete exposed to sulphate attack.
The cement content for any class of concrete shall not exceed 500 kg/m3 of
concrete.
The slump of the concrete shall be within the range as specified in Table 6.1.2.1/2.
Table 6.1.2.1/2: Slump Values
Slump (mm)1)
Type of construction Max. Min.
1. Paving, concrete nosings and

pre-cast units 75 50
2. Pre-stressed concrete 75 25
3. Reinforced foundation walls,

footings and cast in situ
piles (excepting dry cast piles) 125 50
4. Slabs, beams, columns and

reinforced walls 125 50
5. Concrete bases, caissons and

substructure walls 100 25
1) Where high-frequency vibrators are used, the values above shall be reduced by one-
third.
The concrete shall be of suitable workability without the excessive use of water so that it
can be readily compacted into the corners of the formwork and around reinforcement,
tendons and ducts without segregation of the material.
Before the start of any concrete work on Site, the Contractor shall supply to the Engineer,
for his approval, samples of the constituent materials of the concrete and a statement of
the mix proportions which he proposes to use for each class of concrete indicated in the
Bill of Quantities.
The samples shall be accompanied by evidence that they comply with the requirements
for the various materials specified. The statement of mix proportions shall be
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accompanied by evidence establishing that concrete made with the materials in the
proportions proposed will have the properties specified.
Evidence shall be in the form of either:
(i) a statement from an approved laboratory on the results of tests, or
(ii) an authoritative report or record of previous use and experience.
The actual mix proportions used as well as any changes thereto shall be subject to the
Engineer's approval but such approval shall in no way relieve the Contractor of his
responsibility for producing concrete with the specified properties.
The Contractor is cautioned that the quality of cement may vary sufficiently between
consignments to necessitate adjustments in the cement content of mixes. In order to
ensure a uniform quality of concrete, the Contractor shall obtain from the manufacturer
the relevant cement quality data for each consignment for the purpose of ascertaining the
required adjustment in cement content. This information shall be submitted to the
Engineer.
6.1.2.2 Non-Structural Concrete
The Engineer will be responsible for determining the proportion of each constituent
material of the concrete mix. The Contractor shall provide concrete on the Site using the
specified materials and in the proportions ordered by the Engineer.
The Contractor shall be responsible for supplying the constituent materials for the
concrete, and he shall supply to the Engineer, at least two months before the start of any
concrete work on the Site, samples of each aggregate for testing purposes. If the materials
comply with the specification, the Contractor shall supply further samples of sizes
indicated by the Engineer for determination of the mix proportions for each class of
concrete.
The classes for non structural concrete shall be specified in the Specifications of
Particular Application, except for the two "nominal" classes specified hereinafter. For
each class the following shall be specified:
(i) The estimated minimum compressive strength in MPa at 28 days.
(ii) The maximum nominal size of coarse aggregate in mm, and its proportions in
the mix.
(iii) The proportion of fine aggregate in the mix.
(iv) The type and proportion of cement in the mix.
(v) The free water/cement ratio.
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(vi) The slump in mm.
The Engineer shall have the right to vary the proportions of the constituents of the
concrete as the work proceeds. Payment for variations shall be made at the tendered rates
as specified in the Specifications of Particular Application.
The nominal mixes specified for use where indicated on the drawings or in the Bill of
Quantities, or where ordered by the Engineer, are given in Table 6.1.2.2./1.
Table 6.1.2.2/1 Nominal Mixes
Class Class
1:4:8 1:3:6
Constituent or property concrete concrete
Cement (kg) 50 50
Total aggregate (m3) 0.40 0.30
Max. total quantity of water (l) 50 42
Estimated 28-day compressive
strength (MPa 8 15
NOTE:
(1) The maximum size of coarse aggregate in mm required in a mix shall be designated
as a suffix to the class, e.g. Class 1:4:8/40.
(2) The ratio of fine to coarse aggregate shall be adjusted to produce a dense, workable
mix.
(3) The total quantity of water shall include that contained in the aggregates.
(4) Consistency and Workability
Slump obtained on non-structural concrete used in the Works shall fall within the
ranges specified in Table 6.1.2.1/2 above.
6.1.3 Mixing Concrete
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6.1.3.1 Equipment
Before any equipment for batching, mixing, transporting, placing, compacting and
finishing concrete is ordered or delivered to Site, the Contractor shall submit to the
Engineer full details including drawings of all the equipment which he proposes to use
and the arrangements he proposes to make.
Concrete for the Works shall be batched and mixed in stationary mixing equipment
unless the Engineer agrees to some other arrangement.
Batching and mixing equipment shall be modern efficient equipment complying with the
requirements of BS 1305 and capable of producing a uniform distribution of the
ingredients throughout the mass. Truck mixers shall not be used unless the Engineer
agrees otherwise, in which case they shall comply with the requirements of BS 4251. If
the equipment proposed by the Contractor does not fall within the scope of BS 1305, it
shall have been tested in accordance with BS 3963 and shall have a mixing performance
within the limits of Table 6 of BS 1305.
The aggregate storage bins shall be provided with drainage facilities arranged so that
drainage water is not discharged to the weigh hoppers. Each bin shall be drawn down at
least once per week and any accumulations of mud or silt removed.
The weighing and water dispensing mechanisms shall be maintained in good order. Their
accuracy shall be maintained within the tolerances described in BS 1305 and checked
against accurate weights and volumes when required by the Engineer.
The Contractor shall provide standard test weights at least equivalent to the maximum
working load used on the most heavily loaded scale and other auxiliary equipment
required for checking the satisfactory operation of each scale or other measuring device.
Tests shall be made by the Contractor at least once a week or at intervals to be
determined by the Engineer and shall be carried out in his presence. For the purpose of
carrying out these tests, there shall be easy access for personnel to the weigh hoppers.
The Contractor shall furnish the Engineer with copies of the complete results of all check
tests and shall make any adjustments, repairs or replacements necessary to ensure
satisfactory performance.
The blades of pan mixers shall be maintained within the tolerances specified by the
manufacturer of the mixer, and the blades shall be replaced when it is no longer possible
to maintain the tolerances by adjustment.
Mixers shall be fitted with an automatic recorder registering the number of batches
discharged.
If the Contractor proposes to use ready mixed concrete, he shall submit to the Engineer
full details and test results of the concrete mixes for his proposal. The Engineer may
approve the use of ready mixed concrete provided that:
(i) the proposed mixes, the materials to be used and the method of storage and
mixing comply with the requirements of the Specification; and
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(ii) adequate control is exercised during mixing.
Approval to the use of ready mixed concrete may be withdrawn if the Engineer is not
satisfied with the control of the materials being used and control during mixing.
6.1.3.2 Batching
Cement and aggregates shall be batched by weight. Water may be measured by weight or
volume.
The weights of cement and of each size of aggregate as indicated by the mechanisms
employed shall be within a tolerance of plus or minus two per cent of the respective
weights per batch agreed by the Engineer.
The water to be added to the mix shall be reduced by the amount of free water contained
in the coarse and fine aggregates. This amount shall be determined by the Contractor by a
method agreed by the Engineer immediately before mixing begins each day and
thereafter at least once per hour during concreting and for each delivery of aggregates
during concreting. When the correct quantity of water, determined as set out in the
Specification, has been added to the mix, no further water shall be added, neither during
mixing nor subsequently.
The nominal drum or pan capacity of the mixer shall not be exceeded.
6.1.3.3 Mixing
Mixing of materials for concrete shall be conducted by an experienced operator. Unless

otherwise approved, mixing shall be carried out in a mechanical batch mixer of approved
type and capable of producing a uniform distribution of ingredients throughout the batch.
(a) Charging the Mixer
The sequence of charging shall be approved by the Engineer and, unless otherwise
instructed, the same sequence shall be maintained.
(b) Mixing
The period of mixing shall be measured from the time when all the materials are in
the drum until the commencement of discharge.
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The mixing period shall be 90 seconds and may only be reduced if on the basis of
Site tests, the Engineer is satisfied that the reduced mixing time will produce
concrete having essentially the same strength and uniformity as concrete mixed for
90 seconds. The reduced mixing time shall, however, not be less than 50 seconds or
the manufacturers recommended mixing time, whichever is the greater. A suitable
timing device shall be attached to the mixer to ensure that the minimum mixing time
is complied with.
The first batch to be run when starting with a clean mixer shall contain only 2/3 of
the required amount of coarse aggregate in order to facilitate "coating" of the mixer
drum.
(c) Discharge
Discharge shall be so carried out that there is no segregation of the materials in the
mix. The mixer shall be emptied completely before it is recharged.
(d) Maintenance and Cleaning of the Mixer
If the mixer has stopped running for any period in excess of 30 minutes, it shall be
thoroughly cleaned out, particular attention being paid to the removal of any build-up
of materials in the drum, in the loader and around the blades or pads. Worn or bent
blades and paddles shall be replaced.
Before any concrete is mixed, the inner surfaces of the mixer shall be cleaned and all
hardened concrete shall be removed.
(e) Standby Mixer
When casting sections where it is important that casting should continue without
interruption, a standby mixer shall be held in readiness to run at 15 minutes notice in
case of breakdown of the stock mixers.
(f) Mixing by Hand
Hand mixing may be carried out subject to the agreement of the Engineer, and only
for non structural concrete.
The mixing shall be done on a hard impermeable surface. The materials shall be
turned over not less than three times dry, water shall then be sprayed on and the
materials again turned over not less than three times in a wet condition and worked
together until a mixture of uniform consistency is obtained.
For hand mixed concrete the specified quantities of cement shall be increased by
10% and not more than 0.5 cubic metres shall be mixed at one time. During windy
weather efficient precautions shall be taken to prevent cement from being blown
away during the process of gauging and mixing.
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(g) Transport
The concrete shall be discharged from the mixer and transported to the Works by
means which shall prevent adulteration, segregation or loss of ingredients, and which
shall ensure that the concrete is of the required workability at the point and time of
placing. The loss of slump between discharge from the mixer and placing shall not
exceed 25 mm.
No concrete that has partially hardened during transit shall be used in the Works and
the transport of concrete from the mixer to the point of placing shall be such that this
requirement can be complied with.
The time elapsing between mixing and placing a batch of concrete shall be as short
as practicable and in any case not longer than will permit completion of placing and
compaction before the onset of initial set. If the placing of any batch of concrete is
delayed beyond this period, the concrete shall not be placed in the Works.
6.1.4 Placing, Compacting, Finishing and Protecting Concrete
(a) Preparation of surfaces to receive concrete
Concrete shall not be placed in any part of the Works until the Engineer's consent has
been given in writing, and the Contractor shall notify the Engineer at least 18 hours
prior to the time when he intends to place concrete.
If concrete placing is not commenced within 24 hours of the Engineer's consent, the
Contractor shall again request consent as specified above.
Excavated surfaces on which concrete is to be deposited shall be prepared as set out

in Clause 6.6.3 of this Standard Specification.
Existing concrete surfaces shall be prepared as set out in Clause 6.1.5. Before
depositing of further concrete they shall be clean, hard and sound and if required by
the Engineer shall be wet but without any freestanding water.
Any flow of water into an excavation shall be diverted through proper side drains to
a sump, or be removed by other suitable methods which will avoid washing away the
freshly deposited concrete or any of it constituents. Any under-drains constructed for
this purpose shall be completely grouted up when they are no longer required, by a
method agreed by the Engineer.
If so instructed by the Engineer surfaces against which concrete is to be placed shall

receive a prior coating of mortar mixed in the proportions similar to those of the fines
portion in the concrete to be placed. The mortar shall be kept ahead of the concrete.
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The mortar shall be well worked into all parts of the excavated surfaces and shall not
be less than 5 mm thick.
If any fissures have been cleaned out as described in Section 7 of this Standard
Specification they shall be filled with mortar or with concrete as instructed by the
Engineer.
The amount of mortar placed at any one time shall be limited so that it does not dry
out or set before being covered with concrete.
6.1.4.1 Placing Procedures
(a) General
The concrete shall be deposited as nearly as possible in its final position. It shall be
placed so as to avoid segregation of the concrete and displacement of the
reinforcement, other embedded items, or formwork. It shall be brought up in layers
approximately parallel to the construction joint planes and not exceeding 500 mm in
compacted thickness unless otherwise permitted or directed by the Engineer, but the
layers shall not be less than four times the maximum nominal size of aggregate in
thickness.
In plain concrete of at least 300 mm, hard and clean plum stones with a mass of 15
kg - 55 kg may, if approved, be included to displace concrete for up to 20% of the
total volume, provided that:
(i) such plums have no adhering films or coatings;
(ii) no plums have a dimension greater than one-third of the smallest dimension
of the concrete member or 300 mm, whichever is less; and
(iii) each plum is surrounded by at least 75 mm of concrete.
Layers shall not be placed so that they form feather edges nor shall they be
placed on a previous layer which has taken its initial set. In order to comply
with this requirement, a layer may be started before completion of the
preceding layer.
All the concrete in a single bay or pour shall be placed as a continuous

operation. It shall be carefully worked round all obstructions, irregularities in
the foundations and the like so that all parts are completely full of compacted
concrete with no segregation or honeycombing. It shall also be carefully
worked round and between water stops, reinforcement, embedded steel work
and similar items which protrude above the surface of the completed pour.
The Contractor shall arrange that as far as possible the intervals between
placing successive lifts of concrete in one section of the Works are of equal
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duration. This duration shall normally be not less than three or more than
seven days under temperate weather conditions unless otherwise agreed or
Where required by the Engineer to limit the opening of construction joints

due to shrinkage, concrete shall not be placed against adjacent concrete which
is less than 21 days old.
When the Drawings call for contraction gaps in concrete, these shall be of the
widths and in the locations shown on the Drawings, and they shall not be
filled until the full time interval shown on the Drawings has elapsed.
All work shall be completed on each batch of concrete before its initial set
commences and thereafter the concrete shall not be disturbed before it has set
hard.
Fresh concrete shall not be placed against concrete that has been position for
more than 30 minutes, unless a construction joint is formed.
Concrete shall not be placed during rain which is sufficiently heavy or

prolonged to wash mortar from coarse aggregate on the exposed faces of fresh
concrete. Means shall be provided to remove any water accumulating on the
surface of the placed concrete. Concrete shall not be deposited into such
accumulations of water.
In drying weather, covers shall be provided for all fresh concrete surfaces
which are not being worked on. Water shall not be added to concrete for any
reason.
When concrete is discharged above its place of final deposition, segregation

shall be prevented by the use of chutes, down pipes, trunking, baffles or other
appropriate devices.
(b) Placing in Forms
Forms for walls, columns and other thin sections of significant height shall be
provided with openings or other devices that will permit the concrete to be placed in
a manner that will prevent segregation and accumulations of hardened concrete on
the formwork or reinforcement above the level of the placed concrete.
When using sliding formwork the following additional requirements shall apply:
The Contractor shall take all the necessary measures to ensure continuity of
operations. All the necessary lighting and standby equipment for mixing, hoisting,
placing and compaction must be provided and all the materials required for
completing each structure must be ready on Site before casting commences.
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Concrete shall be cast in uniform layers along the formwork so that the top surface of
the concrete does not differ by more than 150 mm at any part of the formwork. In
addition the level of the concrete shall never be more than 300 mm below the top of
the sliding panel. The working platform must be kept clean and no concrete which
has partially dried out may be swept into the formwork.
(c) Placing Underwater
When it is necessary to place concrete under water the Contractor shall submit to the
Engineer his proposals for the method and equipment to be employed. The concrete
shall be deposited either by bottom-discharging water tight containers or through
funnel-shaped tremies which are kept continuously full with concrete up to a level
above the water and which shall have the discharging bottom fitted with a trapdoor
and immersed in the concrete in order to reduce to a minimum the contact of the
concrete with the water. Special care shall be taken to avoid segregation.
If the level of concrete in a tremie pipe is allowed to fall to such an extent that water
enters the pipe, the latter shall be removed from the pour and filled with concrete
before being again lowered into the placing position. During and after concreting
under water, pumping or de-watering in the immediate vicinity shall be suspended if
there is any danger that such work will disturb the freshly placed concrete.
(d) Casting Bridge Decks
When casting bridge decks of substantial thickness care shall be taken to avoid
layering of concrete and the whole thickness shall be placed in one pass.
Pumping of concrete shall be subject to the approval of the Engineer. Aluminium

pipes shall not be used for this purpose.
6.1.4.2 Compaction
Concrete shall be fully compacted by approved means during and immediately after
placing.
The concrete shall be free from honeycombing and places of weakness and successive
layers of the same lift shall be thoroughly bonded together.
Unless otherwise agreed to by the Engineer, concrete shall be compacted by means of

vibrators. Internal vibrators shall be capable of producing not less than 10,000 cycles per
minute. External vibrators shall be capable of not less than 3,000 cycles per minute.
Sufficient standby vibrators shall be held available in case of breakdowns.
Vibration shall be applied by experienced labour and over-vibration resulting in

segregation, surface water and leakage shall be avoided. Contact with reinforcement and
formwork shall, as far as is practicable, be avoided when using internal vibrators.
Concrete shall not be subjected to disturbance by vibration within 4 to 24 hours after
compaction.
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Whenever vibration is applied externally, the design of the formwork and positioning of
vibrators shall be such that efficient compaction and avoidance of surface blemishes is
ensured.
Special attention shall be given to the compaction of concrete in the anchorage zones and
behind the anchor plates and in all places where high concentrations of reinforcing steel
or cables occur.
In such cases where the placing and compaction of concrete is difficult, a mix containing
smaller size aggregate may be used, but only with the approval of the Engineer and after
a mix containing such aggregate has been designed and tested.
6.1.4.3 Surface Finishes
(a) Unformed Surfaces
Horizontal or nearly horizontal surfaces which are not cast against formwork shall be
finished to the class shown on the Drawings and defined hereunder.
(i) UF1 Finish
All surfaces on which no higher class of finish is called for on the Drawings
or instructed by the Engineer shall be given a UF1 finish.
The concrete shall be levelled and screeded to produce a uniform plain or

ridged surface, surplus concrete being struck off by a straight edge
immediately after compaction.
(ii) UF2 Finish
This is a floated finish for roof or floor slabs and other surfaces where a hard
trowelled surface is not required.
The surface shall first be treated as a Class UF1 finish and after the concrete
has hardened sufficiently, it shall be floated by hand or machine sufficient
only to produce a uniform surface free from screed marks.
All imperfections shall be made good as required by the Engineer.
(iii) UF3 Finish
This is a hard trowelled surface for use where weather resistance or

appearance is important, or which is subject to high velocity water flow.
The surface shall be floated as for a UF2 finish but to the tolerance stated
below. When the moisture film has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, it
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shall be steel-trowelled under firm pressure to produce a dense, smooth

uniform surface free from trowel marks.
Table 6.1.4.3/1: Surface Tolerances
Class of finish Tolerance in mm (see notes)

A B C
UF1 Not applicable 10 +20 to -10
UF2 Nil 10 +20 to -10
UF3 Nil 5 +12.5 to -7.5
Notes:
1. Col A is the maximum allowable value of any sudden change of level in the surface.
2. Col B is the maximum allowable value of any gradual irregularity of the surface, as
indicated by the gap between the surface and a three metre long straight edge or
correctly shaped template placed on the surface.
3. Col C is the maximum allowable value of the difference in level or position between
a three metre long straight edge or correctly shaped template placed on the surface
and the specified level or position of that surface.
Where dimensional tolerances are given on the Drawings or in the Specifications of

Particular Application they shall take precedence over those given in Table 6.1.4.3/1
(b) Formed Surfaces
The surface finish to be achieved on formed concrete surfaces shall be as shown on

the Drawings and defined hereunder:
(i) Class F1 Finish
This finish is for surfaces against which backfill or further concrete will be
placed. Formwork may be sawn boards, sheet metal or any other suitable
material which will prevent the loss of fine material from the concrete being
placed.
(ii) Class F2 Finish
This finish is for surfaces which are permanently exposed to view but where
the highest standard of finish is not required. Forms to provide a Class F2
finish shall be faced with wrought thicknesses tongued and grooved boards
with square edges arranged in a uniform pattern and close jointed or with
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suitable sheet material. The thickness of boards or sheets shall be such that
there shall be no visible deflection under the pressure exerted by the concrete
placed against them. Joints between boards or panels shall be horizontal and
vertical unless otherwise directed. This finish shall be such as to require no
general filling of surface pitting; but fins, surface discolouration and other
minor defects shall be remedied by methods agreed by the Engineer.
(iii) Class F3 Finish
This finish is for surfaces which will be in contact with water flowing at high
velocity, and for surfaces prominently exposed to view where good
appearance is of special importance. To achieve this finish, which shall be
free of board marks, the formwork shall be faced with plywood complying
with BS 1088 or equivalent material in large sheets. The sheets shall be
arranged in an approved uniform pattern. Wherever possible, joints between
sheets shall be arranged to coincide with architectural features or changes in
direction of the surface. All joints between panels shall be vertical and
horizontal unless otherwise directed. Suitable joints shall be provided
between sheets to maintain accurate alignment in the plane of the sheets.
Unfaced wrought boarding or standard steel panels will not be permitted for
Class F3 finish. The Contractor shall ensure that the surface is protected from
rust marks, spillage and stains of all kinds.
(iv) Curved Surfaces
For curved surfaces where F2 and F3 finishes are called for, the formwork
face shall be built up of splines cut to make a tight surface which shall then be
dressed to produce the required finish.
Alternatively single curvature surfaces may be faced with plastic or plywood

linings attached to the backing with adhesive or with escutcheon pins driven
flush. Linings shall not bulge, wrinkle or otherwise deform when subjected to
temperature and moisture changes.
All parts of formed concrete surfaces shall be in the positions shown on the
Drawings within the tolerances set out in Table 6.1.4.3/2
In cases where the Drawings call for tolerances other than those given in
Table 6.1.4.3/2 the Drawings shall rule.
Where pre-cast units have been set to a specified tolerance, further

adjustments shall be made as necessary to produce a satisfactory straight or
curved line. When the Engineer has approved the alignment, the Contractor
shall fix the units so that there is no possibility of further movement.
Table 6.1.4.3/2: Tolerances
Class of finish Tolerance in mm (see notes)
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A B C
F1 10 10 +25 to -10
F2 5 10 +15 to -15
F3 2 5 +10 to -10
NOTES:
1. Col A is the maximum allowable value of any abrupt irregularity in the surface due
to misaligned formwork or defects in the face of the formwork.
2. Col B is the maximum allowable value of any gradual deviation from a plane surface
as indicated by a straight edge 3 m long. In the case of curved surfaces the straight
edge shall be replaced by a correctly shaped template.
3. Col C is the maximum allowable amount by which the whole or part of a concrete
face is displaced from the correct position shown on the Drawings.
6.1.4.4 Curing and Protection
(a) Curing
Concrete shall be protected during the first stage of hardening from loss of moisture
and from the development of temperature differentials within the concrete sufficient
to cause cracking. The methods used for curing shall not cause damage of any kind to
the concrete.
Curing shall be continued for as long as may be necessary to achieve the above
objectives but in any case for at least seven days or until the concrete is covered by
later construction whichever is the shorter period.
The above objectives are dealt with below in articles (i) and (ii) of this Sub-clause
but nothing shall prevent both objectives being achieved by a single method where
circumstances permit.
The curing process shall commence as soon as the concrete is hard enough to resist
damage from the process, and in the case of large areas or continuous pours shall
commence on the completed section of the pour before the rest of the pour is
finished.
Details of the Contractor's proposals for curing concrete shall be submitted to the
Engineer before the placing of concrete commences in the Works.
(i) Loss of Moisture
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Exposed concrete surfaces shall be closely covered with impermeable

sheeting conforming to AASHTO M171, properly secured to prevent its
removal by wind and the development of air spaces beneath it. Joints in the
sheeting shall be lapped by at least 300 mm.
If for some reason it is not possible to use impermeable sheeting, the

Contractor shall keep the exposed surfaces continuously wet by means of a
water spray or by covering with a water absorbent material which is kept wet,
unless this method conflicts with article (ii) of this Sub-clause.
Water used for curing shall be of the same quality as that used for mixing as
stated in Sub clause 6.1.1.3.
Formed surfaces may be cured by retaining the formwork in place for the
required curing period.
If the use of the foregoing methods is inappropriate, surfaces which will not
have further concrete bonded to them and which are not to receive and
application of a finish may be cured by the application of a curing compound
having an efficiency index of at least 90 per cent. Curing compounds shall
contain a fugitive dye to enable the extent of the spread to be seen easily.
They shall conform to Type 1-D or 2 in AASHTO M148 standards.
Curing compound used on surfaces exposed to the sky shall if instructed by
the Engineer, contain sufficient finely divided flake aluminium in suspension
to produce a complete coverage of the surface with a metallic finish when
applied at the rate recommended by the manufacturer.
Curing compounds shall become stable and impervious to the evaporation of

water from the concrete surface within 60 minutes of application. The
material shall not react chemically with the concrete and shall not crack, peel
or disintegrate within three weeks after application.
If instructed by the Engineer, the Contractor shall, in addition to the curing

provisions set out above provide a suitable form of shading to prevent the
direct rays of the sun reaching the concrete surfaces for at least the first four
days of the curing period.
(ii) Limitation of Temperature Differentials
The Contractor shall limit the development of temperature differentials in

concrete after placing by any means appropriate to the circumstances
including the following:
- limiting concrete temperatures at placing as set out in Sub-clause 6.1.4.5;
- use of low heat cement, subject to the agreement of the Engineer;
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- insulation of exposed concrete surfaces by insulating blankets. Such

blankets shall have an insulation value at least equivalent to 50 mm of dry
mineral wool;
- leaving formwork in place during the curing period. Steel forms shall be
suitably insulated on the outside;
- preventing rapid dissipation of heat from surfaces by shielding from wind;
- avoiding the use of water sprays when such use would cause rapid cooling
of the surface.
(b) Protection
Freshly placed concrete shall be protected from rainfall and from water running over
the surface until it is sufficiently hard to resist damage from this cause.
No traffic shall be allowed on any concrete surface until such time as it is hard
enough to resist damage by such traffic.
Concrete placed in the Works shall not be subject to any loading until it has attained
at least its nominal strength as defined in Sub-clause 6.1.2.1
If the Contractor desires to impose loads on newly placed concrete, he shall make at
least three test cubes and cure them in the same conditions as the concrete they
represent. These cubes shall be tested singly at suitable intervals in order to estimate
the time at which the nominal strength is reached.
(c) Removal of Formwork
False work and formwork shall not be removed before the concrete has attained
sufficient strength to supports its own mass and any loads that may be imposed on it.
This condition shall be assumed to require that after placing of the concrete the
formwork is to remain in place for the appropriate minimum period of time given in
Table 6.1.4.4/1 unless the Contractor can prove to the satisfaction of the Engineer
that shorter periods are sufficient to fulfil this condition. In such case the formwork
may be removed after the agreed shorter period of time.
False work and formwork shall be removed carefully without shock, disturbance or
damage to the cast concrete or structure.
Weather may be regarded as "normal" when air temperatures adjacent to the

concrete, as measured by a maximum and minimum thermometer, do not fall below
15oC, and as "cold" when temperatures measured similarly fall below 5oC. When
minimum temperatures are between these values, stripping times shall be between
the periods specified for normal and cold weather.
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Any period during which the temperature remains below 2oC shall be disregarded in
calculating the minimum time which shall elapse before forms are removed.
On continuous reinforced concrete structures the false work and supporting

formwork shall not be removed before the concrete of the last pour has reached the
appropriate minimum age given in Table 6.1.4.4/1, or the appropriate minimum
strength. Where the structure is constructed in stages, the false work and supporting
formwork shall be removed as specified on the Drawings or as directed by the
Engineer.
In lieu of the times specified in Table 6.1.4.4/1 the false work and formwork to
soffits of slabs and beams may be removed once the concrete has attained 70% of its
characteristic compressive strength. The compressive strength of the concrete shall
be determined from a representative and adequate number of cubes that have been
stored under conditions that simulate the field conditions. Similarly, side forms may
be removed when the concrete has attained 20% of its characteristic strength.
On pre-stressed concrete structures the false work and supporting formwork shall be
removed after the full pre-stressing force relating to the particular stage of
construction has been applied, unless otherwise shown on the Drawings or directed
by the Engineer.
Table 6.1.4.4/1
Removal of False work and Formwork: Minimum Time in Days
Type of cement used

Portland cement Rapid-hardening Portland blast
Portland cement furnace cement+
Weather conditions
False work and formwork Normal Cold Normal Cold++ Normal Cold
to
Beam sides, walls and 1 1.5 0.5 1 2 4
unloaded columns
Soffits of slabs and beams
a) Spans of to 3 m 4 7 2 4 6 10
b) Spans over 3 m up to 6 10 17 5 10 14 24
m
c) Spans over 6 m up to 12 14 24 10 18 21 28
m
d) Spans over 12 m 21 30 18 28 28 36
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+ Also applicable to a 50/50 mixture of Portland cement and milled granulated

blast-furnace slag.
++ Shorter periods may be used for sections with a thickness exceeding 300 mm.
6.1.4.5 Adverse Weather Conditions
(a) General
The Contractor shall prevent damage to concrete arising from exposure to extreme
temperatures, and shall maintain in good working order all equipment required for
this purpose.
In the event that conditions become such that even with the use of this equipment the
requirements cannot be met, concrete placing shall immediately cease until such time
as the requirements can again be met.
(b) Construction in Hot Weather
During hot weather the Contractor shall take all measures necessary to ensure that
the temperature of concrete at the time of placing in the Works does not exceed 30oC
and that the concrete does not lose any moisture during transporting and placing.
Such measures may include but are not necessarily limited to the following:
(i) Shielding aggregates from direct sunshine.
(ii) Use of a mist water spray on aggregates.
(iii) Sun shields on mixing equipment and transporting element.
(iv) Cooling the mixing water. If ice is used for this purpose it should preferably
be in flake form. Lump ice shall not be allowed to enter the tank supplying
the mixer drum.
(v) Covering skips closely with polythene sheet so that the latter is in contact
with the concrete.
Areas in which concrete is to be placed shall be shielded from direct sunshine and
rock or concrete surfaces shall be thoroughly wetted if instructed by the Engineer to
reduce absorption of water from the concrete placed on or against them.
After concrete in any part of an area has been placed, the selected curing process
shall be commenced as soon as possible. If any interval occurs between completion
of placing and start of curing, the concrete shall be closely covered during the
interval with polythene sheet to prevent loss of moisture.
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(c) Construction in Cold Water
Concrete shall not be placed during falling temperatures when the ambient air
temperature falls below 7oC or during rising temperatures when the ambient air
temperature is below 3oC. If the air temperature is below 5 0 C when placing
concrete, the temperature of the concrete shall not be below 10oC.
The temperature of placed concrete shall not be allowed to fall below 5oC until the
concrete has attained a strength of at least 5 MPa, and the Contractor shall be
responsible for all protective measures necessary to ensure this. All concrete that has
been damaged by frost or the formation of ice in the concrete shall be removed and
replaced by the Contractor at his own expense.
(d) Precautions when Using Sliding Formwork
When sliding operations take place in cold weather, the water only, or the water and
aggregate, shall be heated to ensure that the concrete temperature does not drop
below 10oC until it has attained strengths of 5 MPa or more. The Contractor shall
make all necessary arrangements for heating the material and protecting the concrete
against loss of heat. Heated water and aggregate shall be mixed first and the cement
added only at temperatures below 30oC.
During cold weather the rate of sliding shall be suitably decreased to ensure
sufficient strength in the concrete leaving the bottom of the formwork.
6.1.5 Joints
6.1.5.1 Construction Joints
Whenever concrete is to be bonded to other concrete which has hardened, the surface of
contact between the sections shall be deemed a construction joint.
Where construction joints are shown on the Drawings, the Contractor shall form such
joints in those positions. The location of joints which the Contractor requires to make for
the purpose of construction shall be subject to the agreement of the Engineer.
Construction joints shall be in vertical or horizontal planes except in sloping slabs where
they shall be normal to the exposed surface or elsewhere where the drawings require a
different arrangement.
Construction joints shall be so arranged as to reduce to a minimum the effects of

shrinkage in the concrete after placing, and shall be placed in the most advantageous
positions with regard to stresses in the structures and the desirability of staggering joints.
Feather edges of concrete at joints shall be avoided and any feather edges which may
have formed where reinforcing bars project through a joint shall be cut back until sound
concrete has been reached.
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The intersections of horizontal or near horizontal joints and exposed faces of concrete
shall appear as straight lines produced by use of a guide strip fixed to the formwork at the
top of the concrete lift, or by other means acceptable to the Engineer.
Construction joints formed as free surfaces shall not exceed a slope of 20 per cent from
the horizontal.
The surface of the fresh concrete in horizontal or near horizontal joints shall be
thoroughly cleaned and roughened by means of high pressure water and air jets when the
concrete is hard enough to withstand the treatment without the leaching of cement. The
surface of vertical or near vertical joints shall be similarly treated if circumstances permit
the removal of formwork at a suitable time.
Where concrete has become too hard for the above treatment to be successful, the surface
whether formed or free is to be thoroughly scabbled by mechanical means or wet sand
blasted and then washed with clean water. The indentations produced by scabbling shall
be not less than 10 mm deep and shall not extend closer than 40 mm to a finished face.
If instructed by the Engineer the surface of the concrete shall be thoroughly brushed with
a thin layer of freshly mixed mortar composed of one part of cement to two parts of sand
by weight and complying with Clause 6.6.2. The mortar shall be applied, at a thickness
of 5 to 10 mm, to the construction point surface immediately ahead of concreting. The
mortar shall be kept just ahead of the fresh concrete being placed and the fresh layer of
concrete shall be thoroughly and systematically vibrated to full depth to ensure complete
bond with the adjacent layer.
No slurry or concrete may be placed in position on or against a construction joint until the
joint has been inspected and passed by the Engineer.
When concreting recommences a day or more after the forming of the construction joint,
the following procedure shall be followed:
The construction joint shall be kept continuously wet for a period of least 2 hours before
concreting starts, but shortly before re-concreting further application of water shall cease
so that the surface is just damp when further concreting is commenced.
Any dirt, excess water and loose particles shall be removed prior to starting reconcreting.
Epoxy resins specially designed for bonding old concrete to new concrete shall be used at
construction joints where so directed by the Engineer. The preparation of the construction
joint surface and the application of the epoxy resin shall be strictly in accordance with the
manufacturers recommendations and the Engineer's instructions. The actual brand and
type of resin used shall be subject to the Engineer's approval.
6.1.5.2 Expansion and Contraction Joints
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Expansion and contraction joints are discontinuities in concrete designed to allow for
thermal or other movements in the concrete.
Expansion joints are formed with a gap between the concrete faces to permit subsequent
expansion of the concrete. Contraction joints are formed to permit initial contraction of
the concrete and may include provision for subsequent filling.
Expansion and contraction joints shall be formed in the positions and in accordance with
the details shown on the Drawings or elsewhere in the Specifications.
6.1.5.3 Water Stops
Water stops shall be of the material and form shown on the Drawings. No water stop
material shall be brought onto Site until the Contractor has submitted full details of the
materials he proposes to use, including samples, and these have been approved by the
Engineer. All samples shall be of adequate length for testing.
Water stops shall be made of material which is resistant to chlorides, sulphates, or other
deleterious substances which may be present in the environment of the Works.
Rubber water stops may be of synthetic rubber and shall have an elongation at breaking
stress of at least 500 per cent at 25oC and shall allow a joint movement of at least 50 mm.
Polyvinyl chloride (PVC) water stops shall be extruded from an unfilled plasticized PVC
polymer or copolymer which does not contain any reclaimed or scrap PVC. PVC water
stops shall have an elongation at breaking stress of at least 225 per cent at 25oC and shall
allow a joint movement of at least 10 mm.
Low modulus water stops shall be of rubber of PVC as described above but shall have an
elongation of at least 200 per cent at 25oC under a tensile stress of 6 MPa and shall allow
a joint movement of at least 50 mm.
Water stops shall be supplied in lengths as long as possible consistent with ease of
handling and construction requirements.
In rubber or plastic materials joints other than butt joints shall be supplied ready made by
the manufacturer. Butt joints shall be made on Site in accordance with the manufacturer’s
instructions and with equipment supplied for the purpose by the manufacturer.
Water stop material shall be stored carefully on Site to avoid damage and contamination
with oil, grease, or other pollutants. Rubber and plastic water stops shall be stored in cool
well ventilated places away from direct sunlight.
Rubber and plastic water stops shall be protected from the sun if they are embedded in
one side of a joint more than one month before the scheduled date of placing concrete on
the other side.
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Water stops shall be firmly fixed in the formwork so that they cannot be displaced during
concrete placing and shall be completely free of all dirt, grease, oil, etc. before placing
concrete. Where eyelets are provided they shall be fully wired to the reinforcement. This
shall be the only means whereby the water stop is fixed. In no circumstances shall a water
stop be punctured with nails, etc. as a means of fixing.
Concrete shall be placed carefully round water stops so as to avoid distortion or

displacement and shall be fully compacted. Where water stops lie in a horizontal or
nearly horizontal plane the Contractor shall ensure that no voids are left on the underside
of the water stop.
Formwork round water stops shall be carefully removed to avoid damage. If water stops
suffer any damage which cannot be properly repaired in situ the Engineer may require a
section of concrete to be removed and the water stop replaced.
6.1.6 Grouting of Pockets and Holes and Underpinning of Base plates
Pockets and holding-down bolt holes shall be thoroughly cleaned using compressed air or
water jet. Holes drilled by a diamond bit shall be roughened. The pockets and holes shall
be filled with grout consisting of cement and clean fresh water mixed in proportion of
two parts by weight of cement to one part by weight of water. The pouring of liquid grout
shall cease as soon as hole is filled and any excess grout on the surface of the concrete
foundation shall be completely removed and the surface dried off before the next
operation proceeds.
The space between the top surface of foundation concrete and the underside of base-
plates shall be filled with a special mortar made up in the following proportions:
Portland cement 50 kg
Fine aggregate 50 kg
An additive acceptable to the Engineer to counteract shrinkage in proportions

recommended by the manufacturer
The special mortar shall be mixed with the lowest water cement ratio which will result in
a consistency of mix of sufficient workability to enable maximum compaction to be
achieved. The special mortar shall then be well rammed in horizontally below the base
plate and from one edge only until it is extruded from the other three sides. The mortar
which has extruded shall then be rammed back to ensure complete support without voids.
6.1.7 Testing and Quality Control
6.1.7.1 Process Control
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The Contractor's minimum obligations in terms of Clauses 1.2.12 and Paragraph 2.3
shall be the following:
a) Testing of Aggregates
Coarse aggregate shall be tested for grading once for every 200 m3 delivered on Site
and fine aggregate once for every 100 m3 delivered.
b) Testing of 28-Day Compressive Strength
Test for compliance with the specified characteristic strength shall be carried out as
ordered by the Engineer and may consist of sampling and testing in accordance with
Clause 2.3.2 of this Standard Specification. Any sampling and testing ordered by the
Engineer shall be carried out as outlined in BS 5400, Part 7, and BS 1881.
The 28-day cube compressive strength of concrete shall be controlled by the

Contractor at not less than the frequencies given in Table 6.1.6.1/1, but not less than
one sample shall be taken on each day that concrete of that class is used.
Table 6.1.6.1/1
Volume of No. of tests per LOT

LOT
Method A Method B
0 - 75 m3 3 6
75 - 150 m3 4 9
over 150 m3 5 12
NOTES:
(1) A test by Method A of Sub clause 2.3.2.2 shall be the average test value for three
cubes prepared from the same batch of concrete, the samples being prepared and
cured according to the method described in BS 1881.
The lower specification limit, LLs, shall be the specified characteristic strength of the
concrete class tested.
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(2) A test by Method B of Sub clause 2.3.2.3 shall consist of a single sample taken each
time from a different batch, the samples being prepared and cured in accordance with
the method described in BS 1881.
The average strength determined from any group of four consecutive tests shall
exceed the specified characteristic strength by not less than 5 MPa for concrete of
class 15 and not less than 7.5 MPa for concrete of class 20 or above.
Each individual test result shall be greater than 85% of the specified characteristic
strength.
Where the Engineer in any case runs a full programme of routine tests of 28-day
compressive strength he may, at his sole discretion, relieve the Contractor of his
obligation to run his own tests, but in such a case any reliance placed by the
Contractor on the Engineer's tests shall be entirely at his own risk and no claims
resulting from such reliance placed on tests by the Engineer, which may subsequently
prove to have been incorrect, will be considered.
3) Accelerated Cube Compressive Strength Tests
In the case of major structures the Contractor is advised to carry out regular
accelerated compressive strength testing of the concrete. The methods of testing and
predicting 28-day strengths shall be as determined in consultation with the Engineer.
Whenever accelerated tests indicate that the 28-day strengths will not be obtained,
the Contractor shall immediately effect such changes in materials and mix
proportions as may be necessary to ensure future compliance.
When specified in the Specifications of Particular Application the use of accelerated

tests shall be obligatory.
4) Control Charts
The Contractor shall institute a system of control charts depicting test results of all
28-day concrete strengths and where applicable, accelerated compressive strengths.
5) Provision of Records
The Contractor shall maintain written records that provide the following:
(i) On each section of the concrete works; the date, the class of concrete, the time
taken, and the position of section in the Works.
(ii) Daily maximum and minimum temperatures.
(iii) Nature of samples and dates on which they were taken, including
identification marks.
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(iv) Results of tests on samples taken and description of concrete section

represented by samples.
These records shall be maintained in a form agreed to by the Engineer and shall at all
times be up to date and available to the Engineer for inspection.
6.1.7.2 Quality Control by the Engineer
(a) Criteria for Compliance with Requirements
Routine inspection and quality control will be carried out by the Engineer as
specified in Paragraph 2.3. The criteria for compliance with the requirements
specified for 28-day characteristic strength shall be as given in Clause 2.3.2 of this
(b) Procedure in the Event of Failure to Comply with the Requirements.
Any lot represented by test cubes failing to meet the criteria specified for the
characteristic strength shall be rejected
Or
(i) the Contractor may apply for resubmission of the lot on the basis of cores
drilled from the concrete section in question. The method of taking cores,
testing them and evaluating the test results shall be as described in AASHTO
T24. The procedure for determining compliance of test results shall be as
specified hereinafter in article (c). The cost of drilling and testing the cores
shall be born by the Contractor, regardless of the outcome of the tests on the
cores.
Before cores are taken the members concerned shall be cured and allowed to
age to at least 28 days, but not more than 56 days.
(ii) Where the Engineer so directs full-scale load tests shall be carried out in order
to determine whether a specific structure or member can be accepted. The
cost of such tests shall be for the Contractor's account, regardless of the
outcome of the tests.
In all cases where concrete has been produced that fails to meet the
requirements for strength, the Contractor shall immediately take the required
remedial action by changing the mix proportions to obtain the required
strength.
(c) Concrete Cores - Strength Requirements
The actual number of cores to be taken from a resubmitted lot shall depend on the
size of the lot and the nature of the structure and will be determined by the Engineer.
The lot shall be deemed to have met the requirements for characteristic strength if the
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"estimated potential strength" of the cores, determined as specified in BS 1881,

meets the requirements specified for 28-day cube compressive strength tests.
(d) Testing Ordered by the Engineer
Where routine testing of concrete cubes is not carried out on Site by the Engineer, he
may order the Contractor to have the concrete cubes that have been made by the
Engineer tested at an approved testing laboratory, in which case payment for such
tests shall be made in accordance with the provisions of Clause 2.4.6.
(a) Except as stated below, in situ concrete shall be measured by the cubic metre from
the lines, levels and profiles shown on the Drawings. Separate items are provided for
concrete of different classes. No deduction shall be made in the measurement for:
- bolt holes, pockets, box outs and cast in components provided that the
volume of each is less than 0.15 cubic metres;
- mortar beds, fillets, drips, rebates, recesses, grooves, chamfers and the like of
100 mm total width or less;
- reinforcement.
(b) Blinding concrete shall be measured by the square metre for the specified thickness
from the plan area shown on the Drawings. No deduction shall be made in the
measurement for openings provided that the area of each is less than 0.5 square
metre.
(c) Certain screeds, slabs and other items shall be measured by the square metre for the
specified thickness from the plan area shown on the Drawings. No deduction shall be
made in the measurement for openings provided that the area of each is less than 0.5
square metre.
(d) The rates for concrete shall include for the cost of:
- cement including testing and submission of test certificates and records;
- fine and coarse aggregate including delivery of samples, testing and heating
or cooling as necessary;
- water including heating or cooling as necessary, and testing;
- admixtures including submission of details;
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- design of concrete mixes, preparation of trial mixes, submission of details;
- quality control including cost of samples, curing and testing;
- batching, mixing, transporting, placing and compacting including compacting

around embedded items, except for reinforcement and water stops, allowed
for elsewhere;
- any additional costs of placing different classes or concrete in the same lift;
- preparation of surfaces, diversion of water, and mortar beds;
- curing and protection including impermeable sheeting, use of water sprays,

curing compound and methods to limit temperature differentials;
- methods required during placing of concrete in cold and hot weather;
- Class UF1 finish;
- formwork for blinding concrete;
- laying to sloping surfaces not exceeding 15o from the horizontal and to falls;
- construction joints and shear keys for future concrete and other construction
surfaces;
- placing and compacting against excavated surfaces where required including

any additional concrete to fill over break or working space;
- transport of all materials from source to Site and thence to place of deposition
or use on Site.
(e) Classes UF2 and UF3 finish shall be measured by the square metre. Class UF1 finish
shall not be measured.
(f) The installation of water stops shall be measured by the metre run of each type. The
rates for water stops shall include for the cost of any special metre of cross jointing,
any sealing required at the face of the concrete and for placing and compacting
concrete around the water stops.
(g) Mortar used for bedding base plates and the like shall be measured by the square
metre as the area of the base plate at the specified nominal thickness of bedding.
(h) Mortar used in filling bolt pockets and the like shall not be measured separately and
the costs shall be included in the rates for other work.
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(i) Hardening agents applied to concrete surfaces shall be measured once by the square
metre. The rates for hardening agents shall cover the cost of all applications that are
required.
6.2 REINFORCEMENT
Scope
This section covers the furnishing and placing of steel reinforcement in concrete
structures.
AASHTO standards relating to this Paragraph shall be taken as basic requirements.
6.2.1 Materials
6.2.1.1 Quality Requirements
(a) Steel Bars
Steel reinforcing deformed bars shall comply with BS 4449 for hot rolled
reinforcement of grade 250 or 460 or BS 4461 for cold worked reinforcement. High
yield-stress steel Grade 600 shall specifically be called for on the Drawings.
The use of cold-worked bars shall be subject to the approval of the Engineer.
The type of bar required shall be identified on the Drawings by the symbols in
accordance with the appropriate standards.
(b) Welded Steel Fabric
Welded steel fabric shall comply with AASHTO M55.
(c) Mechanical Couplers
The tensile properties determined on a test specimen of maximum gauge length of

610 mm, consisting of reinforcing bars that have been butt-jointed with a mechanical
coupler, shall comply with the following requirements:
(i) The tensile properties shall be at least 10% better than those required for the
corresponding steel bar.
(ii) When the test specimen is subjected to a load equal to 0.58 of the specified
minimum yield stress of the bar, the elongation measured on the gauge length
shall not exceed the calculated theoretical elongation for a 610 mm length of
bar, based on the same stress level and a Young’s Modulus of 200,000 MPa.
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The Contractor shall submit test certificates from a recognized testing

authority to the Engineer, certifying that the couplers offered comply with the
specified requirements.
All mechanical couplers used shall be subject to the approval of the Engineer.
6.2.1.2 Storage and Handling
Steel reinforcement shall be stacked off the ground and, in aggressive environments,
protection shall be provided in the form of sheds or tarpaulins.
Reinforcement shall be cut or cut and bent to the dimensions shown on the bending
schedules.
No flame-cutting of high-tensile steel bars shall be permitted, except with the approval of
the Engineer.
Except as provided for below, all bars shall be bent cold and bending shall be done
slowly, a steady, even pressure being used without jerk or impact.
If approved, hot bending of bars of at least 32 mm diameter will be permitted, provided

that the strength of the bars will not depend on cold working. When hot bending is
approved, the bars shall be heated slowly to a cherry-red heat (not above 840oC) and after
bending shall be allowed to cool slowly in air. Quenching with water shall not be
permitted.
Reinforcing bars that have already been bent shall not be re-bent at the location of the
original bend without the permission of the Engineer.
Immediately before the concrete is placed around the reinforcement, the reinforcement
shall be clean, free from mud, oil, grease, paint, loose rust, loose mill scale or any other
substance that can have an adverse effect on the steel or concrete, or reduce the bond.
6.2.1.3 Placing and Fixing
Reinforcement shall be positioned as shown on the Drawings and be accurately secured

in these positions within the tolerance given in the Specifications of Particular
Application by tying with 1.6 mm or 1.25 mm diameter annealed wire or by the use of
suitable clips or, where permitted by the Engineer, by tack welding.
Cover and spacer blocks required to support the reinforcement shall be as small as
possible consistent with their use and be of approved design and material.
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Projecting ends of ties or clips shall not encroach into the concrete cover.
Where protruding bars are exposed to the elements for an indefinite period, the bars shall
be adequately protected against corrosion and damage and shall be properly cleaned
before being permanently encased in concrete.
In members that are formed with sliding formwork, spacer "ladders" for the placing and
fixing of the wall reinforcement shall be used at spacings indicated on the Drawings or as
directed by the Engineer. The ladders shall consist of two 3.7 m long bars with lateral ties
of 4 mm diameter welded to them in the form of a ladder. The ties shall be spaced at
multiples of the horizontal bar spacing in the wall, and be used to secure the horizontal
reinforcement. The laps in the horizontal reinforcement shall be staggered to ensure that
no part of two laps in any four consecutive layers lie in the same vertical plane.
The term "cover" in this context shall mean the minimum clear thickness of concrete
between the surface of the reinforcement and face of the concrete.
The minimum cover shall be as shown on the Drawings. Where no cover is indicated, the
minimum thickness provided shall be not less than the appropriate values shown in Table
6.2.1.3/1.
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Table 6.2.1.3/1 Minimum Concrete Cover Over Reinforcement
Min. cover (mm)
Concrete class
Description of member/surface
Condition of exposure to which the cover applies 20 25 30 40 50 60
1. MODERATE 1.1 Enclosed surfaces

1.2 Surfaces protected by overlay
Sheltered from severe 1.3 Buried structures/members 40 40 30 25 25 25
rain and not subject to 1.4 Structures/members continuously
freezing while saturated 1.5 Underwater concrete 75 75 NA NA NA NA
under water 1.6 Surface formed with permanent
formwork 20 20 20 20 20 20
1.7 Railway structures
as for 2.3 to 2.6
1.8+ Piles - cast in situ (wet cast
against casing) 40 40 40 40 40 40
1.9 Piles - cast in situ (dry cast
against soil)
1.10 Piles - cast in situ (wet cast
against soil) 50 50 50 50 50 50
1.11 Piles - precast 35 35 35 30 30 30
2. SEVERE 2.1 Exposed surfaces

2.2 Buried structures/members NA 50 40 30 25 25
Exposed to driving rain 2.3 Railway substructures -
alternate wetting and exposed surfaces NA 50 40 40 40 40
drying. Subject to: 2.4 Railway structures -
heavy condensation surfaces in contact with soil NA 50 50 50 50 50
freezing while wet, 2.5 Railway superstructure NA NA 40 40 40 40
corrosive fumes, chemi- 2.6 Railway superstructures
cals, aggressive soils surfaces in contact with NA NA 50 50 50 50
ballast
against casing) 50 50 50 50 50 50
2.8 Piles - cast in situ (dry cast
against soil) 75 75 75 75 75 75
against soil
2.1 Piles - precast 40 40 40 35 35 35
3. VERY SEVERE 3.1 Piles - cast in situ (wet

against casing) NA NA NA 80 80 80
Exposed to: abrasion 3.2 Piles - precast NA NA NA 50 50 50
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water with pH below 4.5
+ for concrete cast under water 1.5 shall apply.
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The cover shall be increased by the expected depth of any surface treatment, e.g. when
concrete is bush-hammered or when rebates are provided.
Additional cover as directed by the Engineer shall be provided if porous aggregates are
used.
Cover blocks or spacers required for ensuring that the specified cover is obtained shall be
of a material, shape and design acceptable to the Engineer.
Concrete spacer blocks shall be made with 5 mm maximum size aggregate and shall be
of the same strength and material source as the surrounding concrete. The blocks shall be
formed in specially manufactured moulds and the concrete compacted on a table vibrator,
all to the approval of the Engineer.
Laps, joints, splices and mechanical couplings shall be made only by the methods
specified and at the positions shown on the Drawings or as agreed to by the Engineer.
Welding of reinforcement shall be carried out only where shown on the Drawings or
agreed to by the Engineer.
Flash-but welding shall be carried out only with the combination of flashing, heating,
upsetting and annealing to the Engineer's approval, and only those machines that
automatically control this cycle of operations shall be used.
Metal-arc welding of reinforcement shall be carried out in accordance with BS 5135 and
the recommendations of the reinforcement manufacturers, subject to the approval of the
Engineer and the satisfactory performance of trial joints.
Other methods of welding, e.g. resistance welding, may be used subject to the approval
of the Engineer and to their satisfactory performance in trial joints.
Welded joints shall be full-strength welds, and their strength shall be assessed by
destruction tests on samples selected by the Engineer.
(a) Steel plain and deformed bar reinforcement shall be measured by the tonne and shall
be the calculated weight of the steel required including splice lengths shown on the
Drawings. No allowance shall be made in the measurement for rolling margin or
cutting waste. The density of steel shall be taken as 7,850 kilogrammes per cubic
metre.
(b) Steel fabric reinforcement shall be measured by the square metre and shall be the
calculated area required excluding any allowance for laps.
(c) The rates for bar and fabric reinforcement shall include for the cost of testing and
supplying test certificates, checking bar schedules where provided, cutting to length,
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splice lengths additional to those shown on the Drawings, laps, bending, hooking,
waste incurred by cutting, labelling, handling, cleaning, spacer blocks, provision and
fixing of chairs or other type of supports, welding, fixing the reinforcement in
position including the provision of wire or other material for supporting and tying the
reinforcement in place, bending reinforcement aside temporarily and straightening
and for placing and compacting concrete around the reinforcement.
6.3 FORMWORK
Scope
This section covers the design, supply and erection of all false-work and formwork used
in the construction of permanent Work.
The materials used in the construction of false-work and formwork shall be suitable for
the purpose for which they are required and shall be of such a quality that will produce
the standard of work specified. The type, grade and conditions of the materials shall be
subject to the Engineer's approval.
6.3.1.1 False-work
Timber, structural steel and scaffolding used shall be free from defects that may impair
the stability of the false-work. The jacks, devices, clamps and fittings shall all be in good
working order and of adequate design and strength.
6.3.1.2 Formwork
(a) Tongued and Grooved Boarding
Tongued and grooved boarding shall be of suitably dried timber that will not warp,
distort or cause discolouration of the concrete. The widths of the boards shall be as
specified on the Drawings or in the Bill of Quantities, or as directed by the Engineer.
Board shall be supplied in lengths not shorter than 3 m.
(b) Steel Forms to Exposed Surfaces
For Class F3 surface finish for which steel forms are permitted and for Class F2
surface finish the individual and assembled panels shall be sufficiently rigid and
clamped so as not to deform or kick during handling or under the pressure of the wet
concrete.
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The surface of forms that are to be in contact with concrete shall be clean, free from
deposits or adhering matter, weld runs, ridges and spatter that will impart
irregularities and blemishes to the concrete surface. They shall also be free from
indentations and warps.
(c) Void Formers
Void formers used in permanent work shall be subject to the Engineer's approval.
Where void formers of a particular type or special design are required, details of the
material, thickness thereof and relevant information will be specified in the
Specifications of Particular Application or in the Bill of Quantities or on the
Drawings.
Void formers shall be manufactured from material that will not puncture, tear or be
damaged during the course of construction and shall be of such tight construction as
to prevent undue loss of the mortar component of the concrete through leakage. The
units shall be sufficiently rigid so that they are not deformed during handling or
under the pressure of the wet concrete.
Unless otherwise specified the metal thickness for mild steel, spiral lock formed
(seamed) void formers shall be as follows:
(i) Un-braced Void Formers
0.6 mm for diameters of up to 600 mm

0.8 mm for diameters exceeding 600 mm and up to 800 mm
1.0 mm for diameters exceeding 800 mm and up to 1,000 mm
(ii) Braced Void Formers
0.6 mm for diameters of up to 800 mm

0.8 mm for diameters exceeding 800 mm and up to 1,000 mm
1.0 mm for diameters exceeding 1,000 mm and up to 1,200 mm
1.2 mm for diameters exceeding 1,200 mm
The thickness specified for braced void formers shall apply to formers
internally braced with timbers or equivalent braces. The braces shall be at
spacings not exceeding 2.0 m and not further than 1.0 m from the end of each
unit. Timber cross braces shall consists of members with cross-sectional
dimensions of at least 50 mm x 50 mm.
All hollow void former units shall be provided with a 12 mm diameter

drainage hole at each end.
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(d) Chamfer and Recess Fillets
Wooden fillets used to form chamfers and recesses on exposed surfaces shall be of
new material, unless otherwise authorized by the Engineer.
(e) Jack Rods for Sliding Formwork
The jack rods, base plates and couplers shall be strong enough to carry the design
load under all operating conditions without buckling or becoming distorted or
causing damage to the concrete. Jack rods that are to remain permanently embedded
in the concrete shall comply with the requirements of Clause 6.2.1. Under no
circumstances shall bent rods be used in the work.
The jack rods used shall have a diameter of at least 25 mm.
6.3.2 Design
The Engineer may require that the Contractor submits to him, for his consideration and
approval, the design and drawings of the false-work and formwork for any structure.
6.3.2.1 False-work
The Contractor shall make his own assessment of the allowable bearing pressure on the
foundation material and shall design the footings and false-work to guard against
overloading, differential settlement and unacceptable overall settlement. In assessing the
allowable bearing pressure, due consideration shall be given to the effect which wetting
has on the foundation material.
In the design of false-work cognizance shall also be taken of the redistribution of load
that may occur due to the effect of temperature, wind force, pre-stressing of curved and
skewed structures, stage construction, flooding and debris.
Particular attention shall be given to the provision of transverse and diagonal bracing as
well as web stiffeners on cross bearers.
6.3.2.2 Formwork
(i) Formwork shall be designed to be sufficiently rigid to ensure that the specified
dimensional tolerances can be achieved under the combined action of self-weight,
dead loads and imposed loads as well as the additional loads resulting from the rate
of concreting, the lift cast in one operation and the method of placing and
compaction.
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(ii) Sliding Formwork
The Contractor shall be responsible for the design of the sliding formwork assembly.
Prior to fabrication or bringing the assembly and auxiliary equipment to the Site, the
Contractor shall submit drawings of the complete sliding formwork assembly to the
Engineer for approval. The drawings shall show full details of the forms, safety rails
and curing skirts, as well as details of the jacks and jack layouts.
Concrete sections with dimensions smaller than 200 mm shall not be formed with
sliding formwork, unless approved by the Engineer.
The Contractor shall be required to submit to the Engineer, before sliding

commences, an instruction manual wherein the sliding technique, jacking procedure,
methods of keeping the formwork level, procedure to be adopted to prevent bonding
of the concrete to the forms and method to release the forms in the event of bonding,
the instrumentation and monitoring of the slide, correcting for verticality, twisting
and levelness, etc. are described in detail.
The formwork panels shall be inclined to give a small taper, the forms being slightly
wider at the bottom than at the top. The taper shall be designed to produce the
specified concrete thickness at mid-lift level of the form.
The spacing of the jacks with their jack rods must be so designed that the dead load
of the sliding formwork assembly, the frictional load and the mass of materials,
personnel and equipment are evenly distributed and within the design capacity of the
jacks used.
6.3.3 Construction
6.3.3.1 False-work
False-work shall be erected in accordance with the approved drawings incorporating such
modifications as required by the Engineer.
The Contractor shall take precautions to guard against deterioration of the foundations
during the course of construction.
The false-work shall incorporate features that will permit adjustment of the alignment of
the formwork to compensate for the expected settlement and deflection under load.
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6.3.3.2 Formwork
(a) General
The formwork for bridge decks shall be erected to levels calculated from the
information given on the Plans for road works and bridges. The levels shall be
adapted to allow for the specified pre-camber as well as for the expected deflection
and settlement of the fully loaded false-work and formwork. The levels shall be set
out and controlled at intervals not greater than 2.50 m.
For the construction of formwork, the Contractor may, subject to the provisions of
Clause 6.3.1 use any material suited to and compatible with the class of surface
finish and dimensional tolerances specified for the particular member.
Formwork shall be sufficiently rigid to maintain the forms in their correct position,
shape and profile and shall be of such tight construction that the concrete can be
placed and compacted without undue loss or leakage of the mortar component of the
concrete.
The joints between contiguous formwork elements shall be tight fit and, where
necessary, if undue leakage is expected, the joints shall be caulked, taped or packed
with a sealing gasket, all at no extra payment. Paper, cloth or similar material shall
not be used for this purpose.
The formwork construction shall permit accurate erection and easy stripping without
shock, disturbance and damage to the cast concrete. Where necessary the formwork
assembly shall permit the removal or release of side forms independently of the soffit
forms.
Metal supports, ties, hangers and accessories embedded in the concrete shall be
removed to a depth of not less than the cover specified for the reinforcement. The use
of wire ties is not permitted.
All external corners shall be chamfered by fixing fillet strips into the corners of the
formwork to form 25 mm x 25 mm chamfers. Re-entrant angles need not be
chamfered unless this is specified.
(b) Formwork to Exposed Surfaces
The forms and boards shall be arranged to form a uniform a regular pattern in line
and perpendicular with the main axis of the member, unless otherwise approved or
directed by the Engineer.
Joints between contiguous members shall, after caulking, taping or sealing, be treated
to prevent blemishes, stains and undue marks from being imparted to the concrete
surface.
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Bolt and tie positions shall be so arranged that they conform to the symmetry of the
formwork panels or boards. Bolts and rivet heads that will be in contact with the
formed surface shall be of the countersunk type and shall be treated to prevent marks
from forming in the concrete surface.
The formwork at construction joints shall be braced in order to prevent steps from
forming in the concrete surfaces at the joints between successive stages of
construction.
Where moulding or recess strips are specified they shall be neatly butted or mitred.
(c) Formwork to Open Joints
The requirements for formwork to open joints shall, unless otherwise specified, apply
to cases where the distance between opposite concrete surface is equal to or less than
150 mm.
Formwork to open joints shall be constructed to produce a Class F1 surface finish to

concealed surfaces or a class F2 or F3 surface finish corresponding to the in-plane
surface finish of the bordering concrete surfaces. The material used and construction
of the formwork shall permit complete removal thereof to form the open joint.
Where polystyrene or similar material which is susceptible to damage is used to form
open joints, it shall be lined with a hard surface on the side to be concreted. The hard
material shall be sufficiently resilient to ensure that the required quality of work can
be achieved.
(d) Openings and Chases
Openings and chases shall only be provided if detailed or authorizes by the Engineer.
Frames for openings shall be rigid and firmly secured in position to prevent
displacement. Temporary holes shall be formed so that they will not create an
irregular pattern in relation to the rest of the exposed formed concrete surface.
(e) Sliding Formwork
(i) Equipment
Unless otherwise specified in the Specifications of Particular Application

hoisting equipment for sliding formwork that works stepwise with upward
movements of between 10 mm - 100 mm is acceptable. However, it is
preferable to use linked hydraulic or pneumatic jacks that are reversible and
driven by an electrically operated pump, and that can hoist at a steady rate.
The jacks shall have independent controls with which the verticality and
horizontality can be regulated. The jacking system shall ensure that the sliding
formwork assembly can be hoisted evenly.
The use of hoisting systems that work without jack rods shall be subject to the
Engineer's approval.
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All equipment shall be thoroughly tested and inspected before installation and
shall be maintained in good working order throughout the sliding operation.
The Contractor shall keep adequate back-up equipment and quantities of

materials on Site in order to ensure that the sliding can proceed without
interruption.
(ii) Instrumentation and Monitoring
The Contractor shall supply and install suitable instrumentation on the sliding
platform, foundations and at the slides of the structure to monitor the height,
verticality, twisting and horizontality at regular intervals. The equipment
used, the utilization thereof and frequency of recording readings shall be
approved by the Engineer.
The Contractor shall be responsible for all monitoring work and shall ensure
that records of all readings and measurements taken are filed systematically
and are at all times available to the Engineer and the person in control of the
sliding operation.
Unless otherwise specified the verticality of the structure shall be controlled

with laser alignment apparatus or optical plummets, and the horizontality of
the sliding forms with a water-level system with reference control points
placed at strategic locations.
Height and verticality shall be monitored at intervals not exceeding 4 hours.

The measurements shall be plotted immediately on graphs. When the
structure is more than 10 mm out of vertical the Engineer shall be notified
immediately.
(iii) Supervision
During the entire duration of the sliding operations a competent person who is
fully acquainted with the sliding technique and the Contractor's methods of
construction shall be in attendance on the sliding platform and in control of
the sliding operations.
(iv) Construction
The jacking frame shall be constructed with adequate clearance between the
underside of the cross members and top of the formwork to allow the
horizontal reinforcement and embedded items to be correctly installed. A
control procedure shall be agreed on by the Contractor and the Engineer in
order to ensure that all the reinforcement is placed. At all times there shall be
horizontal reinforcement above the level of the top of the formwork panel.
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Guides shall be provided in order to ensure that the vertical reinforcement can
be placed correctly and that the specified concrete cover over the
reinforcement is maintained.
Where the jack rods are to be recovered, adequate provision shall be made for
their removal without causing damage to the concrete.
Where jack rods occur at openings or chases, adequate lateral support shall be
provided to prevent buckling thereof.
Equipment and material shall be distributed on the working platforms in such

a manner that the load is distributed evenly to the jacks.
Deflector plates shall be provided at the top of the forms of the outside walls
to prevent concrete from falling down the outside.
The framework, forms and platforms shall be cleaned regularly so as to

prevent the accumulation of redundant concrete.
The Contractor shall take all precautions to prevent contamination of the

concrete through oil leaks or other causes.
(v) Sliding
The Contractor shall give the Engineer 24 hours notice of his intention to
commence with a slide. Permission to commence with the slide shall not be
given by the Engineer until the sliding formwork assembly is fully operative
and the complete stock of all materials that required for the slide as well as
back-up equipment are on Site.
The Contractor shall ensure that the rate of sliding is such that the concrete at
the bottom of the formwork has obtained sufficient strength to support itself
and all loads that may be imposed upon it at the time, and that the concrete
does not adhere to the sides of the forms.
The sliding operations shall be continuous, without any interruptions, until

the full height of the structure is reached, and shall be geared and organized
for an average rate of sliding of 350 mm/h.
(vi) Interruptions
When the sliding operations are delayed for more than 45 minutes, the
Contractor shall prevent adhesion of the setting concrete to the formwork
panels by easing the forms or by moving them slightly every 10 minutes, or
alternatively, where reversible jacks are used, by lowering the forms by 10
mm - 25 mm. Wherever interruptions occur emergency construction joints
shall be formed and treated in accordance with Sub-clause 6.1.5.1. Before
concreting is restarted, the form shall be adjusted to fit snugly into the
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hardened concrete so as to avoid steps forming on the exposed concrete

surface. When sliding is recommenced care shall be exercised to prevent the
fresh concrete from being lifted off from the old concrete.
(f) Permanent Formwork
Void formers shall be secured in position at regular intervals to prevent displacement

and distortion during concreting. The void formers shall be supported on pre-cast
concrete blocks or rigid welded steel cradles, all subject to the approval of the
Engineer. The ties securing the void formers shall be attached to the formwork and
cross bearers of the false-work. The void formers shall not be tied to or be supported
on the reinforcement.
Asbestos cement plates shall be supported so that the plate spans in direction parallel
to the orientation of the asbestos fibres.
(g) Preparation of Formwork
The surfaces of forms that are to be in contact with fresh (wet) concrete shall be
treated to ensure non-adhesion of the concrete to the form and easy release during
stripping of the formwork.
Coating compounds and agents shall be applied strictly in accordance with the
manufacturers instructions and every precaution shall be exercised to avoid
contamination of the reinforcement, pre-stressing tendons and anchorages. In the
selection of compounds and agents due regard shall be given to the necessity for
maintaining a uniform colour and appearance of exposed concrete surfaces.
Before placing the concrete all dirt and foreign matter shall be removed from the
forms and the forms shall be thoroughly wetted with water.
6.3.4 Contractor's Responsibilities
Notwithstanding the approval given by the Engineer for the design and drawings
prepared by the Contractor for the false-work and formwork as constructed, the
Contractor shall be solely responsible for the safety and adequacy of the false-work and
formwork and shall indemnify the Employer and the Engineer and keep them
indemnified against any losses, claims or damages whatsoever to persons or property,
which may arise out of or in consequence of the design, construction, use and
maintenance of the false-work and formwork and against all claims, demands,
proceedings, damages, costs, charges and expenses whatsoever in respect thereof or in
relation thereto.
For works on, over, under or adjacent to any railway line, the Contractor shall comply,
inter alia, with the requirements for the preparation and submission of drawings for false-
work and formwork, and the submission of certificates for the proper construction
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thereof, all in accordance with the specifications issued from time to time by the railway
authority.
After construction of the false-work and formwork, and prior to the placing of reinforcing
steel and/or placing of concrete, the Contractor shall inspect the false-work and
formwork. Dimensions shall be controlled, unevenness of surface shall be corrected and
special attention shall be paid to the adequacy and tightness of bolts, ties and bracings as
well as to the soundness of the foundations.
The Contractor shall give the Engineer at least 24 hours notice of his intention to place
concrete, in order to enable him to inspect all aspects of the work completed. However,
before notifying the Engineer, the Contractor shall satisfy himself that the work complies
with the Specifications in all respects.
(a) Except as stated below, formwork shall be measured by the square metre of
formwork actually in contact with the finished face of the concrete. No deductions
shall be made in the measurement for openings, pipes, ducts and the like, provided
that the area of each is less than 0.50 square metre. Unless otherwise stated, if the
volume on area of concrete has not been deducted in accordance with other
directions, formwork to the face of the void shall not be measured.
(b) Formwork less than 300 mm high to edges of slabs shall be measured by the linear
metre.
(c) Separate items are provided for formwork to produce the various classes of surface
finish stated in this Standard Specification.
(d) Unless otherwise stated, inclined formwork shall be measured in accordance with the
following classification:
(a) Horizontal 85 to 90o inclination from vertical

(b) Sloping 10 to 85o -
o
(c) Battered 0 to 10 -
(d) Vertical 0o -
(e) Unless otherwise stated, separate items are provided for formwork to sloping upper
surfaces inclined at more than 15o from the horizontal.
(f) Formwork required for blinding concrete, to form construction joints and shear keys
for future concrete and other construction surfaces shall not be measured and the
costs shall be included in the rates for other work.
NOTE: The Contractor may, in a covering letter to the Tender, submit a lump sum reflecting
a saving in cost for the use of sliding formwork in lieu of the conventional formwork.
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6.4 PRECAST CONCRETE
Scope
Pre-cast concrete covers all pre-cast units for use in the Works, whether instructed under
the Contract or proposed by the Contractor, and includes pre-stressed units where
applicable. Additional requirements for pre-stressed units are set out in Paragraph 6.5 of
this Standard Specification.
6.4.1.1 Formwork
Moulds for pre-cast units shall comply with the general requirements of Sub-clauses
6.3.1.2 (b) and (c).
Moulds shall be so constructed that they do not suffer distortion or dimensional changes
during use and are tight against loss of cement or fines from the concrete.
Forms shall be constructed to produce pre-cast units accurate to the dimensions shown on
the Drawings and within the tolerances specified in the Contract.
Moulds shall be set up on firm foundations so that no settlement occurs under the weight
of the fresh concrete.
Moulds shall be constructed so that units may be removed from them without sustaining
any damage.
Release agents used for de-moulding shall not stain the concrete or affects its properties
in any way.
6.4.1.2 Reinforcement
Reinforcement in pre-cast units shall comply with the requirements of Paragraph 6.2.
When preformed cages are used the cages shall be made up on jigs to ensure dimensional
accuracy and shall be carefully supported within the mould in such a way that they cannot
move when concrete is placed. Reinforcement complying with BS 4449 may be tack
welded where bars cross to provide rigidity in the cage but reinforcement complying with
BS 4461 shall not be welded.
Cover to main reinforcement shall conform to Table 6.2.1.3/1 or as instructed by the

Engineer but not less than 25 mm or the diameter of the bar, whichever is the greater.
Cover on distribution steel shall not be less than 15 mm or the diameter of the bar
whichever is the greater if so permitted by the Engineer.
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Bars shall be spaced so that the minimum clear distance between them is the maximum
nominal aggregate size plus five millimetres but in any case not less than the diameter of
the bars.
Bars may be placed in pairs provided that there are no laps in the paired lengths.
6.4.1.3 Concrete
Concrete for pre-cast units shall comply with Clauses 6.1.2 to 6.1.6 using the class of
concrete specified on the Drawings.
6.4.2 Construction
6.4.2.1 Casting
The area in which units are cast shall be adequately protected from the weather so that the
process is not affected by rain, sun or drying winds.
The formed faces of pre-cast units shall be finished to Class F3 as set out in Sub-clause
6.1.4.3 unless another class of finish is specified on the Drawings.
Free faces shall be finished to Class F2 unless another class of finish is specified on the
Drawings.
In cases where a special finish is required a trial panel shall be constructed by the
Contractor which after approval by the Engineer shall be kept available for inspection at
the place of casting, and production units shall thereafter match the approved pattern.
Those parts of the units which are to be joined to other units or to in situ concrete shall be
brushed with a stiff brush before the concrete has fully hardened. Alternatively, if the
concrete has been allowed to harden, the surfaces shall be roughened by sand blasting or
the use of a needle gun.
6.4.2.2 Curing
Requirements for curing shall be generally as set out in Clause 6.1.4.4
The Contractor shall ensure that units do not suffer any loss of moisture or sudden
changes of temperature for at least four days after casting. If a water spray is used for
curing, the water shall be at a temperature within 5oC of the temperature of the unit being
cured.
If the Contractor proposes curing at elevated temperatures, the method shall be subject to
the agreement of the Engineer and shall include means whereby units are heated and
subsequently cooled evenly without sudden changes of temperatures.
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6.4.2.3 Handling and Storing
Pre-cast units shall be handled in a manner which will not cause damage of any kind an
shall be stored on a hard impermeable base. Pre-stressed units and large pre-cast
normally reinforced units shall be handled and stored so that no stresses shall be induced
in excess of those which they will incur in their final positions in the Works unless they
have been designed to resist such stresses.
Units shall be provided with adequate lifting holes or loops, placed in the locations
shown on the Drawings or agreed by the Engineer and they shall be lifted only by such
holes or loops.
Where it is not possible to provide holes or loops, suitable sling positions shall be
indicated in paint on the units.
Units shall be marked indelibly with the reference number and date of casting and shall
be stacked on suitable packers which will not damage the concrete or stain the surfaces.
Not more than two packers shall be placed under each unit and these shall be located
either at the positions of the permanent support points or in positions such that the
induced stresses in the unit will be a minimum.
6.4.2.4 Testing
Pre-cast units shall be capable of safely sustaining the loads which they have been
designed to carry. If instructed by the Engineer, the Contractor shall subject units selected
by the Engineer to load tests simulating the working conditions. Details of such tests
shall be agreed between the Engineer and the Contractor.
In the case of units subject to bending loads, the test piece shall be supported at full span
and a loading equivalent to 1.25 times the sum of the live and dead loads which were
assumed in the design shall be maintained for one hour without the appearance of any
signs of distress. The recovery one hour after the removal of load shall be not less than 75
per cent of the full load deflection.
If the unit fails to meet the above requirements, further tests shall be carried out on two
more units. If either of these fail the whole batch of units will be rejected.
If the Engineer so requires, a test to destruction shall also be carried out which on units
subject to bending shall be as follows:
The units shall be supported at full span and a load applied in increments instructed
by the Engineer up to 95 per cent of the designed ultimate load. This load shall be
held for 15 minutes without failure of the unit. The deflection at the end of this
period shall be not more than 1/40th of the span. The load shall then be further
increased until failure occurs.
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If the unit fails to sustain the required load for the prescribed period or if the deflection
exceeds the specified amount, the Engineer may order two further tests, and if either of
these fail, the batch of units which they represent will be rejected.
(a) Pre-cast concrete shall be measured by the number of elements of each type, or by
the metre or cubic metre as stated and required.
(b) The rates shall include for the applicable costs stated in Article 6.1.7 (d) above and
for the cost of formwork, moulds, reinforcement, casting, curing, surface finish,
handling, storing until required, transporting and fixing the finished unit in position
including all stools, bolts, lifting holes, loops and other means of handling the unit
and holding it in position and jointing.
(c) Load tests shall be measured by number. The rates shall include for the cost of
provision of the unit and testing. If any unit fails to meet the requirements of the
specification, the unit and the load test shall not be measured.
6.5 PRESTRESSED CONCRETE
Scope
This section covers the materials, equipment and work required to prestress structural
concrete members.
6.5.1 General
6.5.1.1 Definitions
The following definitions and terms shall apply to this section:
(a) Anchorage
Anchorage is the device comprising all the components and materials required to
retain the force in a tensioned tendon and to transmit this force to the concrete of the
structure.
(b) Anchorage Reinforcement
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Anchorage reinforcement is the spiral and other reinforcement that forms part of the
anchorage and is required to strengthen the anchorage and/or assist in transmitting
the tendon force to the concrete.
(c) Bursting Reinforcement
Bursting reinforcement is the reinforcing steel required in and adjacent to the

anchorage zones to resist the tensile stresses induced in the concrete by the
anchorage(s).
(d) Cable
Cable is the tendon together with the anchorage, sheathing and all fittings.
(e) Characteristic Strength
Characteristic strength of pre-stressing steel is the manufacturers guaranteed tensile

strength and no more than 5 per cent of the test results in a statistical population shall
fall below this strength.
(f) Duct
Duct is the void formed to house the tendon(s) and may be formed by coring, sheaths
or extractable cores.
(g) Pre-stress
Pre-stress is the stress induced in concrete in which effective internal stresses are
induced by means of tensioned tendons.
(h) Pre-stressed Concrete
Pre-stressed concrete is structural concrete in which effective internal stresses are

included by means of tensioned tendons.
(i) Pre-tensioned Concrete
Pre-tensioned concrete is pre-stressed concrete where the tendon is tensioned before

the concrete has been cast.
(j) Post-tensioned Concrete
Post-tensioned concrete is pre-stressed concrete where the tendon is tensioned after

the concrete has hardened.
(k) Pull-in
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Pull-in is the elastic shortening of the tendon caused by relative movement between
the anchorage or coupler components due to seating and gripping action during or
immediately after transfer.
(l) Release
Release is the specified elastic shortening of the tendon at the anchorage that shall be
achieved before or during transfer.
(m) Sheath
Sheath is the tube or casing enclosing the tendon and which temporarily or
permanently allows a relative movement between the tendon and the surrounding
concrete.
(n) Tendon
Tendon is the pre-stressing steel consisting of the bar, wire or strand individually
placed, or bars, wires or strands placed in a duct, all of which are tensioned to impart
pre-stress to a concrete member.
(o) Tensioning
Tensioning is the action of inducing and regulating the force in a tendon by means of
tensioning and measuring equipment.
(p) Transfer
In the case of post-tensioned concrete transfer is the action of transferring the

tensioning force from the tensioning equipment (jack) to the anchorage.
In the case of pre-tensioned concrete transfer is the action of transferring the force in
the tensioned tendon(s) to the concrete.
6.5.1.2 General Provisions
Pre-stressed concrete work shall be carried out in accordance with the recommendations
of BS 5400: Part 7 and 8 Recommendations for Materials and Workmanship: Concrete,
reinforcement and pre-stressing tendons, except that where the requirements of the code
differ from this Standard Specification, the Standard Specification shall govern.
The Contractor shall submit to the Engineer full details of the equipment he proposes to
use for the installation of pre-stressing tendons, the materials he proposes to use and the
arrangements he proposes to make. He shall also submit evidence of his competence to
undertake the installation.
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6.5.2 Construction
6.5.2.1 Ducting
All ducting shall be sufficiently strong to withstand without damage the stresses to which
it may be subjected during handling and after being fixed in position. The ducting shall
completely protect the wires or cables from contact with concrete and the Contractor
shall ensure that the wires or cables are completely free in the duct before tensioning.
Any ducting which has been damaged during transportation to the Site or which in the
opinion of the Engineer is inadequate for its purpose shall not be used in the Works.
Ducting shall be free from loose material, oil coatings, or other contaminants which may
affect the bond with the concrete.
The stools, saddles or supports for the ducts shall be of rigid construction and of such
form that they remain securely in position and maintain the correct profile of the cables
until the concrete placed round them has hardened.
Vents shall be incorporated into each duct at high and low points, at each end and at
intermediate points not more than five metres apart. Blocking of vents during concreting
operations shall be prevented.
6.5.2.2 Anchorages
Anchorages shall be the correct type for the pre-stressing system used and shall be rigidly
fixed true to alignment in the formwork so that they cannot move during concreting
operations. The anchorages shall be provided with means for injecting grout into the
ducts.
If the anchorage is fixed after the main body of the concrete has been placed, it shall be
carefully bedded so that it is bearing evenly and is in intimate contact with the concrete.
6.5.2.3 Pre-stressing Tendons
Tendons used in pre-stressed concrete shall comply with the British Standards indicated
on the Drawings. The Standards include the following:
BS 5896 for High Tensile Steel Wire

BS 4486 for High Tensile Alloy Steel Bars
BS 5896 for 7 Wire Steel Strand
BS 4757 for 19 Wire Steel Strand
Tendons shall be stored on Site under cover and protected from the weather. The storage
area shall have a hard impermeable floor. Tendons shall be stored either straight or in the
coils in which they left the factory.
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Tendons shall not be allowed to become affected by excessive rusting or by pitting of the
surface by corrosion. If pitting is present, the Contractor shall replace the affected
tendons by new ones.
6.5.2.4 Installation of Pre-stressing Tendons
Pre-stressing steel shall be cut by rotating disc or blade cutters or by such method as is
recommended by the manufacturer.
Before being installed, pre-stressing tendons shall be thoroughly cleaned of mill scale,
mortar, oil, paint, dust, grease, or any other deleterious matter whatsoever, to the
satisfaction of the Engineer.
The pre-stressing steel (or where the tendons are accommodated in ducts, the sheaths,
ducting or formers) shall be accurately placed in the positions shown on the Drawings
and shall be firmly secured in position. Wooden supports shall not be used nor shall the
sheaths, ducting or formers be placed on previous layers of fresh concrete or be adjusted
during the placing of concrete.
The pre-stressing steel, sheaths, ducting or formers shall be so placed and secured that
twisting, kinking or excessive deformation during and subsequent to concreting is
eliminated and the pre-stressing tendons when finally stressed shall conform accurately to
the profiles shown on the Drawings. Ducts and formers shall not be placed with small
radius bends which would induce excessive frictional restraint on the wires or strands.
Where many individual wires or strands are placed in a duct, adequate provision shall be
made to keep the wires separated by means of suitable spacers of approved design,
construction and spacing.
6.5.2.5 Jacks for pre-stressing
Jacks for tensioning tendons shall be hydraulically operated and capable of providing a
slow uniform increase of load. Each jack shall be equipped with an appropriate pressure
gauge capable of indicating the hydraulic fluid pressure at all times during the stressing
operation. A certified calibration chart showing the relationship between gauge readings
and force on the ram for both ascending and descending ram movements shall be
available on the Site.
The Contractor shall maintain tensioning jacks in good working order and shall ensure
true and accurate readings by regular testing, calibration and servicing.
6.5.2.6 Tensioning Operations
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Pre-stressing force, whether partial or full, shall not be transferred to the concrete until
cube compressive strength tests have indicated that the concrete has attained the strength
specified on the Drawings.
Stressing of the tendons shall be carried out with due care by experienced workmen
under competent supervision and adequate steps shall be taken to safeguard against
injury.
Full and accurate records shall be kept of all stressing operations and two copies of the
record, which shall include wedging-device slip measurements during anchoring, loads
and extensions, shall be submitted to the Engineer on the day following each stressing
operation. The accuracy of the measurement of cable extensions shall be plus or minus
two per cent. The Engineer may order the Contractor to cease any or all stressing
operations where proper records are not being kept or where the operations are not being
properly or safely carried out and the Contractor shall take immediate steps to ensure that
the work is carried out to the satisfaction of the Engineer.
Where the required tensions or extensions are not obtained, the tendons shall be re-
tensioned as directed by the Engineer. If on re-stressing, the extensions are not achieved,
the Engineer may at his discretion reject the tendons involved.
6.5.2.7 Post-tensioning
When a post-tensioning system is employed, all cable ducts, excluding extractable

formers shall be thoroughly flushed with water immediately after concreting and before
the concrete has hardened.
Ducts produced by extractable formers shall be flushed out as soon as the concrete has
hardened.
Where anchorage of the pre-stressing tendons is by friction grips or wedges and where no
other slipping limitation is specified, the slip of each individual pre-stressing steel
element, both during tensioning and after anchoring shall not exceed seven millimetres.
Tendons failing to satisfy this limitation shall be re-stressed.
The sequence of stressing shall be as shown on the Drawings and shall be such that
lateral eccentricity of stress on any member is reduced to a minimum.
After stressing and anchoring, no tendon shall be cut, bent or in any way deformed until
the bonding grout or concrete is at least seven days old.
Where tendons are cut back, the exposed ends of the tendons and anchorages shall be
heavily coated with an approved bituminous compound or epoxy resin to prevent
corrosion of the pre-stressing steel.
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6.5.2.8 Pre-tensioning
Pre-tensioning tendons shall be either crimped or indented wire, ribbed or deformed alloy
bar or strand complying with the requirements of Sub-clause 6.5.2.3.
The tendons shall be anchored in such a manner that during concreting they will not
suffer any loss of tension whatsoever due to anchorage yield or deficiency or due to
yielding of the pre-stressing beds. No variation in the tension of the tendons shall be
made subsequent to the commencement of concreting until transfer of pre-stressing force
to the concrete is authorized.
At the appropriate time the pre-stressing force shall be transferred to the concrete
uniformly by means of slow de-tensioning. The tendons shall not be de-tensioned
individually and the de-tensioning operation shall be applied to all the tendons
simultaneously. Where a set of tendons passes through several units, the units shall be
free to move longitudinally during de-tensioning.
The pre-stressing steel shall be cut off flush with the end of the member and the exposed
ends of the pre-stressing steel and anchorages shall be heavily coated with an approved
bituminous compound or with an epoxy resin to prevent corrosion of the pre-stressing
steel.
6.5.2.9 Bonding and Grouting
The post-tensioned tendons shall be intimately bonded to the adjacent concrete by means
of concrete or, in the case of internal cables, by colloidal cement grout after stressing and
anchoring
The properties of grout, the equipment and the grouting procedure shall be as follows:
(a) The grout shall be a colloidal mix of water and ordinary Portland cement in the ratio
of between 0.40 to 1.00 and 0.45 to 1.00 by weight.
(b) Admixtures of an approved type may be authorized by the Engineer for incorporation
in the grout if tests have shown that their use improves the properties of the grout, for
example by increasing the workability, by reducing bleeding, by entraining air or by
expanding grout.
Admixtures shall not contain chlorides or nitrates. When an expanding agent is used,
the total unrestrained expansion shall not exceed 10 per cent.
(c) The mixing equipment shall be of a type capable of producing grout of uniform
consistency with fully dispersed cement particles and shall incorporate suitable
sieves for retaining lumps or other solid ingredients. After water has been added to
the mixer, the cement shall be added. Admixtures if used shall be added during the
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latter half of the mixing time. High speed mixing shall be carried out continuously
for between two and four minutes in a close clearance high speed centrifugal mixer.
Subsequent to mixing and prior to injection the grout shall be continuously agitated
by slow machine mixing. Any grout that has been left standing for more than 30
minutes shall be discarded and the container thoroughly washed before further
mixing is carried out.
(d) A positive displacement pump shall be used for injecting the grout, capable of
developing a pressure of at least one MPa. The pump shall be fitted with a pressure
gauge and an effective control against build-up of excessive pressure. The pump
suction intake shall be kept below the surface level of the grout at all times during
grouting operations.
(e) All tendons shall be grouted in their ducts as soon as practicable after the stressing
operation. Each duct shall be cleaned by blowing through compressed air, flushing
with clean water and surplus water shall be removed by compressed air or other
approved means. Openings at the anchorages other than grout injection nozzle
openings shall be plugged with mortar or other suitable material. Subsequent to the
hardening of the plugging material the nozzle of the injection pipe shall be firmly
connected to the duct in such a way that air cannot be sucked in. Injection shall be
commenced from one end only, and its progress monitored by the appearance of
grout at successive vent holes. When the consistency of the grout emerging from a
vent is equal to that of the grout being injection, that vent shall be plugged.
Injection shall continue until grout of a consistency equal to that being injected
appears at the far end of the duct. The injection nozzle shall then be withdrawn and
all holes and vents plugged to prevent loss of grout.
As far as possible all ducts in any one member shall be grouted in immediate
succession commencing with the lowest duct.
Grouting shall not be carried out when the air temperature is 2oC or lower.
The temperature of newly grouted cable ducts shall be prevented from falling below
2oC for a minimum period of seven days.
6.5.3 Quality of Finished Units
6.5.3.1 Camber of Beams
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Where the predicted camber due to stressing pre-cast beams is indicated on the Drawings,
the actual camber shall not exceed the stated figure by more than 50 per cent.
Where a number of similar units are to be placed side by side, the variation in camber
between adjacent units shall not be more than 6.0 mm for units up to 4.5 metres in length,
or more than 9.0 mm for longer units.
6.5.3.2 Tensional Conditions
Any structural element in which the pre-stressing tendons, the anchorages, or any part
whatsoever of the pre-stressed element has been damaged, or in which excessive loss of
pre-stress has occurred or in which the grouting has not been satisfactorily carried out, or
which is deficient in any other manner, will be rejected and the Contractor shall rectify
the deficiency to the satisfaction of the Engineer, failing which the element shall be
replaced by the Contractor.
6.5.3.3 Testing Pre-stressed Units
If instructed by the Engineer, load testing of structures containing pre-stressed units shall
be carried out generally as set out in BS 5400 Part 2: Specifications for Loads.
Pre-cast units shall be tested in accordance with Section 6.1 of this Standard
Specification and in addition, where a test of the pre-stressing is required, the unit shall
be subjected for a period of five minutes to a load which is calculated to result in a
bending tensile stress in the bottom surface equal to one tenth of the nominal strength of
the concrete. The pre-stressing shall be deemed to be effective if no cracking is observed
during the test.
Details of all testing procedures shall be agreed between the Engineer and the Contractor
before testing is commenced.
6.5.4 Storage and Handling Units
6.5.4.1 Transport and Storage
Unless otherwise agreed, pre-stressed concrete units shall be transported in the same
attitudes and under the same support conditions as they will have in the final structure.
All transporting and storing of pre-stressed units shall be to the satisfaction of the
Engineer, and the Contractor shall ensure that all methods of handling, transporting and
storing pre-stressed units shall be such as to prevent over-stressing or any other damage.
6.5.4.2 Jointing Pre-cast Units
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Where a load bearing structure is to be formed by tensioning together a string of pre-cast

units, the joints between the units shall be formed as shown on the Drawings by one of
the methods set out below so as to achieve a uniform transfer of stress across the joint.
(a) Joints shall be set between 20 and 30 mm wide and shall be packed solid with mortar
mixed in the proportion of one part of cement to 1.5 parts of sand with water
sufficient only to allow the mix to cohere when squeezed in the hand. The mortar
shall be rammed thoroughly into the joint, using formwork to retain it where
necessary.
(b) Where joints are shown on the Drawings as 75 mm or wider, they shall be filled with
concrete of a class similar to that used in the units or as shown on the Drawings. The
concrete shall be compacted by vibration and retained by formwork.
(c) Procedure when using resin adhesives for jointing will depend on the configuration
of the joint and the type of adhesive to be used and will be subject to the Engineer's
agreement.
Irrespective of the method of joint filling employed, the joint shall be completely
filled with material having a uniform consistency. The joint faces shall be flat
without any high spots which might cause local stress concentrations.
Ducts for tendons shall be truly aligned between units and the duct joints in the gap
between units shall be carefully formed and impervious to the entry of grout from the
joint filling operation.
(a) Pre-stressed concrete shall be measured in accordance with paras. 6.1.7 (a) to 6.1.7
(h) and 6.4.3 (a) to 6.4.3 (c) of Section 6 as applicable.
(b) For in situ concrete, tendons shall be measured by the number required for each type
and each length. The length shall be measured along the line of the tendon between
the outside faces of the anchorage units cast into the concrete.
(c) The rates for tendons shall include for the cost of:
- ducting with stools, saddles or supports and vents;

- anchorages;
- wires, bars or strands;
- stressing with use of jacks and provision of records;
- bonding with cement grout and admixtures.
(d) For pre-cast concrete, no separate measurements shall be made for tendons.
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(e) Load tests on pre-stressed units shall be measured in accordance with article 6.4.3(f)
of this Section.
6.6 MISCELLANEOUS
6.6.1 Porous Concrete

Porous concrete is a mix of gravel, graded from 40 to 10 mm without sand, ordinary
Portland Cement and water. When placed and compacted it shall be free draining.
Porous concrete shall only be used where shown on the Drawings or instructed by the
Engineer.
6.6.1.1 Materials
Cement, aggregate and water shall comply with specifications given in Clause 6.1.1
When used in drainage layers the aggregate shall comply with specifications given in
Clause 5.6.5.
The mix shall be made as specified in Clause 6.1.3. The weight of cement mixed with 0.3
m3 of aggregate shall not be less than 50 kg. The quantity of water shall not exceed that
required to produce a smooth cement paste which will coat evenly the whole of the
aggregate, but will not flow when the porous concrete is placed and compacted.
Porous concrete shall be placed in layers of not more than 250 mm thickness and
compacted by external vibration. No strength nor density requirements are applicable.
The finished surfaces shall be cured and protected as specified in Sub-clause 6.1.4.4.
6.6.1.3 Measurement and Payment
Clause 6.1.7 shall apply to porous concrete works.
6.6.2 Mortar
This Clause covers mortar for use ahead of concrete placing, and other uses not covered
elsewhere in the Specification.
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Mortar shall be composed of fine aggregate complying with Sub-clause 6.1.1.2 (a) and
ordinary Portland cement complying with Sub-clause 6.1.1.1. The mix proportions shall
be as stated on the Drawings or elsewhere in this Specification or if not stated shall be
one part of cement to two parts of fine aggregate by weight.
Small quantities of mortar may be hand mixed but for amounts over 0.5 m3 a mechanical
mixer shall be used.
The water content of the mortar shall be as low as possible consistent with the use for
which it is required but in any case the water/cement ratio shall not be more than 0.5.
Mortar which is specified as "dry pack" shall be mixed with sufficient water for the mix
to become cohesive but not plastic when squeezed in the hand. Dry pack mortar shall be
rammed into the cavity it is required to fill, using a hand rammer with sufficient force to
ensure full compaction.
6.6.3 Remedial Work to Defective Surfaces
6.6.3.1 General
Any remedial treatment to surfaces shall be agreed on with the Engineer following
inspection immediately after the removal of the formwork, and shall be carried out
without delay. No surface may be treated before inspection by the Engineer.
6.6.3.2 Repairs
Surface defects such as small areas of honeycombing, cavities produced by form ties,
large isolated blowholes, broken corner edges, etc. shall be repaired as directed by the
Engineer.
Where in the opinion of the Engineer the extent of the honeycombing or defects is such
that doubt exists about the effectiveness of repair work, the Contractor shall, at his own
cost, perform a load test in accordance with Sub-clause 6.1.6.2 prove that the structural
safety of the repaired member has not been impaired; failing which the structure shall be
rebuilt in part or in full at the Contractor's cost.
6.6.3.3 Rubbing of Surfaces
If the finish of exposed formed surfaces does not comply with the requirements for
uniformity of texture, appearance and colour, the Contractor shall, when instructed to do
so by the Engineer, rub down the exposed surfaces of the entire structure or any part
thereof as specified below.
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Where the concrete surfaces formed by sliding formwork require treatment in order to
achieve the surface finish specified for the member, the concrete shall, as soon as the
surfaces are exposed under the formwork, be floated with rubber-lined floats to the
desired finish.
6.6.4 Joints in Structures
Scope
This Clause covers the supply and installation of all permanent joints that permit relative
movement between contiguous structural members.
6.6.4.1 Materials
All materials used in the forming, construction and sealing of permanent joints, as well as
all proprietary or custom-built expansion joint assemblies shall be subject to the approval
of the Engineer.
When required by the Engineer the Contractor shall submit test certificates from an
approved, independent testing authority to show that the respective materials comply
with the specified requirements, or a certificate from the patent holder or designer
certifying that the manufactured item complies in all respects with relevant product
specifications.
(a) Joint Filler
Joint filler shall consist of sheets or strips of the following materials complying with
the requirements of the relevant specifications listed:
(i) Bitumen-impregnated fibre board and bitumen-impregnated cork board - U.S.

Federal Specification HH-F-341F or AASHTOM213.
(ii) Resin-impregnated cork board - U.S. Federal Specification HH-F-341F.
(iii) Flexible foams of expanded polyethylene, polyurethane, PVC or

polypropylene - AASHTO M153.
(iv) Rigid foams of expanded polyethylene, polyurethane or polystyrene - BS

4840 or BS 3837.
Other joint-filler materials may be used if approved by the Engineer after

submission of full specifications and information by the Contractor.
(b) Sealants
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(i) Thermoplastic hot-poured sealants shall comply with the requirements of U.S.
Federal Specification SS-S-1401B, BS 2499 or AASHTO M173.
The sealants shall be of the rubberized bituminous type containing a

minimum of 20% natural or synthetic rubber.
(ii) Thermoplastic cold-applied sealants shall comply with the requirements of

U.S. Federal Specification SS-S-156.
The sealants shall be of the rubberized bituminous type containing a

minimum of 20% natural or synthetic rubber.
(iii) Thermosetting chemically curing sealants shall comply with the requirements
of U.S. Federal Specification SS-S-195B, American National Standards
Institute Specification ANSI A 116.1 (formerly ASA A 116.1 and USASI A
116.1) or BS 4254.
The final IRHD (international rubber hardness degree) of the sealant shall be
20 +- 5.
Other sealants may be used if approved by the Engineer after submission of

full specifications and information by the Contractor.
(c) Preformed Elastomeric Compression Seals
Preformed elastomeric compression seals shall comply with the requirements of

M220.
(d) Water stoppers
Water stoppers shall be of natural rubber, or flexible PVC, and of the type specified
or shown on the Drawings.
(i) Natural rubber water stoppers shall comply with the requirements of
AASHTO M198 Type A.
(ii) Flexible PVC rubber water stoppers shall comply with the requirements of
AASHTO M198 Type B.
(e) Accessory Materials
(i) Primers
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When a primer is to be used in conjunction with the sealant, it shall be of the

prescribed proprietary material.
(ii) Adhesives
Adhesives used in conjunction with preformed seals shall be of a proved and

approved type compatible with the material of the seal.
(iii) Bond Breakers
Polyethylene tape, coated papers, metal foils or similar material may be used
where bond breakers are required.
(iv) Back-Up Material
Back-up material shall consist of a compressible material of correct width and

shape in order to ensure that after installation it is in approximately 50%
compression and the sealant can be formed to the specified depth.
Back-up materials shall be compatible with the sealant used. Material

containing bitumen or volatiles shall not be used with thermosetting
chemically curing sealants.
(a) Filled Joints

Filled joints shall be accurately formed to the dimensions shown and with the filler
material specified on the Drawings. The filler shall be secured in position so that it is
not displaced during concreting or thereafter if the filler is to remain permanently in
the joint.
Wherever polystyrene or similar material susceptible to damage is used to form

joints, it shall be lined with a hard surface on the side to be concreted. The hard
surface shall be sufficiently resilient to ensure that the joint and surfaces can be
formed free from defects.
(b) Concrete Nosings
Concrete nosings forming the edges of expansion joints shall be constructed as

follows:
After the concrete in the structural member has hardened sufficiently, the protruding
ends of the reinforcing steel shall be bent flat onto the concrete surface of the formed
recess.
Before the asphalt surfacing is laid, the recess shall be filled with well-compacted
crusher run sand or weak mortar. The Contractor shall ensure that the concrete
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surfaces and reinforcing steel are not contaminated with bituminous agents.
Thereafter the asphalt surfacing shall be laid continuously over the joint.
The asphalt surfacing corresponding to the width of the nosing shall be cut with a
diamond saw blade and all material shall be removed from the nosing recess. The
concrete surfaces of the recess shall then be roughened to expose the aggregate and
to leave a sound irregular surface. The reinforcing steel shall thereafter be bent, fixed
and placed as detailed on the Drawings.
Immediately before the concrete nosings are cast, the prepared concrete surfaces shall
be treated with an approved epoxy resin adhesive. Opposite concrete nosings,
separated by a 10 mm thick joint filler stick, shall be cast simultaneously in
accordance with Sub clause 6.1.5.1 and be compacted by a surface vibrator. The
nosing shall be screeded flush with the premix surfacing and given a Class U2
surface finish.
Curing shall be in accordance with Sub clause 6.4.2.2 except that the curing period
shall be 10 days.
After the concrete in the nosing has cured for at least 3 days, the gap between the
nosings shall be enlarged to the requisite dimensions by cutting both sides with
parallel diamond saw blades. The depth of the saw cut shall be such that a ledge is
formed along the lower edge of the cut on which the sealer unit can be supported.
The exposed corners of the nosings shall be ground to have a 10 mm chamfer.
After the joint has been sealed, the wearing surface of the nosings shall be treated
with a bituminous primer to the satisfaction of the Engineer.
Traffic shall not be permitted to pass over the joint before the concrete in the nosing
has aged for at least 10 days.
The concrete used in the construction of the nosings shall be Class 40/14 and shall h
ave a slump of not less than 50 mm and not exceeding 75 mm.
(c) Epoxy Mortar Nosings
Epoxy mortar nosings shall not be used unless detailed on the Drawings and
specified in the Specifications of Particular Application. Where epoxy mortar
nosings are permitted, they shall be constructed in accordance with the requirements
specified in the Specifications of Particular Application.
(d) Sealing of Joints
Sealed joints shall be made watertight over the full length of the joints, unless
otherwise permitted by the Engineer.
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Unless a water stopper is equipped with an effective watertight interlocking system

for the joining of sections, all joints in water stoppers shall be bonded or fused to
have a tensile strength of at least 50% of that of the un-jointed material. At
intersections and abrupt changes of direction, water stoppers shall be jointed with
prefabricated junction pieces.
Restrictions on joint width and temperature at the time of installation of the sealant
or seal will be shown on the Drawings. In the absence of these and unless otherwise
specified, installation shall be carried out only within the temperature range of 5oC to
30oC.
(i) Preparation of Joints
Sawing of joints shall be undertaken at such time so as to avoid edge spalling

or ravelling.
After removal of the temporary filler material or breaking out of the excess
concrete, the inside faces of the joint shall be wire-brushed or grit-blasted to
remove all laitance and contaminants. Thereafter the joint shall be cleaned out
and blown out with compressed air to remove all traces of dust. Solvents shall
not be used to remove contaminants from concrete and porous surfaces.
Care shall be exercised to ensure that primers or adhesives are applied only to
surfaces that are absolutely dry. The primer or adhesive shall be applied
strictly in accordance with the manufacturer’s instructions. Unless otherwise
specified the primer shall be applied within the temperature range of 10oC to
40oC and the sealant shall be applied after the curing period of the primer and
within the period that the primer remains active.
(ii) Sealants
Sealants shall be applied strictly in accordance with the manufacturer’s

instructions by a person skilled in the use of the particular type of sealant.
Trapping of air and formation of voids in the sealant shall be avoided. The
sealant shall be finished to a neat appearance flush with the edges of the
concrete or to the specified depth.
Thermoplastic hot-poured sealants shall not be poured into the joints when
the temperature of the joint is below 10oC. The safe heating temperature shall
not exceed the specified pouring temperature by more than 10oC.
Two-part thermosetting chemically curing sealants shall not be applied after

expiry of the specified pot-life period, which commences once the base and
activator of the sealant have been combined.
(iii) Preformed Compression Seals
The seal shall be inserted and secured with a lubricant adhesive covering both
sides of the seal over the full area in contact with the inside faces of the joint.
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The lubricant adhesive shall be applied immediately ahead of inserting the

seal.
The seal shall be installed in a compressed state with the appropriate

equipment so that under the most adverse conditions the seal will remain in
compression. The seal shall at all times be between 5 mm and 10 mm below
the level of the pavement. The seal shall not be stretched during installation.
Unintentional stretching may occur, however, which shall not exceed 5%.
Joints in seals shall be bonded or fused and shall be only at positions agreed
to by the Engineer.
(iv) Water stops
Water stops shall be securely and accurately located in position not to

displace or deform during construction.
(e) Custom Built Expansion Joints
The use of any type of expansion joint shall be subject to the approval of the
Engineer. Bidders are advised to obtain approval for the type of expansion joint they
intend using prior to submitting their tenders.
(i) Dimensions
Attention is drawn to the overall dimensions of the expansion joints and to

the limiting concrete dimensions of that portion of the structure that is to
accommodate the joints. No alterations to the concrete that will be visible in
the final structure nor major re-arrangement of the pre-stressing anchorages
shall be permitted in order to accommodate joints of excessive size.
All joints to be installed along a skew shall be accurately dimensioned to

ensure compliance with article (iii) below.
Unless otherwise specified, proprietary expansion joints shall include the

complete expansion joint assembly traversing the roadway, kerbs, footpaths
and median, and shall include the coping and parapet cover plates as well as
the drainage system to drain the expansion joint.
(ii) Design and Manufacture
The expansion joint shall be designed to withstand the movements,

displacements and rotations specified on the Drawings in conjunction with
the loads prescribed in the code of practice adopted for the design of the
structure without overstressing any part in terms of "working load"
requirements or exceeding the requirement for serviceability limit state. Any
strengthening of the supporting member required to resist forces imparted by
the joint to the structure shall be for the Contractor's account.
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The specified movements, displacements and rotations shall be accepted

without impairment of the efficacy or riding quality of the joint.
The joint shall be vibration free, resistant to mechanical wear and other forms
of abrasion and shall resist corrosion. It shall have good riding characteristics,
be skid resistant and silent, be of watertight construction or have provision for
the disposal of water, debris or grit collecting in the joint, and be of such
construction so as to facilitate easy inspection, maintenance and repair.
Prior to the manufacture of the joints, the Contractor shall submit to the
Engineer for his acceptance detail drawings of each expansion joint, in
accordance with the requirements of Clause 2.1.2.
The expansion joints delivered to the Site shall be suitably marked to clearly
show the sequence and position of installation.
(iii) Installation of Expansion Joints
No expansion joint or part thereof shall be installed prior to the establishment

of final surfacing levels based on a complete level survey of the bridge
deck(s). The survey shall be carried out before the construction of kerbs,
channels or bituminous surfacing.
The expansion joint shall form an even surface with the road surface on either
side and the deviation across and along the expansion joint shall comply with
the requirements of Clause 5.1.4 for surface regularity measured by ordinary
straight-edge.
On completion of the installation of proprietary expansion joint(s), the

Contractor shall submit to the Engineer a certificate from the manufacturer or
supplier of the joint(s), certifying acceptance of the installation.
Notwithstanding the issuing of such a certificate, the manufacturer or supplier
shall not accept any responsibility for the installation of the joint(s) and shall
not relieve the Contractor of his responsibilities under the Contract.
The unit of measurement shall be either the metre of complete joint of each type installed
or the number of complete joints of each type installed.
The tendered rate shall include full compensation for the supply of all materials, for
transport, handling and storage, and for all labour, equipment and incidentals required for
the installation of the expansion joint complete as detailed. (Refer to Notes 1 and 2
hereinafter).
The tendered rate shall be final and binding, irrespective of the type or make of joint
finally installed.
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(a) Expansion Joints as Detailed on the Drawings and/or Specified in the Specifications
The unit of measurement shall be the metre of complete expansion joint of each type
installed.
The tendered rate shall include full compensation for the supply of all material, for
the manufacture of the expansion joint, for transport, handling and storage, and for
all labour, equipment and incidentals required for the installation of the expansion
joint complete as detailed. (Refer to Notes 1 and 2 hereinafter).
(b) Filled Joints
The unit of measurement shall be the square metre of filled joint calculated from the
surface area of the joint. Where the filled joint is 150 mm or less in depth, the unit of
measurement shall be the metre of filled joint.
(c) Sealing of Joints With

The unit of measurement shall be the metre of sealant, seal or water-stop of each type
installed.
forming or cutting the concrete to the required shape and size, for all labour,
equipment and incidentals required to seal the joint complete as detailed and for all
wastage. (Refer to Note 2 hereinafter).
NOTES:
1) The cost of forming the open joint(s) shall not be included in the rates tendered for
6.6.4 (c), as payment for this work shall be made according to Clauses 6.1.7(d) and
6.1.7(e).
2) Separate payment shall not be made for the supply and/or installation of the seal in
proprietary expansion joints or the seal between concrete or epoxy nosings.
6.6.5 Bearings for Structures
Scope
This section covers the construction, supply and installation of bearings for structures.
6.6.5.1 Materials
When requested by the Engineer the Contractor shall submit test certificates from an
approved, independent testing authority to show that the respective materials conform to
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the specified requirements, or a certificate from the patent holder or designer certifying
that the manufactured item complies in all respects with the relevant product
specifications.
(a) Roofing Felt
Roofing felt shall be 3-ply and comply with the requirements of AASHTO M117.
(b) Elastomer
The elastomer used in the manufacture of bearings shall be natural rubber or

synthetic rubber.
(i) Natural rubber shall comply with the requirements of BS 1154 for natural
rubber Groups Z13 and Z14.
(ii) Synthetic rubber shall comply with the requirements of BS 2752 for synthetic
rubber Compounds C3 and C4.
(c) PTFE
PTFE used in conjunction with stainless-steel plates to form low-friction sliding

surfaces shall be unfilled (virgin) PTFE and comply with the requirements of BS
3784 for Grade A, Type 1 PTFE.
The sliding surface of the PTFE may be either smooth or dimpled.
(d) Stainless-Steel Plate
Stainless-steel plate used in conjunction with PTFE to form low-friction sliding

surfaces shall comply with the requirements of BS 1449: Part 2 for Steel 316S16.
The texture of the sliding surface shall be equal to or better than 0.00020 mm Ra, in
accordance with the requirements of BS 1134.
(e) Stainless-Steel Dowels and Bolts
Stainless steel used for the manufacture of dowels, holding-down and anchor bolts
shall comply with the requirements of BS 970: Part 4 for Steel 316S16.
(f) Steel Plate
Steel used for plate reinforcement in laminated elastomeric bearings shall comply
with the requirements of BS 4360 for Grade 43A steel.
(g) Mortar
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Mortar beddings for the seating of bearings shall be composed of an approved sand
and either cement or epoxy resin, or may consist of an approved proprietary mortar.
The mortar shall comply with the following strength requirements:
(i) Sand-Cement Mortar

The 7-day compressive strength of 150 mm cubes made of the mortar and
cured in moist atmosphere for the first 24 hours and thereafter in water of
20oC shall not be less than 1.5 times the average contact stress under the
bearing or 15 MPa, whichever is the greater.
(ii) Sand-Epoxy-Resin Mortar
The cured compressive cube strength of the mortar shall not be less than 2.0
times the average contact stress under the bearing or 20 MPa, whichever is
the greater.
(iii) Proprietary Mortar
The strength requirements for proprietary mortars shall be in accordance with

either Sub clause 6.6.5.1(g) (i) or (ii), as relevant.
6.6.5.2 Construction of Bearings
(a) Concrete Hinges
Concrete hinges shall be constructed in accordance with the details shown on the
Drawings.
The throat shall be formed to have rounded chamfers on all sides and with the upper
and lower surfaces at a slight divergence.
The concrete cover to reinforcing steel in the throat shall not be less than 25 mm.
The concrete used in forming the throat of the hinge shall be as specified on the
Drawings, but shall not have a 28-day cube compressive strength of less than 40
MPa. The maximum size of coarse aggregate in the mix shall not be larger than 10
mm.
Construction joints shall not be formed in the throat area. Where a joint is necessary,
it shall be formed as a recess below the throat, level with the top reinforcement mat.
The width of the recess shall be slightly greater than the width of the throat.
Care shall be exercised to eliminate the formation of shrinkage cracks within the
throat.
During construction adequate bracing and support shall be provided to the

satisfaction of the Engineer to prevent rotation in the throat form the time of casting
to completion of the structure incorporating the hinge. During the course of
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construction the hinge shall not be subjected to conditions that will induce tensile
stresses in the throat area.
Upon completion of the structural members incorporating the hinge, the space
around the throat shall be filled and sealed with a compressible material to prevent
the ingress of dirt, all to the satisfaction of the Engineer.
(b) Roofing Felt
Roofing felt used as bearing strips shall consist of at least 3 layers, laid on the
bearing surface to the dimensions shown on the Drawings.
Where lubricated linings are specified, the roofing felt shall be saturated with used
motor oil and thereafter liberally dusted with graphite powder before it is laid on the
bearing surface.
(c) Elastomeric Bearings
(i) Technical Data
The technical data for the elastomeric bearings required for in the Contract
will be supplied on the Drawings.
Each bearing supplied by the Contractor shall be identified by a number.
Where alternative bearings are offered by the Contractor, they shall be

designed in accordance with the requirements for the loadings and
deformations shown on the Drawings.
Where a bearing consisting of a rubber different to that which is specified, is

offered, the bearing shall be redesigned to allow for the variation in hardness
and/or type of rubber.
(ii) Inspection and Testing
On completion of the manufacture of the bearings, the Contractor shall

submit bearing pads selected by the Engineer, or specially manufactured
sample pads authorized by the Engineer, to an independent testing authority
for testing. The tests to be undertaken shall be as directed by the Engineer and
shall comply with the relevant requirements stated below.
The following tests shall be performed on the completed bearings, sample

pads or test specimens prepared for the purpose as relevant:
- Bond Test
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The test specimens for this purpose shall be prepared from one of the
selected bearings or sample pads, which may have been used
previously for tests specified in article (iii) below.
The test shall be performed in accordance with Method B as specified

in BS 903 : Part A21.
The adhesion value during separation shall not be less than 9 N/mm
width of the test specimen.
Test to BS 1154 or BS 2752
The test specimens shall be prepared either as for the bond test or from
test sheets formed from the rubber used in the manufacture of the
bearing.
The physical properties of the rubber in respect of hardness, tensile

strength, elongation at break and compression set shall comply with the
requirements specified in BS 1154 or BS 2752, both in the as received
and in the aged condition.
The respective tests shall be as described in the relevant part of BS

903, viz:
Determination of hardness BS 903 : Part A26
Determination of tensile
strength and elongation
at break BS 902 : Part A2
Determination of compres-
sion set BS 903 : Part A6
Accelerated aging tests BS 903 : Part A19
- Weathering Test
The tests shall be performed as specified in BS 903 : Part A23.
At the end of the test period after having been subjected to an ozone
concentration of 50 + 5 parts per hundred million at 50oC + 1oC, the
test specimens shall be free from cracks visible to the naked eye.
- Compression Stiffness
The bearings or sample pads shall be loaded to 150% of the design

load and this load shall be maintained for a period of 2 minutes. The
loading shall then be reduced to 10% of the design load and maintained
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at this value for 10 minutes when gauge readings shall be taken. The
bearings or sample pads shall then be reloaded to 150% of the design
load and maintained at this value for 10 minutes. Gauge readings shall
be taken and used in conjunction with the earlier readings to evaluate
the stiffness.
The compression stiffness shall be + 20% of the theoretical value.
- Shear Stiffness
A testing procedure similar to that for testing compression stiffness

shall be followed, the loading being such as will maintain steady shear
distortions of 10% and 150% respectively of the design shear
distortion. In practice, it may be convenient to test two bearings or
sample pads, attached to a common shear plate, one of these bearings
being that tested in compression.
The shear stiffness shall be within + 20% of the theoretical value.
Provided the performance in both compression and shear tests is

satisfactory, the bearings shall subsequently be used for installation in
the structure. No surface flaws shall become apparent during the tests
and bearings or sample pads shall show no irregularities in their
deflected shape.
Payment for this testing, for bearing pads damaged and for sample pads
shall be made under Clause 2.4.11.
A variation of +- 20% shall be permitted between the actual and

theoretical stiffness for compression and shear of the elastomer. Where
this variation is exceeded, acceptance of the pads shall be at the sole
discretion of the Engineer.
Copies of test results and certificates for the above-mentioned testing

shall be timely submitted by the Contractor to the Engineer to enable
the Engineer to assess the information before the bearings are installed.
The dimensional tolerances on bearing pads shall comply with the

requirements specified in the Specifications of Particular Application.
Before the bearings are dispatched to the Site of the Works, each
bearing, with the exception of large bearings as provided for in the
Specifications of Particular Application, shall be subjected
simultaneously to a vertical load equal to 150% of the maximum
design load and to a shear distortion equal to 150% of the maximum
design value. The bearings shall be visually inspected for defects by the
Engineer or his nominee and shall at no stage under this test show any
cracks visible to the naked eye, or other defects. The cost of this testing
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shall be included in the rate tendered for the supply and installation of
the bearing pads.
(d) Proprietary Bearings
This article covers custom-built bearings, bearings manufactured under licence,

except elastomeric bearings. Combined bearings, consisting of an assembly of an
elastomeric bearing in conjunction with a low-friction sliding or mechanical
component, shall fall under this article.
(i) Technical Data
The technical data for the proprietary bearings required for in the Contract
will be supplied on the Drawings.
The Bidder may base his Tender on any bearing that complies with the
specified requirements, provided that the efficacy of the bearing has been
verified by tests and successful previous use. Evidence of these as well as
information on the bearings durability and suitability for the specified use
shall be submitted to the Engineer for his consideration.
Details of the product guarantee shall be submitted with the Tender.
Surfaces in contact with concrete shall receive at least the treatment described
in period one and two above.
(ii) Inspection and Testing
The Engineer may require that tests be carried out to verify compliance of the
bearing with the specifications and/or its performance under the design loads.
Payment for this testing shall be made according to Clause 2.4.11.
Test certificates of all tests carried out shall be made available to the
Engineer.
The Contractor shall give the Engineer at least 7 days notice prior to final
assembly of the bearings in order to enable the Engineer or his nominee to
inspect the bearings at the factory.
Under no circumstances shall bearings be taken apart and reassembled on the

Site, except when it is an unavoidable feature of the installation procedure, in
which case the dismantling, installation and reassembly shall be under the
supervision of qualified personnel.
Rehabilitation, modification and repair work to bearings shall be carried out

only in the factory or at an approved engineer works.
(e) Dowels and Guides
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Dowels and guides shall be of such material, design and construction as is detailed
on the Drawings.
Where dowels and guides are used in conjunction with bearings, they shall not
complicate or prevent the removal of bearings.
6.6.5.3 Storage and Handling
The bearings shall at all times be stored under cover and clear of the ground, away from
sunlight, oils and chemicals deleterious to the bearings. The bearings shall not be stacked
in a manner or on a surface that will cause distortion of the bearings.
The bearings shall be handled with care to ensure that they are not subjected to impact
loads or any other condition that may be harmful.
6.6.5.4 Installation
The concrete surface on elements required to receive bearings shall comply with the
requirements for class UF3 surface finish. Plastering of the surface shall under no
circumstances be permitted.
Before the mortar bedding is constructed, the concrete surface shall be chipped back to
expose the aggregate and leave a sound irregular surface. Bonding of the mortar bedding
to the concrete surface shall be in accordance with the manufacturers recommendations
and the Engineer's instructions. The dimensions of the bedding shall be such that the load
can be spread at an angle of 45o through the bedding. However, the thickness of the
bedding shall not be less than 15 mm and 25 mm for proprietary and elastometric
bearings, respectively, nor shall the maximum thickness exceed 50 mm.
Unless shown otherwise on the Drawings, the bearings shall be installed on a horizontal
plane and shall be in full contact with the concrete and bedding surfaces.
To accommodate soffit irregularities and camber in the case of pre-cast members, the
member shall be lowered onto a mortar skim on top of the bearing. The member shall
thereafter be propped until the mortar skim has hardened into a wedge.
The bearings shall be accurately installed to the specified level, alignment and
orientation, all within the construction tolerances in accordance with the details shown on
the Drawings.
Where the bearing has long sliding plates, these shall be rigidly supported to prevent
distortion under the weight of the wet concrete and the construction loads.
Before the bearing is incorporated into the structure it shall be cleaned to remove all
deleterious substances and adhering matter, and thereafter wrapped in polyethylene
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sheeting and adequately sealed to prevent the ingress of mortar and slush onto the
bearings during the course of construction.
After installation, the polyethylene wrapping shall be removed, the bearing and the space
around the bearing thoroughly cleaned and the lugs removed as directed by the Engineer.
On completion of the installation of proprietary bearings the Contractor shall submit to

the Engineer a certificate from the manufacturer or supplier of the bearings certifying
acceptance of the installation. Notwithstanding the issuing of such a certificate, the
manufacturer or supplier shall not accept any responsibility for the installation of the
bearings and shall not relieve the Contractor of his responsibilities under the Contract.
(a) Custom Built Bearings
Payment for the purchase and taking delivery of custom built bearings complete with
anchor bolts and/or dowels shall be in accordance with the provisions of Clause
2.1.7.
(b) Installation of Custom Built Bearings
The unit of measurement shall be the number of complete bearings of each type and
class installed.
The tendered rate shall include full compensation for the supply of all materials not
covered under item (a) above, the construction of the bedding, transport, handling
and storage, and for all labour, equipment and incidentals required for the installation
of the bearings complete as detailed.
The tendered rate shall be final and binding, irrespective of the types or make of
bearings finally installed.
(c) Bearings
The unit of measurement shall be the number of complete bearings of each type and
class installed.
The tendered rate shall include full compensation for the supply of all materials,
including anchor bolts and/or dowels, for the construction of the bedding, the
manufacture of the bearings, transport, handling and storage, and for all labour,
equipment and incidentals required for the installation of the bearings complete as
detailed, as well as for the testing of bearings as relevant.
(d) Concrete Hinges
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6 / CONCRETE WORKS
The unit of measurement shall be either the metre of complete hinge of each type
manufactured and installed or the number of complete hinges of each type
manufactured and installed.
including formwork, for the manufacture of the hinges, and for all labour, equipment
and incidentals required for the installation of the hinges complete as detailed.
(e) Bearing Strips
The unit of measurement shall be the square metre of bearing area lined with the
specified material, irrespective of the number of layers placed.
transport, handling and storage, and for all labour and incidentals required for the
installation of the bearing strips complete as detailed.
(f) Dowels/Guides
The unit of measurement shall be the number of dowels/guides of each type installed.
including anchor bolts, the manufacture of the dowels/guides, transport, handling and
storage, and for all labour, equipment and incidentals required for the installation of
the dowels/guides complete as detailed.
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7 / STRUCTURAL STEEL WORK
SECTION No7
STRUCTURAL STEEL WORK
7.1 General
7.1.1 Scope
The fabrication and erection of all structural steel work shall be under the constant
supervision of competent and experienced personnel. All workmanship shall be in
accordance with the best modern workshop practice and only skilled workers trained and
experienced in steel fabrication and erection shall be employed.
7.1.2 Applicable Standards
The supply, fabrication and erection of structural steel work shall be in accordance with
the provisions of the relevant clauses of the following British Standards or the latest
revisions thereto:
BS 4 Structural steel sections

BS 4848 Hot rolled structural steel sections
BS 153 Steel girder bridges Part 1 - Materials and workmanship, Part 2 - Weighing,
shipping and erection.
BS 4360 Weldable structural steels
BS 4395 High strength friction grip bolts and associated
Parts 1&2 nuts and washers for structural engineering (metric series)
BS 4604 The use of high strength friction grip bolts in structural steel work
BS 4933 ISO metric black cup and countersunk head bolts and screws with hexagon
nuts.
BS 4190 ISO metric black hexagon bolt screws and nuts
BS 3692 ISO metric precision hexagon bolt screws and nuts
BS 4320 Metal washers for general engineering purposes
BS 5135 Metal arc welding of carbon and manganese steels
BS 638 Arc welding equipment and accessories
BS 639 Covered electrodes for the manual metal-arc welding of mild steel and
medium tensile steel
BS 4870 Specification for approval testing of welding procedures. Part 1-Fusion
welding of steel
BS 4871 Approval testing of welders working to approved welding procedures Part 1-
Fusion welding of steel
BS 5493 Code of Practice for protective coating of iron and steel structures against
corrosion.
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7.2 MATERIALS AND PROCESS REQUIREMENTS
7.2.1 Materials
All structural steel shall be to the Grade as defined on the Drawings and shall comply
with the requirements of BS 4360 in every respect.
Mill certificates shall be supplied to the Engineer in duplicate to confirm the mechanical
and chemical properties.
Steel for headed stud shear connectors shall have a minimum yield stress of 385 MPa and
a minimum tensile strength of 495 MPa.
7.2.2 Storage of Materials
Structural steel work whether plain or fabricated shall be stored above ground on
platforms, skids or other supports and in such a way as to prevent pools of water forming
on the surface. It shall be kept free form dirt, grease and other deleterious material and
shall be protected as far as is practicable from corrosion. Any unpainted or un-primed
steel work stored outside shall have a time limit as detailed in the Special Specification.
7.2.3 Fabrication
Fabrication shall generally be in accordance with the requirements of BS 153 Part 1,

Workmanship. Rolled material, before being processed, must be straight or flat.
Straightening or flattening, where required and where permitted by the Engineer, shall be
accomplished by a process not harmful to the material.
The Contractor shall submit to the Engineer for his approval two sets of shop drawings
with calculations as appropriate and the Contractor shall not commence fabrication until
written approval has been given by the Engineer. The Engineer will give comment or
approval within 28 days after receipt of the shop drawings and calculations. Such
approval shall not relieve the Contractor of any of his responsibilities under the Contract.
Following approval of the shop drawings the Contractor shall supply to the Engineer a
further four copies of each drawing for the use of the Engineer and the Employer.
The components of various members of the structure shall be placed in jigs of approved
design and all welding shall be carried out in accordance with Clause 7.3.2 and to the
satisfaction of the Engineer. Every precaution shall be taken to prevent distortion.
7.3 CONSTRUCTION
7.3.1 Preparation of Edges and Ends of Plates
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Edges and ends shall be either:
. Left as rolled, sawn, machine cut, machine flame cut;

. Hand flame cut and ground to a smooth profile or
. For stiffeners and gussets not exceeding 12 mm thick, sheared and subsequently
ground to a smooth profile.
Where ends of stiffeners are required to be fitted, they shall be ground to be in contact
with the flanges over 80% of the area of stiffeners.
After shearing or flame cutting of plates, one of the following requirements shall be
satisfied:
. the hardness of the cut edge shall not exceed 350 HV 30 of BS 427;
. the cut edge is incorporated in a weld;
. the material from the edge is removed by machining or grinding to demonstrate that
the hardness of the edge is less than 350 HV 30 of BS 427;
. the edge is softened by an approved heat treatment and is shown to be free from
cracks by crack detection procedures;
. the material is grade 43 steel and is not greater than 40 mm thick, and the edge
preparation is by machine flame cutting.
7.3.2 Welding
Welding will be permitted only where shown on the Drawings, and the agreed shop
drawings.
All welding operations shall comply with the requirements of BS 5135.
The details of all welds shall be arranged to achieve the most satisfactory welding
procedure. The details of the welding procedure shall be submitted to the Engineer for his
approval and no welding may commence without the prior approval of the Engineer. No
departure from an approved procedure may be made without the further agreement of the
Engineer. Welding procedure details to be submitted to the Engineer shall include:
. Welding position
. Fusion face preparation
. Pre-heat
. Electrode make, type and size and mechanical properties
. Number and arrangement of runs
. Welding current
. Arc energy
. Method of back gouging and sealing
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. Proposed methods of quality control and testing of welds
Welding shall be carried out under the supervision of an experienced and competent
supervisor in accordance with the requirements of BS 5135. The welders shall be tested
in accordance with the requirements of BS 4871 to the satisfaction of the Engineer prior
to the commencement of the work.
Where required by the Engineer, the Contractor shall carry out procedure trials of the
welding procedure in accordance with the requirements of BS 4870.
Welding equipment and accessories shall comply with the requirements of BS 638 and
shall be used in accordance with the manufacturer's instructions. The welding equipment
shall be capable of maintaining at the weld the current and voltage specified by the
manufacturer and in accordance with the welding procedure.
The electrodes shall be selected with regard to the quality of the material to be welded
and the optimum performance with the welding procedures and shall comply with the
requirements of BS 639. All electrodes shall be stored in their original packets in a dry
and preferably heated placed adequately protected from the weather and shall be handled
with care and in accordance with the manufacturers instructions. Electrodes and fluxes
that show signs of moisture, damage or deterioration shall not be used.
Welds shall be subject to non-destructive examination and testing as specified in the

Special Specification.
Welded fabrication and weld quality shall comply with the requirements of the American
Welding Society Specification ANSI/AWS DI.1.81 Section 9 Part D.
Stud shear connectors shall be subject to the following tests:
(a) The fixing of studs after being welded in position shall be tested to the satisfaction of
the Engineer by striking the side of the head of the stud with a 2 kg hammer.
(b) Any stud selected by the Engineer shall be capable of being bent by striking the side
of the head of the stud with a 6 kg hammer until its head is displaced laterally a
distance of approximately 0.25 times the height of the stud from its original position.
The stud weld shall not show any signs of cracking or lack of fusion. Satisfactory
studs shall not be bent again.
Studs whose welds have failed the tests given in (a) and (b) shall be replaced
according to a procedure to be agreed with the Engineer.
7.3.3 Bolting
7.3.3.1 Black Bolts
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All mild steel bolts, washers and nuts shall be of the grade as specified on the Drawings
and shall comply with the requirements of BS 4190, BS 4933 or BS 3692 as appropriate.
All holes shall be drilled or drilled small and reamed and shall be clean cut without torn
or ragged edges. The holes shall be perpendicular to the member and not more than 2 mm
larger than the nominal diameter of the bolt.
In all cases where the full bearing area of the bolt is to be developed the bolt shall be
provided with a steel washer under the nut to avoid any threaded portion of the bolt being
within the parts bolted together. Tapered washers of the correct angle of taper shall be
provided under all bolt heads and nuts bearing on bevelled surfaces.
7.3.3.2 High Strength Friction Grip (HSFG) Bolts
High Strength Friction Grip bolts shall comply with the requirements of BS 4395, Parts 1
and 2, and shall be used in accordance with the provisions of BS 4604, Parts 1 and 2.
HSFG bolts, nuts and washers shall be supplied cadmium plated to BS 3382 to a
thickness of 5 microns and shall be stamped or otherwise marked with a suitable and
permanent mark and the Contractor shall obtain the written approval of the Engineer to
the proposed marks before commencement of the work.
Each HSFG bolt shall be supplied complete with its nut screwed on. Washers may be
supplied on the bolt or separately, and bolts and washers shall be packed in the
manufacturer's works and delivered to Site in waterproof containers and stored under
cover in these containers until required for use.
The method of tightening HSFG bolts shall be either the part turn method, the torque
control method or with the use of load indicating washers in accordance with the
following:
HSFG BOLTS COMPLYING WITH PERMISSIBLE METHODS OF

STANDARD TIGHTENING
BS 4604 Parts 1 and 2 1) Part turn for bolts M16

and above.
2) Torque control.
3) Load indicating washers.
BS 4604 Part 2 1) Torque control.

Higher Grade (Parallel shank) 2) Load indicating washers.
What ever method of tightening is adopted, the Contractor shall supply to the Engineer
full details of the procedures to be adopted which shall be in accordance with the
requirements of BS 4604, together with details of the tools and equipment he will be
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using at Site and the tests to be carried out to determine the load/torque/shank tension
characteristics of the tools, bolts and the load indicating washers. No bolting shall
commence until the Contractor has carried out sufficient site tests to confirm the
load/torque/shank tension characteristics of the tools and bolts to the satisfaction of the
Engineer.
In the case of torque control tightening methods calibration of the equipment shall be
carried out daily before commencing bolting operations in accordance with the
Where load indicating washers are used, they shall be of a type approved by the Engineer
and used in accordance with the manufacturer's instructions. The general requirements of
BS 4604 shall apply to the assembly and use of HSFG bolts with load indicating washers
including check testing to confirm the minimum shank tension is being achieved.
HSFG bolts that have been slackened off after final tightening by any method shall be
removed, discarded and replaced at the Contractor's expense.
7.3.4 Transportation, Handling and Erection
Erection shall generally be in accordance with BS 153 Part 2, Weighing, Shipping and
Erection. Structural steel shall be handled with due care at all times and in such a manner
as not to cause damage to the steel work or its protective coatings.
The Contractor shall submit to the Engineer for his approval two sets of drawings and
calculations and details showing his proposed methods for transport, handling and
erection of structural steel work including all equipment, temporary supports and
bracings required to ensure stability and safety during erection. The Contractor shall erect
the steel work, remove the temporary supports and do all the work required to complete
the Works in accordance with the Drawings and the Specification. The work shall be
carried out in such a manner that structure or the foundations and any part injured,
overstressed or disfigured shall be removed and replaced or rectified as instructed by the
Engineer at the Contractor's expense.
The steel work shall be temporarily erected at the fabrication works and be subject to
inspection by the Engineer before being dispatched to Site.
Drift pins will be allowed only for bringing together the several parts of the structure, and
shall not be used in such a way as to distort the work or enlarge the bolt holes.
Bolts in site connections shall not be finally tightened until sufficient of the structure is
properly plumbed, aligned and levelled and no subsequent straining into position will be
allowed. Finally all bolts and connections shall be systematically checked and tightened.
7.4 PAINTING STEELWORK
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7.4.1 Surface Preparation
Surface preparation of steelwork shall be by blast cleaning in accordance with the

requirements of BS 4232 Second Quality. The maximum amplitude of the blast cleaned
surface shall not exceed 0.1 mm.
Manual cleaning of structural steelwork including mechanical wire brushing, chipping

hammers, vibratory needle guns and the like shall not be permitted except for small parts
and then only with the prior written permission of the Engineer.
Surfaces shall be painted with the specified primer paint within four hours of having been
blast cleaned.
As soon as the first undercoat has dried, a further stripe coat of paint shall be applied by
brush to all edges, corners, crevices, exposed parts of bolts, rivet heads and welds. The
stripe coat should have the same specification as the undercoat but be a contrasting
shade.
Painted surfaces shall be cleaned of dust immediately prior to the application of further
paint. All loose paint, dirt and grit shall be removed and areas contaminated with oil and
grease shall be cleaned with emulsion cleaners followed by washing and rinsing with
clean fresh water and allowed to dry thoroughly before paint is applied.
In the case of painted steel work where the interfaces of HSFG bolts are bare steel, the
primer coat shall be taken between 10 mm and 20 mm inside the perimeter of the joint
area.
Where paints are to be applied to parent surfaces before making of a joint they shall be
stepped back at 30 mm intervals commencing at 80 mm from welded joints and 10 mm
from the perimeter of all other joints.
All bolted joints shall be sealed against the ingress of water. Gaps at joints shall be
plugged with an approved filler and the perimeter of all joints shall be sealed with
subsequent coats of paint.
All joints, welds and surfaces affected by welding shall receive the same protective
system as applied to the parent surfaces.
Within 14 days of a joint being made and accepted by the Engineer, the parent material,
exposed parts of bolts, nuts and washers, weld and affected areas shall be prepared and
painted.
7.4.2 Paints and Painting
Paint Systems
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The paint system to be used on structural steelwork shall be as specified in the Special
Specification.
7.4.2.1 Paints for Structures
All paint used in the Works shall be subject to the approval of the Engineer.
All paint shall be supplied from the store to the painters ready for application. Any
addition of thinners must be made in the store under the supervision of the Engineer and
only as permitted by the manufacturer's data sheet. All the requirements of the
manufacturer's data sheet shall be strictly complied with.
7.4.2.2 Painting
Paint shall be applied only to surfaces which have been prepared and cleaned in
accordance with the requirements of Clause 7.4.1.
The use of rollers shall not be permitted for the application of paint.
Paint shall not be applied under any of the following conditions:
. when the ambient temperature is less than 4

. when the relative humidity is greater than 90%;
. during fog, rain or mist;
. when any moisture is present or likely to condense on the steel
Each coat of paint shall be generally free from surface defects to the satisfaction of the
engineer.
Successive coats of paint shall have different shades for identifications.
The Contractor shall ensure that the proposed application rates shall enable the specified
minimum dry film thickness to be achieved. If the total dry film thickness is less than the
specified minimum, an extra finishing coat or coats shall be applied until the specified
dry film thickness is obtained.
7.4.2.3 Damaged Surfaces
Any areas of paint which have been damaged following application shall be cleaned
down to bare metal and the full specified painting system shall be re-applied. The new
paint shall overlap the existing paint by at least 50 mm all round the affected area.
Galvanized surfaces damages shall be repaired either by the use of low melting point zinc
alloy repair rods or powders made specially for this purpose or by the use of at least two
coats of a good quality zinc rich paint to BS 4652.
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7.5 TESTING OF STEELWORK
7.5.1 Testing by the Engineer
The Engineer may nominate a testing authority to inspect the Works and to conduct such
tests as he may consider necessary to test compliance with the Specifications. Where
required, test samples of welds shall be prepared, free of charge, by the Contractor for
testing.
The Contractor shall, where required, pay for the cost of testing as described above and
shall be reimbursed as specified in Clause 2.5.11.
7.5.2 Process Control
Welds shall be regularly inspected and tested by the Contractor in terms of his
obligations described in Clause 1.2.12 regarding process control. This shall include visual
inspection of welds to ensure that there is no undercutting, no uneven lengths, no poro-
sity, no evidence of cracking and that full fusion has been achieved. If required by the
Engineer, cores containing welds and adjacent parent material shall be cut out in doubtful
areas. The cores shall be polished and examined and the hole made good.
7.6 MEASUREMENT AND PAYMENT
(a) Structural steel work shall be measured by the tonne and shall be the weight
calculated from the approved shop drawings excluding bolts, nuts, washers and all
other fixings required. No deduction shall be made in the measurement for splay cuts
and notches and holes provided that the area of each is less than 0.1 square metre. No
allowances shall be made in the measurement for rolling margin or cutting to waste.
The density of steel shall be taken as 7,850 kilograms per cubic metre.
(b) The rates for steel work shall include for the cost of:
. design, submission of orders, shop drawings, details, calculations and certificates;
. provision of all materials, bolts, fabrication, including drilling, machining and

welding; testing or welds and welders;
. temporary erection at the fabrication works for inspection by the Engineer;
. surface preparation, painting with specified paint system;
. inspection and submission of test reports and certificates;
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. marking, handling, packing, transporting and storage;
. erection, bolting, welding, including temporary bracings and guys.
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8 / ROAD FURNITURE
S E C T I O N No 8
ROAD FURNITURE
8.1 POSTS
8.1.1 Materials
(a) Concrete
Concrete work shall be carried out in accordance with the provisions in Paragraphs
6.1, 6.2 and 6.3.
(b) Paint
Paint for marker posts shall be non-reflectorized road-marking paint as specified in

Paragraph 8.4.
(c) Retro-Reflective Material
Retro-reflective material shall be engineering grade conforming to the requirements

of Clause 8.3.1 (g).
8.1.2 Marker Posts
8.1.2.1 Manufacturing
Marker posts shall be manufactured to the dimensions shown on the Drawings. Class
20/20 concrete shall be used. Forms shall be smooth and have accurate dimensions. The
mixture shall be placed in the forms and vibrated on a vibrating table or by means of
other approved methods. The posts shall be reinforced as shown on the Drawings and
shall have a F3 surface finish.
The posts shall be true to shape, smooth, and without honeycombing or other blemishes.
The recess near the top of the post shall contain retro-reflective material, while the
remainder of the top half of the post shall be painted with white road marking paint.
8.1.2.2 Erection
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Marker posts shall be erected after completion of the bituminous surfacing. They shall be
set out at the edge of the shoulder with their tops at a constant height above the edge of
the carriageway at such spacing as the Engineer instructs. Holes shall be excavated in the
shoulder and posts placed vertical and square to the road centre line.
Backfilling shall be compacted in thin layers from the bottom of the hole. Surplus
excavated material shall be disposed of as directed.
The posts shall be painted immediately after placing.
Marker posts shall be maintained and protected during the whole of the construction
period and any marker posts that are damaged or broken before the issue of a Certificate
of Completion shall be repaired or replaced, as may be required, at the Contractor's cost.
8.1.3 Reserve Boundary Posts
Where Road Reserve boundary posts are instructed by the Engineer, they shall be erected
as early as possible after the commencement of the Contract, on the boundary of the
Road Reserve at intervals of 150 m or as otherwise instructed by the Engineer, but not
closer than 5 m to any reference peg.
The post shall be in accordance with Standard Drawings and shall be embedded in
concrete Class 15/20 all round and under the butt as shown on the Standard Drawings.
The top 0.9 m of the post shall be painted with one coat of zinc oxide paint, and one coat
of white lead paint, before the post is erected. The chainage shall be cut in to the post and
then painted black.
The posts shall be maintained in position until the issue of the Certificate of Completion
and re-painted from time to time, as instructed by the Engineer.
The rates for marker posts, road reserve boundary posts, kilometre posts, fencing, gates,
road signs, guard rail and trees shall include for all excavation, concrete foundations
where specified, provision and transport of selected backfill, compaction of backfill to
the specified density and disposal of all surplus or unsuitable material.
Road marker posts shall be measured by number specified. The rates for marker posts
shall include for the cost of providing complete including reflectors and for installing at
any point on the Site.
Road reserve boundary posts shall be measured by number specified. The rates for road
reserve boundary posts shall include for the cost of providing complete and installing at
any point on the Site.
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8 / ROAD FURNITURE
Kilometre posts shall be measured by the number specified. The rates shall include for
the cost of providing complete including painting and lettering and for installing at any
point on the Site.
8.2 FENCING AND GATES
Fencing and gates shall be provided where instructed by the Engineer and shall comply
with the details shown on the standard Drawings.
All timber for fencing and gates shall be well seasoned hard wood to the approval of the
Engineer. After all cutting and drilling is complete the timber shall be impregnated with
an approved preservative in accordance with AASHTO M133 or as specified in the
8.2.1 Materials
(a) Posts, Stays, Standards and Droppers
Posts, stays, standards and droppers shall be of the type and size indicated on the
Drawings. Steel sections shall comply with the requirements of AASHTO M281.
Timber posts shall comply with AASHTO M160 and be treated at the Engineer's
opinion with either creosote or copper chrome arsenate. The latter preservative is not
to be used in the case of hardwoods.
Unless otherwise specified or shown on the Drawings, rolled steel posts shall be 15
or 22 kg/m "T" profiles. Standards shall be 2.50 kg/m Y sections.
Droppers shall be 0.56 kg/m, ridgeback pattern droppers.
Where tubular posts are specified they shall be galvanized in accordance with
AASHTO M111 for Class 1 articles and have a minimum wall thickness of 2.95
mm. The length, diameter and hole spacing shall be as shown on the Drawings.
Unless otherwise shown on the Drawings, all tubular sections shall be provided with
a 200 mm x 200 mm footplate and a pressed steel or cast iron cap.
Rolled steel sections shall be provided with a protective coating of one coat of
bituminous paint or other approved material.
Tubular stays shall have a nominal external diameter bore of at least 50 mm and a
wall thickness of at least 2.95 mm. They shall be galvanized as specified in
AASHTO M111.
(b) Bolts for Stays
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Bolts shall be galvanized steel bolts of the required length and diameter. The
diameter shall not be less than 12 mm. All the necessary bolts, together with nuts and
washers, shall be supplied with each post.
(c) Wire
(i) Barbed Wire
Barbed wire shall comply with the requirements of AASHTO M280 and shall
be one or more of the following types:
High tensile grade, oval shaped, single-strand wire, 3.15 mm x 2.50 mm (2.81
mm equivalent diameter), either lightly or fully galvanized, as specified in the
Bill of Quantities.
High tensile grade, oval shaped, single-strand wire, 2.80 mm x 1.90 mm (2.31
mm equivalent diameter), fully galvanized (first class coating). This wire shall
not be used less than 500 mm above ground where there is danger of grass fires.
Mild steel grade, double strand, uni-directional twist wire, each strand 2.50 mm
diameter, for use at any height above ground. The wire shall be either lightly
galvanized or fully galvanized, as specified in the Bill of Quantities.
Barbs shall be manufactured from 2.0 mm galvanized wire and shall be spaced
at not more than 152 mm.
(ii) Smooth Wire
Smooth wire shall comply with the requirements of AASHTO M279 and shall
be of the types specified below:
Straining wire shall be 4.00 mm diameter, lightly galvanized wire, class 1.
Fencing wire shall be high tensile grade 2.24 mm diameter wire, either
lightly or fully galvanized, as specified in the Bill of Quantities.
Tying wire shall be 2.50 mm diameter, mild steel, lightly galvanized wire
for tying fencing wire to standards and droppers, and 1.60 mm diameter,
mild steel, lightly galvanized wire for tying netting and mesh wire to
fencing wire.
(d) Diamond Mesh
The wire for the diamond mesh (chain-link fencing) shall comply with the
requirements of AASHTO M279, Class 1. The width shall be as shown on the
Drawings, and the edge finish shall be both sides clinched or barbed.
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8 / ROAD FURNITURE
The nominal diameter of the wire shall be 2.5 mm and the mesh size shall be 64 mm
x 64 mm.
The wire shall be lightly galvanized, class 1.
(e) Wire Netting
Wire netting shall be galvanized, mild steel wire with a minimum diameter of 1.8
mm and 75 mm hexagonal mesh.
The width shall be as shown on the Drawings.
(f) Gates
Gates shall be manufactured to the dimensions shown on the Drawings.
Gates shall be complete in every respect, including hinges, washers, bolts and
locking chain attached to the gate.
(g) Timber Posts
Timber posts used for holding down mats where the fence crosses streams shall
comply with the requirements of AASHTO M168 and shall be creosote impregnated
in accordance to AASHTO M133.
(h) Manufacturing Tolerances for Wire
The actual diameter of wire supplied shall nowhere be less than the specified
diameters by more than the following tolerances:
Specified Diameter Tolerance
1.0 - 1.8 mm 0.05 mm

2.0 - 2.8 mm 0.08 mm
3.15 - 4.0 mm 0.10 mm
8.2.2 Types of Fencing
The following types of fences shall be erected in accordance with the dimensions shown
on the Drawings:
(a) Stock-proof fences. (Notwithstanding the provisions of Clause 8.2.1, stock-proof

fences shall be constructed using zinc-coated (galvanized) iron or steel farm field and
rail road right-of-way wire fencing according to AASHTO M279 or as shown on the
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8 / ROAD FURNITURE
Drawings or similar approved, erected in accordance with Clauses 8.2.3, 8.2.4 and
8.2.5.)
(b) Vermin-proof fences. (Horizontal barbed wire fence above a mesh wire fence).
(c) Pedestrian fences. (Full height diamond mesh fence).
(d) Security fences. (Veranda type with diamond mesh on the vertical portion and barbed
wire on the overhang).
Where existing fences have to be dismantled and re-erected, they shall either be re-
erected to the same design as originally constructed with such modifications as the
Engineer may require, or they shall be erected to one of the standards specified above, all
as ordered by the Engineer.
8.2.3 Clearing of Fence Line
The fence line shall be cleared over a width of at least 1 m on each side of the centre line
of the fence and surface irregularities shall be graded so that the fence will follow the
general contour of the ground. Clearing and grubbing shall be carried out as described in
Section 3.2.1 of these Specifications. The bottom of the fence shall be located a uniform
distance above the ground line in accordance with the requirements shown on the
Drawings. All material removed shall be burnt or disposed of to spoil.
Any areas outside the road reserve where clearing is not permitted by the owner or is not
practicable shall not be cleared if so directed by the Engineer.
8.2.4 Installing Posts and Standards
Straining posts shall be erected at all ends, corners and bends in the line of fences and at
all junctions with other fences. Straining posts shall not be spaced further apart than
shown on the Drawings. The length of posts above ground shall be such that the correct
clearance between the lowest wire and the ground can be obtained.
Posts shall be accurately set in holes and, where shown on the Drawings, be provided
with concrete bases to the dimensions shown on the Drawings.
Holes shall be dug to the full specified depth of the posts. Where, due to the presence of
rock, the holes cannot be excavated by means of hand or pneumatic tools, the Contractor
shall use core drilling equipment at no additional payment.
Corner, gate, and end straining posts shall be braced by means of stays or anchors, as
shown on the Drawings or as directed by the Engineer. Pipe stays shall be bolted to the
posts.
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8 / ROAD FURNITURE
Standards shall be firmly planted into the ground at the spacing shown on the Drawings
or as directed by the Engineer. The spacing of standards between any two straining posts
shall be uniform and not greater than that shown on the Drawings. In rock or hard ma-
terial, standards shall be either driven or set in holes drilled into the rock. The size of
drilled holes shall be such that a tight fit is obtained. Care shall be exercised when
driving standards in order to prevent buckling or damaging them.
All posts and standards shall be accurately aligned and set plumb. Where veranda type
security fencing is used, the posts shall be planted with the overhang on the road side and
perpendicular to the direction of the fence. After posts and standards have been firmly set
in accordance with the foregoing requirements, the fence wire shall be attached thereto at
the spacing shown on the Drawings.
8.2.5 Installing Wire
All fencing wire shall be wired to the sides of standards or posts in order to prevent the
wires from being displaced or becoming loose. The wire shall be carefully stretched and
hung without sag, and with true alignment, care being exercised not to stretch the wire so
tightly that it will break or that end, corner, straining or gate posts will be pulled up, or
that it will be easily damaged during grass fires.
Each strand of fencing shall be securely fastened in the correct position to each standard
with soft galvanized binding wire. The binder wire for each horizontal fence wire shall
pass through a hole or notch in the standard to prevent slipping of the fence wire in a
vertical direction, while the ends of the wire shall be wound at least four times around the
fencing wire to prevent it from moving in a vertical direction.
At end, corner, straining and gate posts, the fencing wire shall be securely wrapped twice
around the posts and secured against slipping by tying the end tightly around the wire by
means of at least six snug, tight twists.
In the case of high tensile wire, two long windings may first be made before the six tight
twists, to prevent the wire from breaking at the first twist. When using smooth wire, the
loose end shall preferably be bent over and hooked in to the notch between the fencing
wire and the first winding.
Splices in the fencing wire shall be permitted if made in the following manner using a
splice tool. The end of each wire at the splice shall be carried at least 75 mm past the
splice tool and wrapped snugly around the other wire for not less than six complete turns,
the two separate wire ends being turned in opposite directions. After the splice tool is
removed, the space left by it in the splice wire shall be closed by pulling the wire ends
together. The unused ends of wire shall be cut close so as to leave a neat splice.
The gaps between gate posts and the adjacent straining posts shall be fenced off with
short fencing wires or as shown on the Drawings.
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Droppers shall be tied to each fence wire with soft binding wire in the required position
as specified for standards, to prevent slipping in a vertical direction. The spacing of
droppers between any two straining posts shall be uniform. Anchoring to structures shall
be done as shown on the Drawings.
8.2.6 Installing Gates
Gates shall be installed at the positions indicated by the Engineer. The gates shall be
hung on gate fittings in accordance with the requirements shown on the Drawings. Gates
shall be so erected that they swing in a horizontal plane at right angles to the gate posts,
clear of the ground in all positions. At pedestrian and security fences, the double swing
gates shall not leave a gap of more than 25 mm between them when closed and other
gates shall not be further than 25 mm from the gate post when closed.
8.2.7 General Requirements
The completed fences shall be plumb, taut, true to line and ground contour, with all posts,
standards and stays firmly set. The height of the lower fencing wire above the ground at
posts and standards shall not vary by more than 25 mm from that shown on the
Drawings. Other fencing wires shall not vary by more than 10 mm from their prescribed
relative vertical positions.
Where temporary fences are erected, they shall be firm and of sufficient height with a
sufficient number of wires to prevent the passage of stock.
The Contractor shall, on completion of each section of fence, remove all cut-offs and
other loose wire or netting so as not to create a hazard to grazing animals or a nuisance to
the owners of the ground.
Fencing shall be measured by the linear metre specified and gates shall be measured by
number specified. The rates for fencing shall include for the cost of fence posts, struts,
and all wires. The rates for gates shall include for their installation at any point on the
Site.
8.3 ROAD SIGNS
Scope
This section covers the supply and erection of permanent road traffic signs alongside and
over the carriageway, ramps and cross-roads at interchanges and at the locations
indicated on the Drawings or directed by the Engineer.
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The signs shall be of the standard regulatory, warning and information signs as detailed
on the Drawings or directed by the Engineer and shall be fabricated in accordance with
the requirements of the most recent Road Traffic (Signs) Regulations.
8.3.1 Permanent Road Signs
Before placing any order for the manufacture of the signs, the Contractor shall submit to
the Engineer two copies of the following information:
(i) name of the firm from whom he proposes to obtain the signs together with place
of manufacture or fabrication;
(ii) a description of the items to be supplied with manufacturers specification

together with a description of quality, grade, weight and strength;
(iii) manufacturers "type" test certificates, or recent test results carried out on similar
items.
All colours on the permanent road signs, with the exception of black and grey, shall be
reflectorized, unless otherwise specified or instructed by the Engineer. The reflective
sheeting shall comply with the requirements given in Clause 8.3.2 (a), and shall be
applied by mechanical vacuum-heat application method to the approval of the Engineer.
The sign plate shall be covered by clear lacquer of a make recommended by the
manufacturer of the reflective material.
Permanent road signs shall comply with the requirements of BS 873 Parts 2, 6 and 7 in
respect of quality including the pre-treatment, preparation and protective coatings for the
frame, posts and fittings. Unless directed otherwise, posts, frames, fittings and the backs
of signs shall be painted with a finish coat of grey. Bolts and nuts shall be crimped or
spot welded to prevent theft.
Finished sign plates (with sign face attached) shall be clearly and durably marked on the
back, with the following information:
(a) the number of the British Standard to which they have been manufactured;
(b) the name, trade mark or other means of identification of the manufacturer or vendor;
(c) the classification of any retroflective material used in the manufacture of the sign
face;
(d) the month and year of assembly.
These markings shall be in characters legible at a normal reading distance so that the total
area of the marking does not exceed 30 cm2 and shall be sufficiently durable to last the
expected life of the sign plate to which it is applied.
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The manufacturer or vendor shall make available the following information:
(e) instructions on the assembly and erection of the sign;
(f) details of any limitations in location or usage;
(g) instructions on the operation and maintenance of the sign.
The foundation for permanent road signs shall be as shown on the Standard Drawings or
as instructed by the Engineer. Foundation for signs of areas over 5 m2 shall not be
covered up until they have been approved by the Engineer.
The Contractor shall cut back trees and vegetation to permit visibility and shall not
permit material to be dumped so as to obscure the signs.
All signs shall be maintained in clear and legible condition and shall be washed down as
8.3.2 Materials
(a) Structural Steel
Structural steel shall comply with the requirements of BS 4360 for the type of steel
specified or shown on the Drawings. Where specified, all structural steel, including
tubes, shall be galvanized in accordance with the requirements of BS 729
Steel tubes shall comply with the requirements of BS 3602.
(b) Bolts, Nuts and Rivets
Steel bolts and nuts shall conform to AASHTO M253 Type 3. Aluminium bolts and
nuts shall be manufactured from alloys according to BS 1473.
All steel bolts, nuts and washers shall have a hot-dip (galvanized) zinc coating that
complies with the requirements of BS 1706.
Blind rivets used for fixing sign faces to square tubing framework shall be 4.76 mm
rivets manufactured from or coated with a material that will not cause corrosion
through electrolytic action. Blind rivets used for jointing aluminium extrusions shall
be hardened aluminium blind rivets.
(c) Steel Plate
Steel plate shall be 1.60 mm thick and comply with the requirements of BS 4360.
Unless otherwise specified in the Special Specification or shown on the Drawings,

steel plate shall be galvanized in accordance with the requirements of BS 729.
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(d) Particle Board
Particle board shall be an exterior-grade timber particle board, 12.7 mm thick, unless
otherwise specified or indicated on the Drawings, and shall consist of a phenolated,
resin-bound timber particle core faced with a phenolated, resin-impregnated paper
overlay, heat bonded under high pressure to form a homogeneous structure.
(e) Aluminium
Aluminium extrusions shall be of the sizes detailed on the Drawings, shall be

manufactured from Grade 50S alloy and shall conform to the provisions of BS 1474
(HE9).
Aluminium plate shall be manufactured from Grade M57 alloy and shall conform to
the requirements of BS 1470 (NS4) and shall be 2.0 mm in thickness.
(f) Concrete
Concrete shall be manufactured and placed as specified in Section 6. Normally Class

1:3:6/38 concrete shall be used for the erection of road signs, unless otherwise shown
on the Drawings or directed by the Engineer.
(g) Reflective Material on Road Signs
The reflective material, when applied to the sign plate, shall give the appearance of a
continuous reflecting surface under any angle of observation. It shall consist of a
smooth exterior film with spherical lenses embedded beneath the surface, and shall
have a protected, pre-coated adhesive backing which shall be tack-free, heat-
activated for mechanical vacuum-heat application. The combination of various
elements shall result in a non-exposed lens type of optical reflecting system. The
reflective material shall be applied as per the instructions from the manufacturer of
the retro-reflective material used.
The reflective material shall comply with the following specifications:
(i) Reflective Brightness
The minimum coefficient of luminous intensity CIL (Coefficient d'Intensité

Lumineuse) of the reflective sign surface, when illuminated by CIE Standard
Illuminant A (colour temperature of 2854oK), shall be as specified in table
8.3.2/1. The response of the photoelectric receiver shall be corrected to the
colour sensitivity of the average photopic human eye.
Table 8.3.2/1
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Angle of Minimum CIL value

Candelas per lux per m²
Divergence Incidence White Yellow Red Green Blue
+ ++
5º 70 50 14.5 9.0 4.0
0.2º
30º 30 22 6.0 3.5 1.17
40º 12 10 2.7 1.5 0.7
5º 50 35 10.0 7.0 3.0
0.33º
30º 24 10 4.0 3.0 1.0
40º 9 6 1.8 1.2 0.4
5º 30 25 7.5 4.5 2.0
0.5º
30º 15 13 3.0 2.2 0.8
40º 7 5 1.4 1.1 0.3
5º 4 5 1.0 1.0 0.6
2º
30º 2 2.5 0.5 0.4 0.1
40º 1.5 1.3 0.3 0.2 0.06
+ Divergence Angle The angle between the line formed by a light beam striking
the surface and the line formed by its reflected light.
++ Incidence Angle The angle between a light beam striking a surface at a point
and the line perpendicular to the surface at the same point.
The brightness of the reflective material totally wet by rain shall be not less than 90%
of the values indicated in table 8.3.2/1.
(ii) Weather Resistance
The reflective surface of the sign shall be weather resistant and shall show no
appreciable cracking, blistering, crazing or dimensional changes after 2 years
unprotected outdoor exposure at 45o upwards inclination to the vertical, facing
West at an outdoor test location indicated by or approved by the Employer.
After cleaning, the CIL Values of the reflective surface shall then be not less
than 80% of the values given in the table above, and the colours shall still
conform to the specified requirements.
(iii) Bonding Strength
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When reflective surfaces are laminated to the base materials, the adhesion shall
be such that the reflective material shall resist peeling, scuffing and marring
during the normal handling or shocking off when jabbed with a spatula at -20oC.
It shall withstand 8 hours of soaking in water at 20oC without any noticeable
edge lifting or curling. The adhesive shall have no staining effect on the
reflective material. The adhesive shall permit the reflective material to adhere
securely 48 hours after application at temperatures between -20oC and +93oC.
(iv) Flexibility
When bent around a 20 mm diameter mandrel at a temperature of 20oC, the

reflective material applied to an aluminium panel of 0.5 mm thickness shall
show no evidence of cracking around the outside of the bend. After flattening
out, the CIL values shall be not less than those given in Table 8.3.2/1.
(v) Impact Resistance
When a 25 mm diameter steel ball is dropped from 2 metres height onto the
reflective face of the sign specimen at an ambient temperature of 20oC, the re-
flective material around the impact point shall show no evidence of cracking or
peeling off. The CIL values of the impact area shall be not less than those given
in Table 8.3.2/1.
(vi) Solvent Resistance and Cleaning
After immersion of a specimen of reflective sign material for 10 minutes in

methyl alcohol, kerosene or turpentine, or for 1 minute in toluol or xylol, the
reflective material shall show no evidence of dissolving, puckering or blistering.
The reflective material shall be capable of withstanding washing with a mixture
of water and mild detergent, turpentine and methanol. The reflective surface
shall be such as to be readily refurbished by cleaning and clear over-coating in
accordance with the manufacturer’s recommendations.
(h) Colours for Road Signs
Standard colours to be used for signs, posts and fittings shall be as described in the
relevant BS as follows:
Red BS 381C No. 537

Blue BS 4800 No. 18 E 53
Yellow BS 381C No. 355
Green for primary route signs BS 4800 No. 14 C 39
Grey for posts,
fittings and backs of signs BS 4800 No. 10A 11
Cream BS 381C No. 352
White BS 873 Part 1, clause 1-3.2
Black BS 873 Part 1, clause 1-3.3
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(i) Timber Poles for Sign Supports
Timber poles for sign supports shall be treated with a preservative as specified
below and after treatment only one cut per pole shall be allowed to obtain the
correct length and chamfer at the top of the post. The exposed surface of the cut
shall be given two coats of the applicable preservative.
(j) Timber Treatment
Timber poles shall be creosote pressure impregnated in accordance with BS 913.
(k) Steel Reinforcement
Steel reinforcement shall be mild steel reinforcement in accordance with the

provisions of Paragraph 6.2.
(l) Corrosion Protection Tape
Corrosion protection tape used between aluminium and steel shall be "Scotchrap 50"
or an equally approved material.
8.3.3 Painting
The preparation of surfaces and painting shall be carried out as specified in Subclauses
8.3.3.1 and 8.3.3.2.
Unless otherwise specified, aluminium road signs will not require painting, except for
painted sign faces.
Road sign faces and legend shall not be painted more than six months prior to their
erection.
8.3.3.1 Painting of Structural Steel
(a) Surface Preparation
After drilling, welding and punching have been completed, it must be ensured that all
sharp edges are uniformly rounded off and smoothed down. All physically adhering
contaminants shall be removed and the surfaces abrasive-blasted according to BS
4232. The profile limit of the surface finish shall be 0.050 mm.
No abrasive blasting shall be done during rainy weather or when corrosive air
conditions prevail.
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Unless the application of a primer follows within 4 hours of the abrasive blasting and
before any oxidation of the prepared surfaces takes place, the abrasive-blasted
surface shall be given one coat of wash primer immediately after blasting.
(b) Priming
The prepared surface shall be given two coats of a zinc chromate primer. The first
coat is to be applied within 12 hours in the case of wash-primed surfaces and within
4 hours, but before any oxidation of the surface takes place, in the case of abrasive-
blasted surfaces that have not been wash primed. A fast-drying zinc chromate may
be used as primer. In all cases, the dry film thickness shall not be less than 0.030
mm per coat.
(c) Undercoat
Where the finishing coats are to be applied on Site the primed surfaces shall be given
one coat of a universal undercoat of suitable colour in the manufacturers shop before
dispatch. The undercoat shall be applied as soon as the prime coat has dried
sufficiently. The dry film thickness shall not be less than 0.025 mm per coat.
(d) Finishing Coat
Two finishing coats of high-gloss structural paint of the specified colour shall be
applied to a dry film thickness of not less than 0.025 mm per coat.
Where the finishing coats are applied on Site, the undercoat shall be lightly sanded
and the members washed and cleaned of all contaminants. The first finishing coat
shall be applied as soon as the structural members are dry.
The dry film thickness of the total system shall not be less than 0.100 mm when no
undercoat is used and not less than 0.135 mm when an undercoat is used. When the
second finishing coat is an iron-ore pigmented paint, these thicknesses shall be
increased by 0.005 mm.
(e) Mating Surfaces
When mating surfaces are brought together both surfaces shall have been given the
full treatment specified, but where this is not possible each surface shall be given a
copious coating of primer and the surfaces drawn up while the paint is still wet.
(f) Back-to-back Members and Inaccessible Areas
Back-to-back members and inaccessible areas shall be fully coated up to an including

the finishing coats before erection.
8.3.3.2 Painting of Galvanized Surfaces
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Galvanized surfaces shall be painted as specified for steel surfaces in this section, except
that the surface preparation and priming shall be as follows:
(a) Surface Preparation
Newly galvanized surfaces shall be thoroughly scrubbed down using an approved

galvanized iron cleaner to remove all traces of the resin protective coating.
The surface shall be washed down and scrubbed to remove all traces of grease, oil,
dirt, etc.
(b) Priming
Two coats of calcium plumbate primer shall be applied to dry film thickness of at
least 0.025 mm.
The undercoat shall follow within one week of the primer.
8.3.4 Storage and Handling
All road signs or portions of road signs shall be so handled and stored in a weather-proof
store room that any permanent deformation or damage to painted surfaces is prevented.
All unpainted surfaces and steel work shall be protected against corrosion.
8.3.5 Erection of Road Signs
(a) Position
Road signs shall be erected in the positions shown on the Drawings or indicated by
the Engineer.
(b) Excavation and Backfilling
Excavations for the erection of road signs shall be made according to the dimensions
shown on the Drawings. Where the excavations are to be backfilled with soil, a 1:12
cement: soil mixture shall be made and backfilled at Optimum Moisture Content in
100 mm thick layers and compacted to a minimum of 97% MDD (AASHTO T99).
Where posts or structures are to be fixed in concrete, or where concrete footings are
to be cast, the concrete, formwork and reinforcement shall comply with the
requirements of Section 6. The holes shall be completely filled with concrete up to
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the level shown on the Drawings or indicated by the Engineer. The upper surface of
the concrete shall be neatly finished with sufficient fall to ensure proper drainage.
(c) Erection
Road signs shall be erected as shown on the Drawings or as directed by the Engineer.
During erection, the structural steel work shall be firmly bolted and protected in
order that no buckling or damage is caused during erection or by the equipment used
for erection.
Posts to which road signs are to be fixed shall be vertical and the underside of road
signs shall be horizontal after completion of erection.
The month and year of erection of the road signs shall be indicated by means of
white paint on the back of the sign in the bottom right hand corner. The letters and
figures shall be 25 mm high.
Where signs are erected using timber poles, all holes that are drilled in timber shall
be impregnated with hot creosote.
(d) Field Welding
All welding done during erection shall comply with the requirements for welding
during manufacture.
(e) Painting on Site
All painting done after erection shall comply with the requirements for painting
during manufacture.
All places where the paint work has been damaged during erection shall be made
good by the Contractor, at his own cost, to the satisfaction of the Engineer.
(f) Time of Erection
Road traffic signs shall be erected immediately prior to the opening of the road to
public traffic, unless otherwise decided by the Engineer.
8.3.6 Protection and Maintenance
The Contractor shall protect the completed road signs against all damage until the road is
finally accepted by the Employer, and he shall maintain the road signs until the
Maintenance Certificate is issued. Damage or defects caused by faulty workmanship or
negligence shall be made good by the Contractor, at his own cost, to the satisfaction of
the Engineer.
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8.3.7 Dismantling and Re-Erection of Existing Road Signs
Where ordered by the Engineer, the Contractor shall dismantle existing road signs and re-
erect them at new positions indicated. This work shall be done with as little damage as
possible to the signs.
Where required by the Engineer, the signs shall be re-painted or repaired, and new
materials shall be used for part or all of the supporting structure.
Warning, prohibition, mandatory and priority signs shall be measured by number as

instructed by the Engineer. The rates for warning, prohibition, mandatory and priority
signs shall include for the cost of all materials, fabrication and installation at any point on
the Site.
Direction, advance direction and confirmatory signs shall be measured by surface area in
m2 in accordance with the following groups.
GROUP AREA OF SIGNBOARD
I Less than 1 m2
II 1 - 2 m2
III 2 - 5 m2
IV More than 5 m2
The rates for direction, advance direction and confirmatory signs shall include for the
cost of all materials, fabrication and installation at any point on the Site.
8.4 ROAD MARKING
Scope
This Section covers the permanent marking of the road surface with white or yellow
painted lines or symbols and the supply and fixing of retro-reflective road studs as
indicated on the Drawings or where required by the Engineer.
8.4.1 Materials
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8.4.1.1 Thermoplastic Materials for Road Marking
a) General
The material to be used for road marking and striping shall be a thermoplastic
reflectorized type of material specifically produced for the purpose. The material
shall be applied to the pavement in a molten state by mechanical means.
Upon cooling to normal pavement temperature, it shall produce an adherent

reflectorized stripe of specified thickness and width capable of re-siting deformation
by traffic.
b) Thermoplastic Material
Thermoplastic material shall be a high quality, elastic type wit mix-in of 20%
reflectory beads. The beads shall be ballotini, or similarly approved and shall be
reasonably spherical and free from flaws and of a size suitable for this type of
reflectorization.
The raw thermoplastic material shall be composed by the pigment the reflectory
beads and filler uniformly dispersed in the resin. It may be supplied in bags, ready
mixed as powder, which shall be heated and stirred prior to application in accordance
with the manufacturer's recommendations.
c) Colour
The thermoplastic material shall be available in yellow and white colour.
(i) White
The colour of white markings shall match the colour No. 00E55 of BS 4800.
(ii) Yellow
The colour of yellow markings shall match the colour No. 08E51 of BS 4800.
d) Test Certificates
The Contractor shall submit, for each consignment of thermoplastic material

delivered to site, the Manufacturer's certificate to show that the materials comply in
all respects with the relevant product specifications.
8.4.1.2 Paint for Road Marking
a) General Requirements
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The paints to be used for road surface marking shall be specifically manufactured for
such purposes. It shall be suitable for applying by brush, low pressure spraying
equipment and high pressure spraying equipment. The paint shall be reflectorized
unless otherwise specified.
The paint shall be of a type approved for road marking, and if not on the current
approved list, samples shall be submitted to the Engineer for approval at least 6
months prior to the proposed use.
b) Colour
i White
The colour of white markings shall be BS Colour No 00E55 of BS 4800.
The pigment used for white materials shall be titanium dioxide Type A
(Anatase) or Type B (Rutile) complying with BS 1851.
ii Yellow
The colour of yellow markings shall be to BS Colour No 08E51 of BS 4800.
(c) Drying Time
The drying time allowed shall be as specified by the manufacturer, subject to the
touch dry condition being reached in a maximum of 15 minutes.
(d) Reflectorization
(i) Non-reflectorized
Paint specified to be non-reflectorized shall have minimum reflective brightness

values, as compared to magnesium oxide (MgO) or for white 80% and for
yellow (using a yellow filter of 5800oA) 65%.
(ii) Internal reflectorization
Internally reflectorized paint shall be specifically manufactured for this purpose

and shall contain ballotini beads to BS 6088. The ballotini shall be reasonably
spherical and free from flaws, and of a size suitable for this method of
reflectorization, subject to a maximum nominal size of 0.5 mm.
(iii) Surface reflectorization
Surface reflectorization of the paint shall be by application of ballotini beads to

BS 6088 to the wet paint film. The ballotini shall be reasonably spherical and
free from flaws and of a size suitable for this method of reflectorization, subject
to a maximum nominal size of 0.8 mm.
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(e) Test Certificates
When required by the Engineer, the Contractor shall submit, for each consignment of
paint delivered to Site, test certificates from an approved, independent testing
authority to show that the respective materials comply in all respects with relevant
product specifications.
8.4.2 Application of Road Marking
8.4.2.1 Weather Limitations
Road marking material shall not be applied to a damp surface or when the relative
humidity exceeds 80%, or at temperatures lower than 10o C, or when in the opinion of
the Engineer, wind strength is such that it may adversely affect the application operations.
8.4.2.2 Mechanical Equipment for Application
a) Thermoplastic Marking
The equipment shall consist of a suitable apparatus to clean the surfaces, a melting
pot of minimum 250 l capacity, an automatic, self propelled thermoplastic laying
machine and all additional hand operated equipment necessary to complete the work.
The laying machine shall be capable of laying road markings of different widths in
the range of 50-500 mm.
b) Paint
The equipment shall consist of an apparatus to clean the surfaces, a mechanical road
painting machine and all additional hand-operated equipment necessary to complete
the work. The mechanical road marking machine shall be capable of painting at least
two lines simultaneously and shall apply the paint to a uniform film thickness at the
rate of application specified. The machine shall be so designed that it will be capable
of painting the traffic markings to a uniform width with sides within the tolerances
specified hereinafter, without the paint running or splashing. The machine shall
further be capable of painting lines of different widths by adjustment of the spray jets
on the machine or by means of additional equipment attached to the machine.
The machine shall be capable of spraying at a speed of not less than 5.0 km/h.
8.4.2.3 Surface Preparation
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Traffic markings shall be applied to bituminous surfaces only after sufficient time has
elapsed to ensure that damage will not be caused to the surface by volatile substances
evaporating from the bituminous surfacing. In no case shall traffic paint markings be
applied until at least 48 hours after the completion of the bituminous surfacing or any
longer period required by the Engineer.
Before the material is applied, the surface shall be clean and dry and completely free
from soil, grease, oil, acid or any other material which will be detrimental to the bond
between the marking material and the surface. The portions of the surface where the
marking is to be applied shall be properly cleaned by means of watering, brooming or
compressed air if required.
Where road markings are to be applied on a concrete pavement, all laitance and loose
curing compound shall be removed. Particular care shall be taken to expose a surface of
fresh concrete on all areas where road studs are to be fixed.
8.4.2.4 Setting Out of Road Markings
The lines, symbols, figures or marks shall be set out by means of paint spots of the same
colour as that of the proposed final lines and marks. These spot marks shall be at such
intervals as will ensure that the traffic markings can be accurately applied, and in no case
shall they be more than 1.5 m from each other. Normally, spots of approximately 10 mm
in diameter should be sufficient.
The dimensions and positions of traffic marking shall be as shown on the Drawings or as
specified in the national regulations for traffic signs and markings.
After spotting, the positions of the proposed road marking such as dotted lines and
starting and finishing points of barrier lines are to be indicated on the road. These pre-
markings must be approved by the Engineer prior to the commencement of any marking
operations.
The positions and outlines of special markings are to be produced in chalk on the finished
road and must be approved by the Engineer before they are applied. The use of approved
templates will be permissible on condition that the positioning of the marking is
approved by the Engineer before application is commenced.
The position of road studs shall be marked out on the road and shall be approved by the
Engineer before they are fixed in position.
The Contractor shall be responsible for all setting out of road marking as agreed with the
Engineer.
8.4.2.5 Construction Requirement
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The road marking material shall be applied as figures, signs, letters, symbols, broken or
unbroken lines or other marks, as shown on the Drawings or directed by the Engineer.
Where the marking material is applied by means of a machine, it shall be applied in one
layer. Before the road marking machine is used on the permanent works, the satisfactory
working of the machine shall be demonstrated on a suitable site which is not part of the
permanent works. Adjustment to the machine shall be followed by further testing. Only
when the machine has been correctly adjusted and approved by the Engineer may the
machine be used on the permanent work. The operator shall be experienced in the use of
the machine. The rate of application shall be checked and adjusted if necessary before
application on a large scale is commenced and thereafter daily.
Where two or three lines are required next to each other, the lines shall be applied
simultaneously by the same machine. The marking material shall be treated before
application, in accordance with the manufacturers instructions. Paint shall be applied
without the addition of thinners.
Where, under special circumstances, painting is done by hand, it shall be applied in two
layers, and the second layer shall not be applied before the first layer has dried out
sufficiently. As most road marking paint reacts with the bitumen surface of the road, the
paint is to be applied with only one stroke of the brush or roller at any one point on the
road.
Ordinary road marking paint shall be applied at a nominal rate of 0.42 l/m2, or as directed
by the Engineer, and proprietary brand paints shall be applied at the rates specified in the
Thermoplastic road marking material shall be applied at a nominal rate of 5 kg/m² on

asphalt concrete and 6 kg/m² on surface dressing.
Road marking shall be completed before a particular section is opened to traffic. Each
layer of paint shall be continuous over the whole area being painted.
Edge lines of thermoplastic material shall be broken by a 100 mm gap for every 10 m
continuous line.
Where retro-reflective paint is required, the retro-reflective glass beads shall be applied
by means of a suitable machine immediately after the application of the paint in one
continuous operation. The rate of application of the beads shall be 0.8 kg/l paint or such
other rate as may be indicated by the Engineer. Machines that apply the beads by means
of gravity only shall not be used. The beads shall be sprayed onto the paint layer.
8.4.2.6 Protection
After the application, the traffic markings shall be protected against damage by traffic or
other causes. The Contractor is responsible for the erection, placing and removal of all
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warning boards, flags, cones, barricades and other protection measures which may be
necessary.
8.4.3 Road Studs
Road studs shall be of the types indicated on the Drawings or specified in the Special
Specification and shall be fixed in the positions indicated and approved by the Engineer.
The Contractor shall submit samples of the type of road studs he proposes to supply, to
the Engineer for his approval prior to delivery
The studs shall be fixed to the road surface by means of an approved epoxy resin, in
accordance with the manufacturer’s instructions, after the road lines have been
completed. Sufficient adhesive shall be used to give complete coverage of the contact
area and to provide a slight excess. The road studs shall be pressed down on the prepared
area and all excess adhesive pressed out. The excess adhesive shall then be removed
immediately with a suitable solvent. The studs shall be protected against impact until the
adhesive has hardened. Before fixing, the surface shall be thoroughly cleaned as specified
in Sub-clause 8.4.2.3.
8.4.4 Tolerances
8.4.4.1 General
Road traffic markings shall be constructed to an accuracy within the tolerances given
below:
(a) Width
The width of lines and other markings shall not deviate from the specified width by
more than 5%.
(b) Position
The position of lines, letters, figures, arrows, retro-reflective road studs and other
markings shall not deviate from the true position specified by more than 20 mm.
(c) Alignment of Markings
The alignment of any edge of a longitudinal line shall not deviate from the true
alignment by more than 10 mm in 15 m.
(d) Broken Lines
The length of segments of broken longitudinal lines shall not deviate from the
specified length by more than 150 mm.
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In broken lines, the length of segments and the gap between segments shall be as
indicated on the Drawings. If these lengths are altered by the Engineer, the ratio of
the lengths of the painted sections shall remain the same.
Lines and curves, whether broken or unbroken, shall not consist of chords but shall
follow the correct radius.
8.4.4.2 Faulty Workmanship or Materials
If any materials not complying with the requirements is delivered at the Site or used in
the Works, or if any sub-standard work is carried out, such material or work shall be
removed, replaced or repaired as required by the Engineer, at the Contractor's own cost.
Rejected traffic markings and paint that has been splashed or has dripped onto the
surfacing, kerbs, structures or other such surfaces shall be removed by the Contractor at
his own cost, in such a way that the markings or spilt paint will not show up again later.
Road marking lines shall be measured by the linear metre for each width of line. Words
and symbols shall be measured by number. The rates for road marking lines, words and
symbols, shall include for the cost of a tack coat of bituminous material, if instructed,
paint, or thermoplastic material, ballotini, stencils, setting out, temporary signs, barriers,
all traffic control and making good.
8.5 GUARD RAILS
Scope
This section covers the supply, installation and maintenance of metal plate beam guard
rails at locations and in conformity with the details, dimensions and design shown on the
8.5.1 Materials
8.5.1.1 Guard Rails
Guard rails shall comply with the requirements of AASHTO M180.
Dimensions of guard rails and terminal sections shall be as shown on the Drawings.
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Guard rails shall be supplied together with all bolts, nuts, washers and fixing materials
required other than bolts for fixing to posts.
(i) Galvanizing
When galvanized guard rails are called for on the Drawings or in the Bill of
Quantities, a hot-dip (galvanized) zinc coating that complies with the re-
quirements of AASHTO M232 for coatings on Type A articles shall be applied.
All bolts, nuts and washers shall have a hot-dip (galvanized) zinc coating that
complies with the requirements of AASHTO M232 for coatings on Type C
articles. Galvanized guard rails shall not be nested when stacked for storage.
(ii) Painting
When painted guard rails are called for, two coats of zinc chromate primer as
specified in Clause 7.4.2 shall be applied after manufacture and surface
preparation.
(iii) Galvanizing and Painting
When galvanized and painted guard rails are ordered, galvanizing shall be in
accordance with AASHTO M232. Painting shall be in accordance with Clause
8.3.3
8.5.1.2 Guard Rail Posts
(i) Steel Posts
Steel posts shall be of the type and size shown on the Drawings or described in
the Special Specification.
(ii) Timber Posts
Only under exceptional circumstances may timber posts be used.
Timber posts shall be supplied in lengths as shown on the Drawings and shall
comply with the requirements of AASHTO M168.
Posts shall have a top diameter of at least 150 mm. Posts with a top diameter of
up to 230 mm will be acceptable, provided that posts of widely varying diameter
are not used together in the same length of guard rail.
Posts shall be drilled and shaped as shown on the Drawings and shall be
provided with the necessary bolts, nuts, washers and spacer blocks for fixing.
Timber post and spacers shall be creosoted.
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Where cutting of posts is unavoidable, however, the Engineer may permit that
the required length be cut off the bottom of a post, provided the exposed area is
subsequently treated with creosote.
Timber posts shall not exhibit excessive cracking at the ends, particularly not
cracks aligned at an angle of more than 45o to the guard rail. Posts which, in the
opinion of the Engineer, exhibit a degree of cracking that would seriously
impair their life or strength shall not be used.
8.5.1.3 Reflector Plates
V-shaped reflector plates shall be manufactured form 1.5 mm thick mild steel plate to the
dimensions shown on the Drawings. When supplied with galvanized guard rails, they
shall be galvanized, and when supplied with painted guard rails they shall be finished in
white baked enamel. The outer surfaces shall be provided with retro-reflective material,
such as "3 M high intensity Scotchlite" in the colours shown on the Drawings. Holes for
fixing shall be drilled before galvanizing or painting.
8.5.2 Construction
8.5.2.1 Erection
The holes for the timber posts shall be of sufficient size to permit proper setting of the
posts and to allow sufficient room for backfilling and tamping. At least 1 m of the posts
shall be embedded in the ground.
The holes for the timber posts shall be spaced to suit the standard length of guard rail
supplied. Where shown on the Drawings or directed by the Engineer, posts shall be set at
half spacing. The hole for the concrete block at the end of a length of guard rail shall be
neatly excavated and the top 120 mm shall be shuttered.
The posts, spacer blocks (if applicable) and guard rails shall be completely erected, set
true to line and level, so that the rail is at the required height above the level of the
completed road shoulder and the lap is in the direction of the traffic movement. The
guard rail shall be suitably braced to prevent any movement, and all bolts shall be
tightened prior to any backfilling of holes.
After the Engineer has signified his approval of the guard rails so erected, the holes shall
be backfilled with a 12:1 soil:cement mixture. The material may be mixed either by hand
or mechanically and the correct quantity of water shall be added to ensure that the
mixture is placed at or near the Optimum Moisture Content. The mixture shall then be
placed and thoroughly rammed in layers not exceeding 100 mm compacted thickness.
The approach ends, where the guard rail has to be bent down and anchored, shall be
constructed as shown on the Drawings.
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When the backfilling is complete and the bracing removed, the posts must be rigid and
vertical and the guard rail true to line and level and firmly fastened to the posts. Excess
excavated material shall be disposed of as directed by the Engineer.
Steel posts shall be erected and fixed as shown on the Drawings.
All guard rails shall be erected in such a way that there are no projecting ends that might
interfere with or endanger traffic. The edges and the centre of the rail elements shall
make contact with the spacer block, or with the post where no spacer blocks are used.
Guard rail elements shall lap in the direction of the traffic and, if specified, guard rails
shall be provided with terminal sections which shall be lapped on the traffic face. All
splices of rail elements shall be at a post and plate ends shall make contact through the
entire area of the splice.
Reflector plates shall be fixed in accordance with the details shown on the Drawings. The
reflective surfaces shall be arranged with the colours as shown on the Drawings.
8.5.2.2 Painting
Before installation, the rail elements shall be cleaned, primed and painted as specified in
Sub-clause 8.5.1.1. After installation, all abraded or damaged surfaces shall be re-painted
with the finishing coat.
When galvanized guard rails are to be painted they shall be thoroughly washed down to
remove all traces of contaminants and painted in accordance with Sub-clause 8.5.1.1.
When existing guard rails must be re-painted, they shall be thoroughly cleaned with wire
brushes and be de-scaled with suitable tools to remove rust, loose and oxidized paint.
Thereafter they shall be washed down and all exposed steel surfaces shall be given a coat
of zinc chromate primer.
The prepared surface shall then be given a full coat of zinc chromate primer and two
finishing coats.
8.5.2.3 General Requirements
The completed guard rails shall be neat, and there shall be no visible deviations from line
and grade. The posts shall be straight and vertical. The rail beam shall be straight and
vertical. The rail beam shall not be warped but shall be in a vertical plane parallel to the
road centre line except at flared sections. The painted or galvanized surface on the rail
shall be smooth and continuous, free from abrasions and scratches. Any damage to the
painted surface shall be made good at the Contractor's expense.
Guard rails not complying with the specified requirements shall be replaced or otherwise
made good.
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8.5.2.4 Removal of Existing Guard Rails
Where ordered by the Engineer, the Contractor shall dismantle and remove existing
guard rails and posts. The guard rails shall be carefully removed, posts dug out and
excavations for removing posts backfilled and compacted. Guard rails and accessories
shall be removed, transported and stacked in the positions indicated by the Engineer.
Guard rails shall be measured by linear metre. The rates for guard rail shall include for
the supply of all materials, excavation, erection, backfilling including supply and mixing
in of cement in backfill material if instructed, cutting, bolting, splicing, galvanizing or
painting, spot welding of nuts, repairs of galvanizing and all work necessary for the
completion of the guard rail.
8.6 LANDSCAPING AND GRASSING
Scope
This paragraph covers the landscaping of areas outside the road prism, the establishment
of vegetation for functional and aesthetic purposes such as, landscaped areas and other
areas as may be required.
8.6.1 Materials
8.6.1.1 Fertilizer
The type of fertilizer to be used shall be one or more of the following and any other
fertilizer as may be specified in the Special Specification or ordered by the Engineer.
a) Agricultural lime
b) Super phosphate
c) Limestone ammonium-nitrate
d) 2:3:2
8.6.1.2 Grass Cuttings
Grass cuttings shall be fresh cuttings of an approved type of local couch grass with
sufficient root material to ensure good growth.
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8.6.1.3 Grass Seed
Only good-quality fresh seed shall be used and the types of seed in the seed mixture shall
be as specified in the Special Specification.
8.6.1.4 Grass Sods
Grass sods shall be harvested, delivered and planted within 36 hours, unless otherwise
authorized by the Engineer. Grass sods shall be free from noxious weeds and diseases
and shall contain a minimum of 30 mm of soil. The sods shall be of the variety of grass
specified in the Special Specification, unless otherwise approved by the Engineer. The
grass shall have been grown specifically for sod purposes, mown regularly and
maintained to provide an approved quality of uniformity. It shall be harvested by special
machines manufactured for this purpose to ensure an even depth of cut with sufficient
root material and soil.
8.6.1.5 Topsoil
Topsoil shall consist of fertile loamy soil, selected from areas showing a good coverage
of natural vegetation, preferably grasses. It shall be free from deleterious matter such as
large roots, stones, refuse, stiff or heavy clays and noxious seeds, which would adversely
affect its suitability for planting grass.
Topsoil shall be obtained wherever suitable material occurs either in the road reserve
from areas where cuts and fills are to be constructed or from borrow areas to be cleared,
as described in Clause 3.2.1. The Engineer shall indicate to the Contractor his re-
quirements regarding the quantity of topsoil required and the areas from which it shall be
selected and removed. Unless otherwise specified, topsoil shall be taken from not more
than 400 mm from the surface. If the Contractor fails to conserve topsoil as instructed, he
shall obtain suitable substitute material from other sources at no extra cost to the
Employer.
Where so specified, the Contractor shall procure and furnish topsoil from his own
sources outside the Site, such source to be approved by the Engineer.
Topsoil shall be stockpiled in separate loose heaps as tipped from the trucks and shall not
be stockpiled higher than 2.0 m. Care shall be exercised to prevent the compaction of
topsoil in any way, especially by trucks travelling over such material.
8.6.1.6 Manure and Compost
Manure shall, unless another type is approved by the Engineer, be pure farm manure free
from soil, weed seeds or other objectionable material. It shall not contain particles that
will not pass a 50 mm size screen and shall be approved by the Engineer before being
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delivered to the Site. Compost shall be well-decayed, friable and free from weed seed,
dust and other objectionable materials.
8.6.2 Landscaping of Areas
8.6.2.1 Shaping
Areas within the road reserve but outside the road prism that require shaping involving
bulk earthworks, such as contoured areas of interchanges and intersections, and rest areas
requiring earthworks, shall be excavated, filled, compacted when required and shaped to
the correct contours to within a tolerance of plus or minus 150 mm. Such work shall be
considered as earthworks and measurement and payment shall be made under Section 3
of these Specifications, except that quantities may be measured by means of a grid of
levels taken at 10 m intervals before and after shaping, or they may be determined by
levelled cross-sections.
8.6.2.2 Trimming
Trimming shall consist of bringing the existing or previously shaped ground to an even
surface with the final levels generally following the original surface. Trimming shall
normally be done by means of a grader, or in more confined or steep areas by bulldozer.
Where machine operations are not practicable, because of confined space or steep slopes,
trimming shall be done using hand tools. Where instructed by the Engineer, trimming
shall be done to areas inside the road reserve but outside the road prism, normally outside
the top of cuts or the toe of fills, but trimming of rock outcrops and hillocks will not be
required.
Trimmed surfaces shall be left slightly rough to facilitate binding with topsoil or the
natural establishment of vegetation.
When requiring subsequent grassing or when ordered by the Engineer, areas previously
shaped shall be trimmed as described above to within a tolerance of plus or minus 100
mm, with all undulations following a smooth curve. The above tolerances shall apply
only to areas where the final contours are given in the Drawings.
During trimming, all stones in excess of 100 mm in size and all excess material shall be
removed. Trimming of any areas requiring grass shall be done in such a way that, after
cultivation and application of any topsoil, the finished surface of the areas shall be
approximately 25 mm below the top of adjacent kerbing, channelling or pavement.
8.6.3 Preparation of Areas for Grassing
The various areas to be grassed shall be prepared as follows:
(a) Areas not Requiring Topsoil
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Where the areas to be grassed consist of organically suitable material, they shall be
scarified to a minimum depth of 150 mm. All loose stones larger than 100 mm on
areas to be mowed by machines and falling within the road reserve and all stones
larger than 150 mm in other areas shall be removed.
(b) Areas Requiring Topsoil
Where areas to be grassed consist of organically unsuitable material, the surface shall
be roughened to ensure a proper bond between the topsoil and the subsoil. If
required, the area shall be scarified as described in Sub clause 8.6.3.a above.
Topsoil shall be placed on the prepared surfaces and be trimmed to the uniform
thickness required. The topsoil shall be prepared by means of hand raking or soil
mixers and all stones shall be removed as specified for areas not requiring topsoil in
Sub clause 8.6.3.b above.
(c) Fertilizing
The Contractor shall have the top 150 mm of the prepared surfaces tested to
determine the amount and type of fertilizer required for establishing proper growth
conditions for the grass. The fertilizer shall be evenly applied over all surfaces where
grass is to be planted and shall be thoroughly mixed with the soil to a depth of 150
mm either mechanically or manually.
8.6.4 Grassing
The method of establishing grass shall depend on the circumstances relating to each case
and the Engineer shall decide which method is to be used.
8.6.4.1 Planting of Grass Cuttings
The areas to be planted shall, unless they are wet, be thoroughly watered before planting
to ensure that soil will be uniformly wet over a depth of at least 150 mm when planting
takes place.
An approved variety of couch grass cuttings shall be evenly planted by hand or

mechanically means at a rate of at least 70 grain bags of cuttings per hectare. Only fresh
cuttings shall be used and no grass cuttings that have been allowed to dry out shall be
used. Immediately after planting, the grass cuttings shall be given a copious watering and
when sufficiently dry shall be rolled with a light agricultural roller.
8.6.4.2 Sodding
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Areas to be grassed by sodding shall be given a layer of topsoil at least 75 mm thick

unless, due to the presence of suitable sub-soil, the Engineer orders that the topsoil be
omitted. The areas to be sodded shall be thoroughly watered beforehand so that they are
wet to a depth of at least 150 mm when sodding is done. The surface shall be made
slightly rough to ensure a good penetration of roots into the soil. Sods shall be protected
against drying out and shall be kept moist from the time of harvesting until finally placed.
The first row of sods shall, where it is possible, be laid in a straight line and, if on a slope,
starting at the bottom of the slope. The sods shall be butted tightly against each other,
care being taken not to stretch or overlap sods. Where a good fit cannot be obtained, the
intervening space shall be filled with topsoil. The next row shall be placed in the same
manner tightly against the bottom row with the joints staggered and so on until the full
area is covered with sods. On steep slopes, when instructed by the Engineer, the sods
shall be held in position by sufficient wooden stakes approximately 300 mm long by 20
mm in diameter.
The Contractor shall water the sods directly after placing to prevent undue drying out. As
sodding is completed, each section shall be lightly rolled and thoroughly watered.
8.6.4.3 Seeding
The types and mixtures of seeds to be used shall be agreed between the Engineer and the
Contractor. The Contractor shall be solely responsible for establishing an acceptable
grass cover and any approval by the Engineer of seed or seed mixture proposed for use
shall not relieve him from his responsibility.
8.6.4.4 Top soiling
Where, in the opinion of the Engineer, the planting of grass or seeding can be dispensed
with due to favourable climatic and other conditions, he may attempt to establish grass by
top soiling only. Topsoil shall be selected for the presence of natural grass and seeds and
shall be removed and placed whenever possible at a time that would be favourable for the
subsequent establishment of grass.
After placing of the topsoil it shall be rolled lightly and watered well. Thereafter it shall
be watered and cut whenever instructed by the Engineer.
When this procedure is followed, the Contractor shall not be held responsible for the
establishment of an acceptable grass cover as defined below, but shall be responsible for
the consequences of any omission to water or mow the grass as instructed by the Engi-
neer.
No payment for grassing shall be made other than for placing the topsoil, mowing and
watering, which shall be paid for at tendered rates. Re-planting of bare patches, repairs
due to erosion and similar work shall be paid for as day works.
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8.6.4.5 Miscellaneous
Whenever specified in the Special Specification other methods of grassing may be

employed.
Grassing of borrow pits, temporary by-passes, camp sites, access roads and stockpile sites
shall not be paid for separately unless specifically included in the Bill of Quantities as
areas to receive grassing.
8.6.5 Establishment and Maintenance of the Grass
8.6.5.1 Watering, Weeding, Cutting and Re-Planting
All sodded and planted areas shall be adequately watered at frequent and regular intervals
in order to ensure proper germination of seeds and growth of grass until the grass has
established an acceptable cover and thereafter until the beginning of the maintenance
period of the grass. The amount and frequency of watering shall be subject to the
Engineer's approval.
The Contractor shall further mow the grass on all areas that have been grassed whenever
so instructed by the Engineer, until the end of the maintenance period. All grass cuttings
shall be collected and disposed of if so directed by the Engineer. Weeds shall be
controlled by means of pulling, cutting or any other approved means. Any bare patches
where the grass has been damaged or has dried up, shall be cultivated, planted, sodded or
seeded at the Contractor's expense.
All grassed areas shall have acceptable cover as defined below at both the beginning and
the end of the maintenance period.
8.6.5.2 Acceptable Cover
An acceptable grass cover shall mean that not less than 75% of the area planted or seeded
shall be covered with grass and that there shall be no bare patches of more than 500 mm
in maximum dimension. In the case of sodding, acceptable cover shall mean that the full
area shall be covered with live grass at the end of any period not less than three months
after sodding.
8.6.5.3 Maintenance Period
The maintenance period of grass shall commence when an acceptable cover as defined
above has been established and shall be one year. This means that the maintenance period
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for grass can commence earlier or later than the maintenance period for other portions of
the Contract.
If the maintenance period for grass expires before the end of the maintenance period for
the other road works, the Contractor shall further mow the grass on such areas as
instructed by the Engineer up to the end of the maintenance period for the main road
works.
8.6.6 Supplementary Requirements
8.6.6.1 Time of Planting
The planting of grass, trees and shrubs shall be carried out as far as is practicable during
periods most likely to produce beneficial results. The Contractor shall make every effort
to programme his operations in such a manner that this is done as far as possible.
8.6.6.2 Traffic on Grassed Areas
The Contractor shall not plant grass until all operations that may require road building
equipment to be taken over grassed areas have been completed. No road building
equipment, trucks or water carts shall be allowed on areas that have been grassed and
only equipment required for the preparation of areas, application of fertilizer and
spreading of topsoil will be allowed to operate on areas to be grassed.
8.6.6.3 Erosion Control
During construction, the Contractor shall protect all grassed areas susceptible to erosion
by installing all necessary temporary and permanent drainage works as soon as possible
and by taking such other measures as may be necessary to prevent the concentration of
surface water and scouring of slopes, banks and other areas.
Any runnels or erosion channels developing during the construction period or during the
maintenance period shall be backfilled and consolidated and the areas restored to their
proper condition. The Contractor shall not allow erosion to develop on a large scale
before effecting repairs and all erosion damage shall be repaired as soon as possible and
in any case not later than three months before the termination of the maintenance period.
All topsoil or other material accumulated in side drains shall be removed at the same
time. Topsoil washed away shall be replaced.
8.6.6.4 Responsibility for Establishing an Acceptable Cover
Notwithstanding the fact that the Engineer will determine the method of grassing and that
the type of seed or grass used and the rate of application of seed may be specified or
agreed to by the Engineer, and that the frequency of mowing will be as ordered by him,
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the Contractor shall be solely responsible for establishing an acceptable grass cover and
for the cost of replanting or reseeding where acceptable cover is not obtained. Where,
however, in the opinion of the Contractor, it is doubtful from the outset whether it will be
possible to establish an acceptable cover, he may inform the Engineer of his reasons for
this and the Engineer shall, if he agrees, either adopt another method of grassing or agree
to accept whatever cover can be obtained, provided that all reasonable efforts are made to
establish a good cover using the method proposed. Any such agreement shall only be
valid if given in writing by the Engineer.
In the case of grassing by top-soiling only, the Contractor shall not be held directly
responsible for the establishment of an acceptable grass cover but shall be held
responsible for the consequences of supplying workmanship that does not conform to the
specifications or for lack of proper care.
(i) Grassing
Grassing shall be measured by the square metre of area specified. The tendered
rate shall include full compensation for furnishing, planting, and watering the
grass sprigs or hydro-seeding as specified.
(ii) Top-soiling and Grassing
Topsoil shall be measured by the cubic metre placed and lightly compacted
measured as the product of the area specified and the specified thickness.
The tendered rate shall include full compensation for furnishing all materials,
compaction, trimming, grassing, watering and for all other work necessary to
complete the work according to the Specifications.
Measurement and payment for other relevant items covered by this Paragraph and
entered in the Bill of Quantities shall be made as specified in the Special Specifications.
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Zambia Road Specifications

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1 / GENERAL

1.1 TERMINOLOGY. UNITS OF MEASUREMENTS AND ABBREVIATIONS

A mixture to predetermined proportions of aggregate, filler and bituminous binder

The term "borrow" applies to all borrow materials.

Catch-water Drain or Bank

Inlet and Outlet Drain

This ratio may also be expressed as a percentage.

Open surface working from which stone is removed by blasting or drilling.

Surface treatment is the sealing or resealing of the carriageway or shoulders by means of

1.1.2 Units of Measurement

Symbols for units of measurement conforming to the SI system:

The following abbreviations are used:

ACV Aggregate Crushing Value

1.2 SCOPE OF WORKS

1.2.1 Location and Extent of the Site

1.2.2 Extent of Contract

The extent of the Contract is defined in the Specifications of Particular Application.

1.2.4 Order of Work

1.2.5 Method of Construction

1.2.7 National Specifications

In referring to specifications the following abbreviations are used:

BSCP or CP British Standard Code of Practice

AASHTO American Association of State Highway

ASTM American Society of Testing and Materials

ISO International Organization for Standardization

1.2.8 General Construction Requirements

The following general requirements shall apply:

(f) The Contractor shall take all reasonable precautions:

(ii) in connection with underground water resources (including percolating water)

Examination by the Engineer or the Engineer's Representative of the Contractor's

1.2.9 Water Supply

1.2.10 Use of the Site

1.2.11 Protection of the Work

1.2.12 Workmanship and Quality Control

1.2.13 Progress Photographs

The number of photographs required is given in the Specifications of Particular

1.2.14 Final Clearance

1.2.15 Measurement and Payment

1.3 LEGAL RELATIONS AND RESPONSIBILITY

1.3.1 Preservation and Maintenance - Fences and Gates

1.3.2 Protection of Existing Works and Services

Notwithstanding the foregoing requirements, and without reducing the Contractor's

1.3.3 Dealing with Water

1.3.4 Health, Safety and Accidents

1.3.5 Accommodation of Traffic

1.3.6 Measurement and Payment

1.4 SERVICES AND TRAFFIC

1.4.1 Diversion of Services

1.4.2 Closure of Roads

1.4.3 Access to Construction Site, Borrow Pits and Quarries

It is the Contractor's responsibility to plan and execute the construction of any

1.4.5 Haul over Completed Road

1.4.6 Liaison with Government and Police Officials

1.4.7 Measurement and Payment

(a) Diversion of Services

Unless an item for construction and maintenance of diversions is specifically entered

1.5.1 List of Equipment

The list will state:

1.5.2 Working Condition of the Equipment

All equipment on Site shall be in perfect working condition.

1.5.3 Maintenance of Equipment

1.5.4 Measurement and Payment

1.6 FACILITIES OF THE ENGINEER