Road Spec

FOR INTERNAL USE ONLY Standard Specification For Road Works
KERAJAAN MALAYSIA
JABATAN KERJA RAYA MALAYSIA
STANDARD SPECIFICATION
FOR
ROAD WORKS
CAWANGAN JALAN KETUA PENGARAH KERJARAYA

IBU PEJABAT JABATAN KERJARAYA MALAYSIA JABATAN KERJARAYA MALAYSIA
JALAN SULTAN SALAHUDDIN, JALAN SULTAN SALAHUDDIN
50582 KUALA LUMPUR. 50582 KUALA LUMPUR
Cawangan Jalan, Ibu Pejabat JKR, K.L Page 1

FOR INTERNAL USE ONLY
Mix Type Wearing Course Binder Course
Mix ACW 20 ACB 28

Designation
B.S Sieve % Passing by weight
37.5 mm 100
28.0 mm 100 80 100
20.0 mm 76 100 72 93
14.0 mm 64 89 58 82
10.0 mm 56 81 50 75
5.0 mm 46 71 36 58
3.35 mm 32 58 30 52
1.18 mm 20 42 18 38
425 um 12 28 11 25
150 um 6 16 5 14
75 um 4 8 3 8
ACW 20 Wearing Course 4.5 6.5 %
ACW 28 Binder Course 4.0 6.0

ADDENDUM NO. 1
This Addendum shall be made part of the ‘JKR Standard Specification For Roads Works’
1. Table 4.8 - Gradation Limit For Asphaltic Concrete Clause 4.2.4.2, page S4 – 21
should read as follows :
2. Table 4.9- Design Bitumen Contents Clause 4.2.4.3, page S4 - 23 should read as follows :

ADDENDUM NO. 2
6.2.5.5 Sign Faces
Sign faces for permanent traffic sign shall be as where shetting is applied to the extruded
shown on the Drawing and shall comply with section by pressure roller, it shall extend over
the Malaysian Standard Specification for the top and bottom edges of this sections by not
Reflective Sign Faces Materials (MS 1216). All less than 3 mm.
retro-reflective sheeting shall be fixed in accor-
dance with the manufacturer’s instruction. Any cut-outlet letters, numerals, symbols and
borders shall be of material compatible with the
Unless otherwise agreed by the S.O., sign sheeting to which they are applied. They shall
faces shall be formed from a single piece of be applied in accordance with the sheeting
retro-reflective sheeting. manufacturer’s instruction.
Where, with the aggrement of the S.O., more The finish of all sign faces shall be capable of
than one retro-reflective sheeting is used, the passing the tests described in MS 1216, and
number of sheets shall be kept to a minimum. and standard of fabrication and workmanship
All faces up to 1 m in size shall be produced shall be such that under normal conditions of
with a single sheet and no joint will be service and proper maintenance, the sign faces
accepted. shall last not less than 5 years without any
seriousblemishes or defects for Engineering
Only vertical and horizontal joint shall be per- Grade retro-reflective sheeting and 8 years for
mitted and all join in retro-reflective shetting High Intensity and prismatic retro-reflective
shall be overlapped by not less than 6 mm. The sheeting.
overlap in the horizontal joint shall be from the
top and the vertical joint shall be from the left; The Contractor shall furnish to the S.O. a letter
but joints will be only be accepted for prismatic of warranty for the specified period for all sign
retro-reflective sheeting. faces from the manufacturer of the sheeting or
the sign fabricator.
Retro-reflective sheeting shall be applied
evenly over the whole surface of the sign plate The retro-reflective sheeting manufacturer shall
and shall adhere fully. it shall be free from furnish the S.O. written warranty that the fluo-
twists, cracks, folds or cuts, air bubbles and rescent colours shall be durable for a minimum
other blemishes. 3 years for temporary signs.
All retro-reflective sheeting used on the same

sign shall be carefully matched for colour to
produce a uniform appearance both by day and
by night. Non-uniform shades of colour on any
one sign will not be accepted.
The edges of all the retro-reflective sheeting

shall be properly fitted to ensure no
delimination of the sheeting from the base
substrate.

Observation Angle ( ° ) Entrance Angle ( ° ) Orange
0.2 -4 200
0.2 +30 120
0.2 +50 50
1.5 -4 80
0.5 +30 50
0.5 +50 20
Standard Specification For Road Works
ADDENDUM NO. 3
6.2.6.1 FLUORESCENT ORANGE WIDE ANGLE PRISMATIC RETRO-

REFLECTIVE SHEETING FOR THE WORK ZONE
6.2.6.1.1 Description 6.2.6.1.2 Requirements
The flurescent orange wide angle prismatic i) Photometric - Coefficient of

retro-reflective sheeting is specifically designed Retroreflection RA
for use on rigid substrade work zone signs to
provide high visual impact under nighttime and when the sheeting applied on aluminium
daytimedriving condition, including low test panels is measured in accordance
visibility periods such as dawn, dusk, and wth ASTM E 810, it shall have
overcast days. The sheeting shall consist of minimum coefficient of retro-reflective
prismatic lenses formed in a transparent value as shown in Table I. The rotation
flurescent orange synthetic resin, sealed, and angle shall be *90° , the observation
baked with and aggressive presure sensitive angles shall be 0.2° and 0.5°, the
adhesive protected by a removable liner. The entrance angles and +50°, and the
sheeting shall have a smooth surface with a entrance angle (component ß1) shall be
distinctive interlocking diamond seal pattern - 4°, +30°, and +50°, and the entrance
and orrientation marks visible from the face. angle component ß2 = 0°.
TABLE I
Minimum Coefficient of Retroreflection RA

(Candelas per footcandle per square foot)
(90° Rotation Angle*)
* The datum mark (arrow) imprinted on the face of the sheeting shall be the datum mark for test
purposes. For the specified 90° rotation angle, the sheeting shall be positioned on the goniometer
so that the direction of this datum mark is perpendicular to the observation plane (this geometry is
equivalent to a 90° orientation angle with a presentation angle of 0° in the measurement geometry
described in Fed. Test Method Standard 370).

i) Daytime Color
Color shall conform to the reqiurement The value shall be determined on a HunterLab
of Table II. Daytime color and Labscan 6000 0/45 spectrocolorimeter with
maximum spectral radiance factor (peak option CMR 559 [or approved equal 0/45
reflectance) of sheeting mounted on (45/0) instrument withcircumferential viewing
aluminium test panels shall be (illumination)]. Computation shall be done in
determined instrumentally in accordance accordance with ASTM E 308 for the 2°
with ASTM E 991. observer.
TABLE II
Color Specification Limit ** (Daytime)
Color 1 2 3 4 Reflectance
Limit Y (%)
X Y X Y X Y X Y Min. Max.
Orange .583 .416 .523 .397 .560 .360 .631 .369 30 -
(New)
Orange .583 .416 .523 .397 .560 .360 .631 .369 20 45

(Weathered)
Maximum spectral radiance factor, new : 110%, min.
weathered : 60%, min.
** The four pairs of chromaticity coordinates determine the acceptable color in terms of the CIE
1931 standard colorimetric system measured with standard illuminatant D65.
iii) Nighttime Color.
Nighttime color of the sheeting applied to alumium test panel shall be determined
instrumentally in accordance with ASTM E 881 and calculated in the u’, v’ coordinate
system in accordance with ASTM E 308. Sheeting shall be measured at 0.33° observation
and - 4° entrance at 90° rotation. Color shall conform to the requirements of Table III.
TABLE II
Color Specification Limit ** (Nighttime)
Color 1 2 3 4
u’ v’ u’ v’ u’ v’ u’ v’
Orange
(New and .400 .540 .475 .529 .448 .522 .372 .534
Weathered)

FOR INTERNAL USE ONLY iv) Resistance to Accelerated Weathering.
The retro-reflective surface of the sheeting
shall be weather resistant and show no vi) Resistance to Heat.
appreciable cracking, blistering, crazing, or
dimensional change after 1 year’s The retroreflective sheeting, applied to a
unprotected outdoor exposure in south test panel as in E., above and conditioned
Florida, south-facing and inclined 45° for 24 hours, shall be measured in
from the vertical, or after 1500 hours’ accordance with paragraph. A. at 0.2°
exposure in a xenon arc weatherometer in observation and - 4° entrance angles at 90°
accordance with ASTM G 26, Type B, rotation and exposed to 170 + 5°F (77 +
Method A. Following exposure, panels 3°C) for 24 hours in an air circulating
shall be washed in a 5% HCL solution for oven. After heat exposure the sheeting
45 seconds, rinsed throughly with clean shall retain a minimum of 70% of the
water, blotted with a soft clean cloth and original coefficient of retroreflection.
brought to equilibrium at standard
conditions. After cleaning, the coefficient
of retroreflection shall be not less than 100 vii) Field Performance
when measured as in D.2, below, and the
color is expected conform to the Retroreflective sheeting processed and
requirements of Table II and III for applied to sign blank materials in
weathered sheeting. The sample shall : accodance with the sheeting
manufacturer’s recommendations, is
a) Show no appreciable evidence of expected to perform effectively for a
cracking, scaling, pitting, blistering, minimum of 3 years. the retroreflective
edge lifting or curling or more than 1/32 sheeting will be considered unsatisfactory
inch (0.08 cm) shrinkage or expansion. if it has deteriorated due to natural causes
to the extent that : (1) the sign is ineffective
b) Be measured only at angles of 0.2° for its intended purposed when viewed
observation, - 4° entrance and 90° from a moving vehicle under normal day
rotation. Where more than one panel of and night driving conditions; or (2) the
a color is measure, the coefficient or coefficient of retroreflection is less than
retroreflection shall be the averange of 100 when measured at 0.2° observation
all determinations. and - 4° entrance at 90° rotation. All
measurements shall be made after sign
cleaning according to the sheeting
v) Impact Resistance. manufacturer’s recommendations.
The retroreflective sheeting applied

according to the sheeting manufacturer’s
recommendations to a test panel of alloy
6061-T6, 0.040” (0.10 cn) by 3” (7.6 cm)
by 5” (12.7 cm) and conditioned for 24
hours, shall show no cracking outside the
impact of 100 inch-pounds (11.3Nm) using
a weight with a 5/8 in. (15.8 mm) diameter
rounded tip dropped from a height
necessary to generate an impact of 100
inch-pounds, at test temperatures of both
32° F (0° C) and 72° F (22° C).
Cawangan Jalan, Ibu Pejabat JKR, K.L
Page 6
STANDARD SPECIFICATION FOR ROADS WORKS

CONTENT PAGE
SECTION 1 General S1-11 to S1-31
SECTION 2 Earthworks S2-1 to S2-20
SECTION 3 Drainage Works S3-1 to S3-31
SECTION 4 Flexible Pavement S4-1 to S4-55
SECTION 5 Portland Cement Concrete Pavement S5-1 to S5-21
SECTION 6 Road Funiture S6-1 to S6-22
SECTION 7 Street Lighting S7-1 to S7-19
SECTION 8 Traffic Signals S8-1 to S8-33
SECTION 9 Concrete S9-1 to S9-39
SECTION 10 Piling Works S10-1 to S10-35

SECTION 1
GENERAL

SECTION 1 - GENERAL
Page
1.1 GENERAL DESCRIPTION OF THE PROJECT S1-11

1.2 SCOPE OF WORKS S1-11
1.3 NOTES, ABBREVIATIONS AND UNITS OF MEASUREMENT S1-11
1.3.1 Notes S1-11
1.3.2 Abbreviations S1-11
1.3.3 Units of Measurement S1-11
1.4 PROGRAMME OF WORKS S1-12
1.5 LIMITATION OF SITE S1-12
1.6 SUPPLY OF MATERIALS S1-12
1.7 MATERIALS OF MALAYSIAN ORIGIN S1-12
1.8 SETTING OUT S1-13
1.9 DIMENSIONS AND LEVELS S1-13
1.10 PROTECTION OF WORKS S1-13
1.11 DESIGN OF TEMPORARY WORKS BY THE CONTRACTOR S1-13
1.12 CONTRACTOR'S SUPERINTENDENCE S1-14
1.13 INSPECTION AND TESTS S1-14
1.14 COVERING UP OF WORK S1-14
1.15 OFFICE ACCOMMODATION FOR S.O. AND HIS STAFF S1-14
1.16 VEHICLES FOR THE S.O.'S STAFF S1-16
1.17 CONTRACTOR'S OFFICE AND ACCOMODATION S1-16
1.18 MATERIAL TESTING LABORATORY AND STAFF S1-16
1.19 PROVISION FOR SURVEY INSTRUMENTS AND CHAINMEN S1-17
1.20 MAINTENANCE OF EXISTING ROADS AND PROTECTION
OF TRAFFIC S1-17
1.20.1 Maintenance of Existing Roads, Bridges, Culverts, etc. S1-17
1.20.2 Temporary Diversions S1-17
1.20.3 Half-width Construction and Traffic Control S1-18
1.20.4 Temporary Traffic Signs S1-19
1.20.5 Temporary Works S1-19
1.21 LOCATION, TEMPORARY PROTECTION AND TEMPORARY
DIVERSION OF PUBLIC UTILITY INSTALLATIONS AND
OTHER SERVICES S1-19
1.22 WATER AND ELECTRICITY SUPPLY S1-20
1.23 PROJECT SIGNBOARD S1-20
1.24 PHOTOGRAPHIC RECORD OF WORKS S1-20
1.25 AS-BUILT DRAWINGS AND MICROFILMING S1-21
1.26 CLEARING UP OF SITE S1-21
1.27 OPPORTUNITIES FOR OTHER CONTRACTORS S1-21

Page
APPENDIX 1A GENERAL DESCRIPTION OF PROJECT S1-22
APPENDIX 1B SCOPE OF WORKS S1-23
APPENDIX 1C VEHICLES FOR S.O. AND HIS STAFF S1-24
APPENDIX 1D LIST OF LABORATORY EQUIPMENT

(a) Soil Testing Equipment S1-25
(b) Concrete Testing Equipment S1-27
(c) Flexible Pavement Testing Equipment S1-27
APPENDIX 1E SURVEY EQUIPMENT S1-30
FIGURE 1-1 APERTURE CARD FOR MICROFILM S1-31

FOR INTERNAL USE ONLY construction and completion of the Works as
given in Appendix 1B all to the approval of the
SECTION 1 - GENERAL S.O.
1.3 NOTES, ABBREVIATIONS AND

1.1 GENERAL DESCRIPTION OF UNITS OF MEASUREMENT
THE PROJECT
1.3.1 Notes
The general description of the project is as
i) Any clause in this Specification which
given in Appendix 1A.
relates to work or materials not included
1.2 SCOPE OF WORKS in the Works shall be deemed not
applicable.
The Works covered in this Contract comprise
ii) Unless stated to the contrary, any
the provision by the Contractor at his own risk
and cost of all materials, tools, plants, labour, dimension of material described means
transport and everything else necessary for the the finished or fully compacted
dimension.
iii) All Standards and Codes of Practice
referred to in this Specification shall be iv) The terms "Engineer" and
deemed to be the editions current at the "Superintending Officer" shall be
time of Tender. If the Malaysian synonymous.
Standard exists, which the S.O. deems to
be equivalent to the British or other
Standard specified, then the Malaysian 1.3.2 Abbreviations
Standard shall be followed.
a) M.S. means Malaysian Standards
In the event of any discrepancy between published by the Scientific and
the provision of this Specification and Industrial Research Institute of
the provision within the relevant Malaysia (SIRIM).
Standards or Codes of Practice as
mentioned in this Specification, then the b) B.S. means British Standards
provision of this Specification shall take published by the British Standard
precedence. Institution.
Cawangan Jalan, Ibu Pejabat JKR, K.L c) A.A.S.H.T.O. means The American
Association of State Highway and
Transportation Officials.
d) A.S.T.M. means The American

Society for Testing and Materials.
e) M.D.D. means Maximum Dry

Density.
f) O.M.C. means Optimum Moisture

Content.
g) C.B.R. means California Bearing

Ratio.
h) S.O. means Superintending Officer.
i) B.Q. means Bill of Quantities.
1.3.3 Units of Measurement
All units of measurement used in this

Specification and in the Bill of
Quantities shall be in accordance with
the metric system unless otherwise
stated.
Where British Imperial units are shown

or stated the following conversions shall
apply :-
Page 11
FOR INTERNAL USE ONLY 1 foot = 0.3048 metres
1 lb = 0.4536 kilograms
1 inch = 25.40 millimetres 1 gallon = 4.5461 litres
1 lb/sq.in = 6.895 x 10-3 N/sq.mm
1.4 PROGRAMME OF WORKS Should the Contractor require additional

land outside the Site for his workyards,
Within thirty (30) days after the receipt stores, offices, temporary haul roads or
of the Letter of Acceptance of Tender, any other temporary structures, he shall,
the Contractor shall submit to the S.O. on his own, purchase or rent any
for his approval a programme showing additional area he may need.
the order of work activities and time
schedule in which the Contractor Areas or area to be rendered as part of
proposes to carry out the Works and the Site shall be subject to the S.O.'s
shall, whenever required by the S.O. or approval.
the S.O.'s representative, furnish in
writing, particulars of the Contractor's 1.6 SUPPLY OF MATERIALS
arrangement for carrying out such works
and of the construction plants and The Contractor shall place orders for
temporary works, if any, which the specified materials at such times as
Contractor intends to supply, use or will enable him to execute the Works in
construct as the case may be. The accordance with his approved
submission to and approval by the S.O. programme.
or the S.O.'s representative of such a
programme or the furnishing of such If the Contractor's failure to supply any
particulars shall not relieve the material causes any interruption or delay
Contractor of any of his duties or in the progress of the Works, the
responsibilities under the Contract. Government may supply any portion
or all of the materials and the cost
If at any time it should appear to the borne by the Contractor shall be either
S.O. that the actual progress of the that as calculated at the current market
Works does not conform to the approved rates or the actual cost to the
programme referred to herein before, the Government at the date of supply,
Contractor shall submit for approval, a including overheads or any other
revised programme showing the charges, whichever is the greater.
modifications to the previously
approved programme necessary to Any costs incurred under this Section
ensure the completion of the whole shall be deducted from the Contract
Works within the time set for Sum. No claim for loss of profit under
completion. the conditions of this Contract shall be
deemed to have arisen. No action taken
under this Section shall in any way
1.5 LIMITATION OF SITE affect or modify the right of the
Government to claim for damages in the
The Contractor shall ensure that all his event of the Contractor's failure to
plants, materials, temporary workshops, complete the Works by the agreed date.
stores and offices are kept within the
Site at locations approved by the S.O. 1.7 MATERIALS OF MALAYSIAN
ORIGIN
Materials of Malaysian origin where
available must be used by the Contractor
to the exclusion of imported materials
and this requirement shall be allowed
for in his tender.
Page 12
FOR INTERNAL USE ONLY Contractor be permitted to use imported
materials unless he can prove to the
Under no circumstances shall the satisfaction of the S.O. that the
materials are not available locally, or if
available are not of an acceptable Standard Specification For Road Works
standard.
Before the Works or any part thereof are
commenced, the Contractor shall verify
1.8 SETTING OUT the levels of the existing ground surface
within areas where earthworks are to be
Before commencing the Works at any performed and the locations and bed
location, the Contractor shall provide levels of water-courses. These may
and install precast concrete reference differ from the locations and levels
beacons on both sides of the road shown on the Drawings owing to
centre-line at a spacing of 300 metres. changes which could have taken place
The beacons shall be firmly sited at right during the interval between the original
angles to the centre-line at a distance survey and construction.
from the centre-line of 15 metres or such
other distance as directed by the S.O. The levels and dimensions taken by the
The beacons shall be not less than 75 Contractor jointly with the S.O. shall
mm square in plan and shall project at form the basis of measurement of the
least 600 mm above the surrounding relevant work quantities.
ground. Each beacon shall be clearly
marked with its chainage and elevation
above datum. 1.10 PROTECTION OF WORKS
The Contractor shall take all practicable From the commencement of the Works
steps to safeguard the beacons including to the date the Works are taken over by
fencing and concreting-in where the Government, the Contractor shall
necessary in the opinion of the S.O. and take full responsibility for the care there
shall immediately replace any damaged of together with all temporary works
beacons. The Contractor shall give the and in case any damage, loss or injury
S.O. not less than 24 hours notice of his shall happen to the Works or to any part
intention to set out or give levels for thereof or to any temporary works from
any part of the Works in order that any cause whatsoever, he shall at his
arrangements may be made for own cost repair and make good the
checking. same so that at completion, the Works
shall be in good order and condition and
in conformity in every respect with the
1.9 DIMENSIONS AND LEVELS requirements of the Contract and the
S.O.'s instructions. The Contractor shall
All temporary benchmarks, reference also be liable for any damage to the
markers and levels as shown on the Works occasioned by him in the course
Drawings shall be checked on the Site of any operations carried out during the
by the Contractor at his own expense Defects Liability Period.
and be confirmed by the S.O.
1.11 DESIGN OF TEMPORARY
WORKS BY THE CONTRACTOR
Unless otherwise provided in the

Cawangan Jalan, Ibu Pejabat JKR, K.L Drawings, the Contractor shall submit to
the S.O. for his approval, 2 copies of all
working or shop drawings produced by
him including all drawings made by his
approved sub-contractors for all
temporary works.
Page 13
FOR INTERNAL USE ONLY two weeks before the temporary work is
scheduled to commence.
Such submission shall be made at least Notwithstanding the approval by the
S.O., the Contractor is solely responsible
for the adequacy and safety of his work Standard Specification For Road Works
and for any necessary modification or
addition whenever found necessary by The Contractor shall provide the
the S.O. necessary attendance whenever required
by the S.O. or his representative.
1.12 CONTRACTOR'S Notwithstanding any tests which may
SUPERINTENDENCE have been carried out off the Site, the
S.O. shall be empowered to order
The Contractor shall provide all further tests of any materials or goods to
necessary superintendence during the be made on the Site and to reject such
execution of the Works and as long materials or goods should they fail to
thereafter as the S.O. may consider pass such tests on Site.
necessary for the proper fulfillment of
the Contractor's obligations under the When required by the S.O., the
Contract. Contractor shall submit a copy of the
result of any quality control test carried
A competent Site Agent, whose out by the Contractor on his own during
appointment shall be approved by the the progress of the Works.
S.O., shall be employed by the
Contractor for management on Site. 1.14 COVERING UP OF WORK
The Site Agent shall have the authority
to receive instructions from the S.O. and Before any part of the Works is
to act on behalf of the Contractor. The permanently covered up, the Contractor
Site Agent shall be stationed on Site for shall give due notice to the S.O. for the
the whole duration of the Contract and inspection and measurement of
shall not be replaced without the dimensions. The S.O. shall attend
approval of the S.O. without unreasonable delay for the
purpose of examination and
If the Site Agent needs to be absent from measurement unless he considers it
Site for more than three (3) consecutive unnecessary and advises the Contractor
days, he shall give prior notice to the accordingly.
S.O. who may require the Contractor to
temporarily appoint another Site Agent. 1.15 OFFICE ACCOMMODATION FOR
S.O. AND HIS STAFF
1.13 INSPECTION AND TESTS
The Contractor shall provide and
The S.O. or his representative may at maintain a site office for the use of the
any stage of the Works carry out S.O. and his supervisory staff, all in
inspection, measurement and tests on accordance with the relevant Drawings
any part of the Works to ensure inclusive of all furniture and fittings as
compliance with the requirements of this shown on the Drawings.
Specification and of the Drawings.
The Contractor is permitted to provide a
relocatable site office as an alternative to
the JKR designed type shown on the
Cawangan Jalan, Ibu Pejabat JKR, K.L Drawings.
Page 14
FOR INTERNAL USE ONLY office shall be of equivalent standard but
not inferior to the JKR designed type
The quality of such a relocatable site and shall be equipped with similar
furniture and fittings as indicated in the
JKR designed site office. Standard Specification For Road Works
Where a relocatable site office is to be Sanitary facilities with disposal to

provided, the Contractor shall submit septic tanks located not nearer than 5 m
details of the relocatable site office from the building shall be provided.
together with his tender. Such details
should include the name of the The office shall be illuminated by
manufacturer, floor area and layout, list fluorescent fittings giving a general level
of furniture and fittings and brochures if of illumination of at least 2 lumens/
available. The Contractor shall also sq.m. Additional lighting in the form of
indicate whether the proposed site office wall or deck lamps shall be provided
is new or otherwise. where required by the S.O. Lighting to
toilets and corridors may be by tungsten
Unless otherwise shown on the filament bulbs.
Drawings, the site office is to be sited,
constructed and positioned as approved Thermostatically controlled air-
by the S.O. conditioners capable of maintaining a
temperature below 23°C in the office
The Contractor shall make proper shall be provided.
arrangements for and pay all charges in
connection with conservancy. The site The Contractor shall arrange for the
office shall comply with local building installation of a telephone with a
by-laws. It shall be erected or provided separate connection to the telephone
by the Contractor within four (4) weeks exchange for the exclusive use of the
from the date of possession of Site. S.O. at all times. The telephone shall
also be be fitted with 4 extensions unless
On completion of the Works, the not required by the S.O. The Contractor
Contractor shall further maintain the site shall be responsible for the connection
office till the end of the Defects Liability to such exchange and the payment of
Period unless otherwise directed by the rental for the telephone services but the
S.O. and thereafter remove from the Site Government shall reimburse the
the site office with all furniture and Contractor for the cost of making calls.
fittings which become the property of
the Contractor. Where a telephone exchange is not
within practical distance, an automatic
Where electricity and piped water are mobile telephone such as the ATUR
available from public utility authorities, (Automatic Telephone Using Radio)
the Contractor shall arrange for the site service shall be provided.
office to be connected to the electricity
and water supplies.Otherwise, the The Contractor shall keep the offices
Contractor shall supply the site office accessible at all times and in every way
with electric power from generators and habitable for working purposes
shall provide an adequate supply of throughout the duration of the Contract.
water for washing and potable filtered The Contractor shall also provide such
water for drinking purposes. labour and cleaning materials as are
required to maintain the site office in a
Cawangan Jalan, Ibu Pejabat JKR, K.L thoroughly clean and sanitary condition.
Page 15
FOR INTERNAL USE ONLY STAFF
1.16 VEHICLES FOR THE S.O.'S The Contractor shall provide new
vehicles as listed in the B.Q. and
Appendix 1C for the sole use of the S.O. Standard Specification For Road Works
and his staff at all times. All necessary
fuel, oil and lubricants, general When instructed by the S.O., the
maintenance, comprehensive insurances Contractor shall remove all such
and roadtax shall be provided by the buildings and appurtenant works from
Contractor together with a licensed and the Site, clean up the area and restore it
competent driver for every vehicle. to its original condition.
Replacement vehicles shall be provided
when normal vehicles are not available The Contractor shall provide adequate
such as during periods of servicing, first aid facilities appropriate to the size
maintenance or repair. The vehicles will and composition of his staff and labour
revert to the Contractor at the force. The Contractor shall afford the
completion of the Contract unless S.O.'s site staff full use of the services
otherwise stated in the B.Q. and facilities as and when required.
1.17 CONTRACTOR'S OFFICE AND 1.18 MATERIAL TESTING

ACCOMODATION LABORATORY AND STAFF
The Contractor shall provide and The Contractor shall provide and
maintain a suitable office for himself maintain a laboratory at the Site
and his staff in a position or positions to throughout the duration of the Contract.
be approved by the S.O. Earthworks and pavement construction
will not be permitted to commence until
In addition, the Contractor shall provide the laboratory and necessary equipment
and maintain temporary accomodation have been provided.
and living facilities, stores, workshops,
etc., including all necessary services for The said laboratory shall be in
water supply, drainage and lighting for accordance with the Drawings and shall
his staff. Before any work can be equipped as indicated in Appendix
commence the Contractor shall submit 1D. It shall be maintained in a clean
to the S.O. details of the proposed and tidy condition to the satisfaction of
buildings and services and shall obtain the S.O. The laboratory shall be
the S.O.'s approval together with any adequately supplied with water and
necessary approval in writing from the electricity.
relevant statutory authority.
The laboratory shall be used exclusively
The Contractor shall be responsible for by the S.O. and his staff. However the
all fees and other charges or expenses Contractor shall provide helpers to assist
incurred in connection with such office the S.O. as and when requested.
and housing and shall keep the whole
area in a clean, tidy and well drained All laboratory equipment shall become
condition. the property of the Contractor on
completion of the Works.
On completion of the Works, the

building shall be removed from the Site
Cawangan Jalan, Ibu Pejabat JKR, K.L and the Site left in a neat and tidy
condition.
Page 16
FOR INTERNAL USE ONLY INSTRUMENTS AND CHAINMEN
1.19 PROVISION FOR SURVEY The Contractor shall provide for the sole
use of the S.O. and his staff all such
instruments, equipment and chainmen as Standard Specification For Road Works
the S.O. may require to enable him to
check the accuracy of the Contractor's He shall also be responsible for
setting out and any measurements taken. maintaining the free flow of traffic on
The chainmen shall have knowledge of these sections of existing road.
Bahasa Malaysia or English and as far
as possible the same men shall be The Contractor shall arrange for the
provided throughout the Contract conveyance of materials and plants so as
period. to cause minimum damage to existing
roads and installations and minimum
The instruments and equipment to be inconvenience to the public. He shall
provided are as listed in Appendix 1E. not deposit any earth, rubbish or
materials upon any road, street,
The Contractor shall be responsible pavement or footway to cause hindrance
throughout the Contract period for all or obstruction of vehicles or pedestrians.
such instruments, equipment and
chainmen and shall ensure that the The Contractor shall be responsible for
instruments and equipment are at all any damage caused by any work carried
times in good working condition and out by him or by construction traffic to
adjustment. All instruments and any existing roads or installations from
equipment shall remain the property of whatsoever cause arising thereof and
the Contractor on completion of the shall repair, maintain and reinstate the
Works. same to their original condition to the
satisfaction of the S.O. The Contractor
shall also keep such roads clear of
1.20 MAINTENANCE OF EXISTING slurry, boulders and loose earth which
ROADS AND PROTECTION may be dropped in the course of
OF TRAFFIC transportation.
1.20.1 Maintenance of Existing Roads, Upon failure on the part of the

Bridges, Culverts, etc. Contractor to fulfill his obligations
under this Section, the S.O. may take
The Contractor shall maintain all whatever action and any means
sections of existing roads and all necessary to satisfy the requirements
bridges, drains and culverts included and all costs incurred by the S.O. shall
therein within the Site to the be deducted from any monies due or to
conditions at the time of possession become due to the Contractor under this
of Site for the full duration of the Contract.
Contract. Such maintenance shall
include routine activities such as 1.20.2 Temporary Diversions
grass cutting, clearing of drains,
patching of potholes, etc. Temporary diversions shall be
constructed wherever the Site is
intersected by existing roads, footpaths,
cycle tracks, access to properties, etc.
Cawangan Jalan, Ibu Pejabat JKR, K.L Such diversion ways shall be of a
standard of construction at least
equivalent to that of the original road,
path, track or access.
Page 17
FOR INTERNAL USE ONLY of the closure of the existing ways
and regularly maintained, for as long
They shall be constructed in advance as required, in a satisfactory
condition. On completion of the
work, the original ways shall be Standard Specification For Road Works
reinstated to their original condition
to the approval of the S.O. At least If the Contractor fails to maintain
fourteen (14) days notice in writing and/or reinstate these temporary
of any proposed temporary diversion ways to the satisfaction of
diversions of traffic shall be given to the S.O., the S.O. shall have the right
the S.O. for his approval. to carry out these works himself and
all costs incurred shall be deducted
Where access roads are to be from the Contract Sum.
permanently closed by the
construction of the Works, as shown Where, in the opinion of the S.O., a
on the Drawings, diversion ways detour is not feasible, construction
shall not be required. Such on existing public roads shall be
closures shall not be effected until undertaken only over half of the full
any specified alternative access has width of the roadway at any time.
been provided and only with the The lengths of such half-width
written approval of the S.O. construction shall be kept as short as
is practicable.
The Contractor shall maintain
reasonable access to all properties For all temporary diversions, the
adjoining the Works where such Contractor shall provide, install and
access exists during construction, maintain adequate temporary
and shall ensure that all the construction signs in accordance
necessary fences, planking and with Sub-Section 1.20.4.
gangways are adequately lit to the
satisfaction of the S.O. 1.20.3 Half-width Construction and Traffic
Control
Where the Contractor proposes to
use existing local streets as Where half-width construction is
temporary diversion ways, he shall necessary, work on culverts shall be
give at least fourteen (14) days completed and the embankment
notice in writing of his proposal to adjacent to them must be reinstated
the S.O. for his approval. The so that at least half the full width
Contractor shall maintain and/or shall be available for use by the
reinstate these temporary diversion public at all times.
ways to their original condition
throughout the entire duration of the In the event of the operation of
temporary diversion, all to the single-way traffic becoming
satisfaction of the S.O. necessary and when approved by the
S.O. on any particular length of the
Works or on the Works or on the
approaches to the Works, the
Contractor shall maintain through
traffic routes by providing a width of
at least 3 metres for single-way
traffic. He shall also provide
Cawangan Jalan, Ibu Pejabat JKR, K.L approved electrically operated
signals for traffic control on each of
the affected lengths and any
additional traffic signs as may
be directed.
Page 18
FOR INTERNAL USE ONLY automatic in operation, but the
S.O. may, at any time, require them
The electrical signal lights shall be to be hand operated by a competent
operator.
The Contractor shall make suitable
arrangements for emergency Construction and excavation shall be
servicing of the electrically operated sign posted and, during periods of
traffic signals to be available at all darkness, shall be lit to the approval
times. Manually operated "Stop/Go" of the S.O.
signs shall only be used with the
prior approval of the S.O.; and shall, Temporary traffic signals shall
if so approved, be of the size, colour comply with the requirements of the
and type as shown on the Drawings ARAHAN TEKNIK (JALAN)
and complying with the requirements 2C/85 published by Cawangan
of the ARAHAN TEKNIK(JALAN) Jalan, Ibu Pejabat JKR, Kuala
2C/85 (Manual on Traffic Control Lumpur and shall be reflectorised
Devices for Temporary Signs and and kept clean and legible at all
Work Zones Control), published by times.
Cawangan Jalan, Ibu Pejabat JKR,
Kuala Lumpur. The Contractor shall position, cover
or remove these signs as may be
At least fourteen (14) days notice in directed by the S.O.
writing of any proposed single-way
traffic system shall be given to the 1.20.5 Temporary Works
S.O. for his approval before such a
system can be implemented. The Contractor shall provide,
maintain and remove on completion
1.20.4 Temporary Traffic Signs of the Works all temporary works
including diversion ways, tracks,
The Contractor shall at all times take staging, bridging, etc., and shall
full and sufficient precautions to make them safe and suitable in every
ensure the safety of all traffic respect for carrying all plants and
through and around the Work Site materials and for all purposes related
and of traffic that is diverted owing to the Works.
to the Works.
1.21 LOCATION, TEMPORARY
To this end the Contractor shall erect PROTECTION AND
and maintain on the Site and at TEMPORARY DIVERSION OF
prescribed points on the approaches PUBLIC UTILITY
to the Site, all traffic signs, signals INSTALLATIONS AND OTHER
and warning lights necessary for the SERVICES
direction and control of traffic. The
sizes of all such signs and the The Contractor shall be responsible for
lettering and wording thereon shall locating the positions of all public utility
be as shown on the Drawings and installations, including water mains,
approved by the S.O. before erection. overhead and underground cables, pipes,
sewers and drains and all service
connections to buildings, and where
necessary, shall adopt such methods of
Cawangan Jalan, Ibu Pejabat JKR, K.L excavation as may be required by the
appropriate authorities or owners to
ensure that no damage is caused to
them.
Page 19
FOR INTERNAL USE ONLY own expense, any damage caused by him
to the existing services to the approval of
The Contractor shall make good, at his and in accordance with the instruction of
the appropriate authority or owner
concerned, and shall keep the Government Standard Specification For Road Works
indemnified at all times from all claims,
costs and expenses which may arise on 1.22 WATER AND ELECTRICITY
account of any damage (whether SUPPLY
permanent, temporary or recurring) to the
said services. The Contractor shall provide at his own
risk and cost all water, lighting and
All such installations which are electric power where required for use in
encountered in the course of the Works the Works and shall pay all costs, fees
shall be adequately supported, slung-up, and charges and comply with all safety
strutted or otherwise protected from injury regulations and statutes in connection
to the satisfaction of the respective therewith.
authority.
The Contractor shall also provide and
The temporary diversion or relocation of maintain temporary water storage
any service within or outside the Works to together with any distribution piping
permit the construction of the Works shall which may be necessary.
be the responsibility of the Contractor.
Where a service is required to be
interrupted or relocated the Contractor 1.23 PROJECT SIGNBOARD
shall inform and obtain the approval of the
S.O. who shall notify the appropriate The Contractor shall provide, erect and
authority or owner of the required removal maintain signboards at locations to be
and/or relocation. decided by the S.O. and pay all charges
in connection with this, including
Temporary diversion shall mean works obtaining permission, licences and fees,
involved in the diversion of services that etc. Each sign board shall comply with
will be reinstated to their original position the design and specification as shown on
and condition on completion of the works the Drawings. On completion of the
in the affected areas. In planning his work project, the Contractor shall dismantle
for the diversion or relocation of services, and clear away the signboards as
the Contractor shall make reasonable directed by the S.O.
allowance for the time necessary to obtain
the S.O.'s approval for the work and for the 1.24 PHOTOGRAPHIC RECORD OF
appropriate authorities or owners to WORKS
authorise the work, obtain the necessary
materials and carry out the work. The Contractor shall provide a camera
of reasonable quality for the purpose of
The Contractor shall not be entitled to any taking record photographs and slides of
extension of time due to his failure to the Works as and when directed by the
allow for a reasonble period of time S.O. The Contractor shall bear the costs
necessary for obtaining approval and of providing the film, development of
completing the work. film, printing two (2) copies of each
exposure in 3R size and documenting
the photographs in suitable albums.
Cawangan Jalan, Ibu Pejabat JKR, K.L The negatives of the photographs shall
be the property of the Government and
no prints from these negatives may be
supplied to any person or persons except
with the approval of the S.O.
Page 20
FOR INTERNAL USE ONLY to the reverse side of each photograph
describing the subject and the time at
A suitably typed caption shall be affixed which it was taken. One copy of each
photograph shall be signed by the
Contractor and the S.O. Standard Specification For Road Works
On completion of the Works, the

1.25 AS-BUILT DRAWINGS AND Contractor shall remove all rubbish,
MICROFILMING debris and surplus materials from the
Site and leave the whole Site in a neat
Drawings for recording as-built and tidy condition to the satisfaction of
construction details of the Works shall the S.O.
be prepared by the Contractor and shall
be certified by the S.O. or his
representative. The originals, in good 1.27 OPPORTUNITIES FOR OTHER
quality transparencies, and two (2) CONTRACTORS
printed copies of all as-built drawings
shall be supplied by the Contractor to The Contractor shall, when required by
the S.O. progressively as sections of the the S.O., afford all reasonable
Works become completed. All drawings opportunity to any other Contractors
shall be completed within one month employed by the Government and their
after the completion of the respective workmen and to the workmen of the
section. Government and of any other duly
constituted authorities who may be
As-built drawings shall be A1 size (838 employed in the execution on or near
mm x 584 mm) unless otherwise the Site of any work not included in the
approved by the S.O. Contract.
The Contractor shall also microfilm the

as-built drawings using 35.0 mm film
with the aperture card format as shown
in Figure 1-1 and submit the same to the
S.O.
1.26 CLEARING UP OF SITE
The Contractor shall make every effort

to keep the Site in a reasonably clean
and tidy condition for the duration of the
Works. He shall, in addition, from time
to time on the completion of any area of
the Works or where directed by the S.O.,
remove rubbish, surplus materials, or
any other construction debris from such
areas as may be attributable to his work
under this Contract and generally leave
them in a satisfatory condition, to the
approval of the S.O.
Page 21
APPENDIX 1A
GENERAL DESCRIPTION OF PROJECT

APPENDIX 1B
SCOPE OF WORKS

APPENDIX 1C
VEHICLES FOR S.O. AND HIS STAFF

All vehicles shall be NEW and of the types listed below :-
Type A - 2000 c.c. four-door, air-conditioned saloon car;
Type B - 1600 c.c. five-door, air-conditioned estate car;
Type C - 1500 c.c. four-door, air-conditioned Proton Saga;
Type D - 2000 c.c. four-wheel-drive, air-conditioned Trooper or equivalent with hard top;
Type E - 2250 c.c. four-wheel-drive, air-conditioned long-wheel- base Land Rover or

equivalent with hard top.

APPENDIX 1D
LIST OF LABORATORY EQUIPMENT
The Contractor shall provide and maintain the following testing laboratory equipment which shall
become the property of the Contractor at the end of the Contract :-
No.
(a) Soil Testing Equipment
(1) Moisture content tins - 76 mm x 25 mm with lids. 25
(2) Electric balance of 1 kg capacity, accurate to 0.1 g with a tare correction of

not less than 100 g. 1
(3) Electric forced draught oven, capacity of 0.08 cu.m. 1
(4) Atterberg limit machine calibrated with a grooving device as specified in B.S. 1377. 1
(5) Glass plates - 457 mm x 609 mm x 6 mm. 2
(6) Linear shrinkage moulds - 254 mm. 5
(7) Spatulas - 152 mm. 2
(8) 203 mm diameter B.S. sieves - 75 mm, 63 mm, 50 mm, 37.5 mm,
28 mm, 25 mm, 20 mm, 14 mm, 12.5 mm, 10 mm, 9.5 mm, 6.3 mm,
5 mm, 4.75 mm, 3.35 mm, 2.36 mm, 2 mm, 1.18 mm, 600 um,
425 um, 300 um, 212 um, 150 um, 75 um. Lid and pan together with
vibrating machine. 1 of each
(9) 203 mm diameter B.S. sieves - 75 um, 425 um. 2 of each
(10) Wash sieves - 75 um. 2
(11) Sample splitter - 50 mm. 2
(12) Sample splitter - 12 mm. 2
(13) Balance of 10 kg capacity, accurate to 1 g. 1
(14) Standard compaction hammer, electric motor operated, as specified in B.S. 1377. 1

No.
(15) Standard compaction mould as specified in B.S. 1377. 1
(16) Compaction mould extruder as specified in B.S. 1377. 1
(17) Steel scoop. 1
(18) Rubber mallet. 1
(19) Measuring flasks - 1000 c.c. 2
(20) Vernier calipers - 152 mm. 1
(21) Steel rule - 305 mm. 1

(22) Compression machine suitable for laboratory and field C.B.R.'s with all
fittings necessary for field and laboratory operation as specified in B.S. 1377. 1
(23) C.B.R. moulds fitted with collars and base plates for compaction and soaking
and tripods for small measurement fitted with dial gauges having 0.01 mm
divisions and 25 mm travel as specified in B.S. 1377. 10
(24) 2.26 kg surcharge weights - ring type. 6
(25) 2.26 kg surcharge weights - horseshoe type. 9
(26) Complete field density kit, sand replacement type suitable for volume
measurement of 0.005 cu.m to an accuracy of not less than 0.0001
cu.m as specified in B.S. 1377. 2
(27) Hand auger suitable for boring to depths of 3 m and supplied with 100 mm
diameter heads suitable for boring in cohesive and cohesionless soils. 1
(28) Crowbar, pick and spade. 1 of each
(29) Drying pans - 406 mm x 406 mm x 76 mm. 6
(30) British Standard 1377 - "Methods of Test for Soils for Civil Engineering
Purposes", latest edition. 1

(b) Concrete Testing Equipment
No.
(1) 152 mm x 152 mm x 152 mm standard concrete test cube steel moulds
as specified in B.S. 1881. 6
(2) Slump cones with tamping rods as specified in B.S. 1881. 2
(3) Compacting factor apparatus as specified in B.S. 1881. 1
(4) Tank for curing of concrete specimens to accomodate 50 Nos. x 152 mm

cubes in layers not more than 50 mm deep. 1
(c) Flexible Pavement Testing Equipment
(1) Metal tray, 0.6 m square or similar suitable for measuring spray rates of
bituminous materials and spread rates of cover aggregate for surface dressing. 4
(2) Metal thickness gauge (or set of slotted sleeves) as specified in M.S. 30 for
determination of aggregate flakiness index. 1
Additional items required for asphaltic concrete and/or bituminous Macadam :-
(3) Balance of 2 kg capacity, accurate to 0.1 g suitable for weighing samples

suspended in liquid. 1
(4) Steel moulds for Marshall test specimens (100 mm diameter) with base,
extension collar, extraction collar and extraction plate as specified in B.S. 598. 6
(5) Extractor for removing Marshall test specimens from moulds without distortion
or shock as specified in B.S. 598. 1
(6) Compaction hammer and automatic compactor for Marshall test specimens as
specified in B.S. 598. 1 of each
(7) Compaction pedestal and mould holder for Marshall test as specified
in B.S. 598. 1 of each
(8) Thermostatically controlled hot plate. 1
(9) Thermometers for use in laboratory and in asphaltic mixes for Marshall test as
specified in B.S. 598. 2 of each

No.
(10) Rubber and heat resistant gloves. 2 pairs of each
(11) Filter papers - 100 mm diameter. As needed
(12) Containers for heating aggregates and bituminous materials. As needed
(13) Pavement coring machine of the thin-walled diamond bit type for
obtaining 100 mm diameter samples of bituminous surfacings. 1
(14) 100 mm diameter thin-walled diamond bits for use with pavement
coring machine. As needed
(15) Tools for cutting and trimming pavement cores. As needed
(15) Metal bottles of suitable capacity for bitumen extraction by direct

determination as specified in B.S. 598. As needed
(16) Machine to rotate the bottles about their longitudinal axes at a speed of
between 10 rev/min to 30 rev/min as specified in B.S. 598. 1
(18) Volumetric flasks of suitable capacity. As needed
(19) Centrifuge capable of developing an acceleration of 25,000 m/sq.

second as specified in B.S. 598. 1
(20) Filtration apparatus for extraction of bitumen by direct determination as

specified in B.S. 598. 1
(21) Recovery apparatus for extraction of bitumen by direct determination

as specified in B.S. 598.
(22) Pressure filter of appropriate size, air pump and funnel for extraction
of bitumen by direct determination as specified in B.S. 598. 1 of each

No.
Further items required for asphaltic concrete :-
(23) Wire basket of 6.5 mm or smaller mesh with wire hanger as specified in
M.S. 30, for determination of specific gravity and water absorption
of aggregates. 1
(24) Airtight container of similar capacity as wire basket above. 1
(25) Gas jar - 1.5 litre. 1
(26) Pyconometer - 1 litre. 1
(27) Warm air blower. 1
(28) Mechanical mixer of 2 kg capacity, for preparation of asphaltic concrete mixtures. 1
(29) Thermostatically controlled water bath for Marshall test specimens as

specified in B.S. 598. 1
(30) Steel Marshall testing head as specified in B.S. 598. 1
(30) Compression testing machine with proving ring, capable of applying loads of
up to at least 22 kN at a constant rate of strain of 50 mm + 3 mm per minute
and recording the maximum load achieved as specified in B.S. 598. 1
(31) Dial gauge and mounting assembly for measuring Marshall test flows of up to
10 mm with accuracy of + 0.1 mm as specified in B.S. 598. 1
Testing which is specifically required in the Contract and any test defined in quoted British
Standard Specifications which are required to ensure compliance with the Contract but cannot be
done in the Site testing laboratory shall be carried out at approved laboratories off the Site. These
tests shall be carried out as directed by the S.O. The cost incurred by the Contractor shall be
deemed to have been included in the tendered rates.

APPENDIX 1E
SURVEY EQUIPMENT
The Contractor shall provide and maintain the following instruments and equipment for the
purpose of measurements and setting out. These shall become the property of the Contractor at the
end of the Contract :-
1 No. Theodolite of direct read out accurate to 1 second.
2 No. Automatic levels - Wild NA2 or Koni 007 or equivalent.
2 No. Levelling staves - 5 m aluminium.
1 No. 50 m x 5 mm steel measuring band divided throughout and numbered at 5 m intervals.

Divided over first 30 m at 1 m intervals. Divided over first 5 m at 50 mm intervals.
1 No. Repair set for the same.
2 No. 30 m steel box tapes, white face.
2 No. 30 m fibreglass box tapes.
10 No. 2.5 m ranging rods.

2 No. 1 m spirit level, steel or aluminium.
2 No. Survey umbrellas.
Templates, straightedges, canvas bags, pegs, hammers, parangs, etc.

Figure 1.1
APPERTURE CARD FOR MICROFILM

SECTION 2
EARTHWORKS
SECTION 2 - EARTHWORKS
Page
2.1 CLEARING, GRUBBING AND STRIPPING TOPSOIL S2-35
2.1.1 Description S2-35

2.1.1.1 Clearing S2-35
2.1.1.2 Grubbing S2-35
2.1.1.3 Stripping Topsoil S2-35
2.1.2 Construction Methods S2-35
2.1.2.1 Areas To Be Cleared S2-35
2.1.2.2 Areas To Be Cleared, Grubbed and Stripped Of Topsoil S2-36
2.1.2.3 Topsoil S2-36
2.1.2.4 Timber S2-36
2.1.2.5 Structures S2-37
2.1.2.6 Disposal Of Material S2-37
2.2 EARTHWORKS S2-38
2.2.1 Definitions S2-38
2.2.2 General Requirements S2-39
2.2.3 Roadway Excavation S2-39

2.2.3.1 Dimensional Tolerances S2-39
2.2.3.2 Separation and Stockpiling of Suitable Material S2-40
2.2.3.3 Removal of Excavated Material From Site S2-40
2.2.3.4 Removal of Unsuitable Material S2-40
2.2.3.5 Replacement of Unsuitable Material Under Standing Water S2-40
2.2.3.6 Widening Cuts S2-40
2.2.3.7 Excavation of Rock S2-41
2.2.3.8 Storage and Handling of Explosives S2-42
2.2.3.9 Blasting S2-42
2.2.3.10 Safety Measures S2-42
2.2.3.11 Insecure Material S2-43
2.2.4 Earth Embankment S2-43

2.2.4.1 Material S2-43
2.2.4.2 Borrow Pits S2-43
2.2.4.3 Placement of Fill Material S2-43
2.2.4.4 Compaction S2-44
2.2.5 Rock fill Embankment S2-45

Page
2.2.6 Embankment Over Soft Ground S2-46

2.2.6.1 Foundation Treatment S2-46
2.2.6.2 Surcharge and Staged Construction S2-46
2.2.6.3 Settlement Markers S2-46
2.2.6.4 Settlement Records S2-47
2.2.7 Subgrade S2-47
2.2.8 Protective Vegetation for Erosion Control S2-48

2.2.8.1 Topsoil S2-48
2.2.8.2 Turfing S2-48
2.2.8.3 Seeding S2-48
FOR INTERNAL USE ONLY or clearance is otherwise
provided for in the Contract).
SECTION 2 - EARTHWORKS

2.1 CLEARING, GRUBBING AND
STRIPPING TOPSOIL
2.1.1 Description
This work shall consist of clearing,

grubbing and stripping topsoil in the
areas designated hereunder and/or
shown on the Drawings and/or
directed by the S.O., and of clearing
only in other areas designated here
under and/or shown on the Drawings
and/or directed by the S.O., all as
specified herein and as required by
the S.O. The work shall also include
the demolition and disposal of
structures in said areas, except where
otherwise provided for in the
Contract, as specified herein and as
required by the S.O.
2.1.1.1 Clearing
Clearing shall consist of the

cutting and/or taking down,
removal and disposal of
everything above ground
level, including objects
overhanging the areas to be
cleared such as tree branches,
except such trees, vegetation,
structures or parts of structures,
and other things which are
designated in the Contract to
remain, or be removed by others,
or which the S.O. directs are to
be left undisturbed. The material
to be cleared shall include but not
necessarily be limited to trees,
stumps (parts above ground),
logs, brush, undergrowth, long
grasses, crops, loose vegetable
matter and structures (except
those structures whose removal
2.1.2 Construction Methods
Clearing shall also include the
levelling of obsolete dikes, 2.1.2.1 Areas To Be Cleared
terraces, ditches, etc., unless
otherwise directed by the S.O. The entire road reserve area shall
be cleared as described above,
2.1.1.2 Grubbing unless otherwise shown on the
Drawings and/or directed by the
Grubbing shall consist of the S.O.
removal and disposal of surface
vegetation, the bases of stumps, Clearing shall be carried out to
roots, the underground parts of the extents deemed necessary and
structures, and other obstructions approved or directed by the S.O.
to a depth of at least 0.50 metre in areas outside the road reserve
below ground level, all to the where channel excavation or
satisfaction of the S.O. other work is required.
2.1.1.3 Stripping Topsoil In areas which are to be cleared

only, and in which grubbing and
Stripping topsoil shall consist of stripping topsoil are not required,
the removal of topsoil to an the methods of work shall be
average depth of at least 100 mm such as will not unduly damage
below ground level, and its the surface vegetation and
stockpiling for use in the Works, topsoil, and care shall be taken
and/or its disposal, as directed by
the S.O. Page 35
FOR INTERNAL USE ONLY ground;
not to disturb the topsoil and the ii) embankment is to be

root systems of grasses and other constructed to a height at the
surface vegetation. No topsoil centre-line of 1.50 metres or
shall be removed from such more on ground with a
areas, except as directed by the cross-slope of not more than 1
S.O., and any topsoil, grasses and (vertical) to 30 (horizontal).
other surface vegetation other
wise removed or disturbed shall Clearing, grubbing and stripping topsoil shall
be replaced and made good at the be carried out to the extents deemed necessary
Contractor's own expense, all to and approved or directed by the S.O. in areas
the satisfaction of the S.O. both inside and outside the road reserve where
channel excavation or other work is required.
2.1.2.2 Areas To Be Cleared,Grubbed
and Stripped Of Topsoil Except where further excavation is required,
holes and cavities in the ground surface after
Except as otherwise shown on clearing, grubbing and stripping topsoil shall be
the Drawings and/or directed by filled with materials similar to the adjacent
the S.O., clearing, grubbing and ground, and such fill shall be compacted to a
stripping topsoil shall be carried dry density similar to that of the surrounding
out in all areas of roadway material, all to the satisfaction of the S.O.
excavation and in all areas where Cawangan Jalan, Ibu Pejabat JKR, K.L
embankment is to be constructed,
except that grubbing and
stripping topsoil shall not be
carried out in those areas where :-
i) embankment is to be
constructed on earth
designated as swamp or soft
Standard Specification For Road Works Otherwise, topsoil removed
during grubbing and stripping
This work shall be considered operations shall be separated
incidental to the work of clearing, from objectionable materials and
grubbing and stripping topsoil, spread within the road reserve or
and shall not be measured for borrow areas, or otherwise
payment. disposed of, as approved or
directed by the S.O.
2.1.2.3 Topsoil
2.1.2.4 Timber
Topsoil to be stockpiled for the
Works shall be sufficiently fertile The ownership of timber is
to promote and support the vested in the Government.
growth of vegetation, and shall be Saleable timber shall be trimmed
taken from such areas where and stacked in accordance with
clearing, grubbing and stripping the requirements of the
topsoil is required as approved or appropriate Government agency,
directed by the S.O. Before in accessible places within the
stockpiling, topsoil shall be road reserve as approved or
separated from objectionable directed by the S.O.
materials, all to the satisfaction of
the S.O. The Contractor shall The Contractor shall have the
arrange for stockpile sites either right to use unsaleable timber (or
within or outside the road saleable timber when permission
reserve, at his own expense, and is granted in writing by the
all to the satisfaction of the S.O.
Page 36
FOR INTERNAL USE ONLY and encumbrances of any
character within the limits of the
appropriate Government agency road reserve, except those to be
or authority) for his own removed by others or designated
purposes in connection with the to remain, shall be demolished
Contract, always provided that he and removed by the Contractor.
shall comply with the
requirements of the S.O. agency Materials designated in the
or authority) for his own Contract or directed by the S.O.
purposes in connection with the to be salvaged, shall be carefully
Contract, always provided that he removed and stored, and shall be
shall comply with the the property of the Government.
requirements of the S.O.
2.1.2.6 Disposal Of Material
2.1.2.5 Structures
Unwanted material from clearing,
Major structures are those which grubbing and stripping topsoil
cannot practicably be cleared by (including the demolition of
bulldozer and/or hydraulic structures) shall be disposed of as
excavator, whose demolition approved or directed by the S.O.
requires pneumatic tools,
explosives and/or other
specialised equipment. A brief
description of each major Cawangan Jalan, Ibu Pejabat JKR, K.L
structure (if any) and depth to
which extent it shall be
demolished is given in the Bill of
Quantities.
All fences, buildings, structures,

Standard Specification For Road Works adjoining the road reserve
and damaging vegetation
Combustible material and property therein.
including all timber (except
timber to be salvaged or Should the clearing,
used), all brush, stumps, grubbing and stripping of
roots, vegetation and other topsoil be carried out at a
combustible refuse may be time when burning is not
piled up within the road permitted, the Contractor
reserve and burned, where may pile up combustible
burning is allowed. materials within the road
reserve outside the limits of
All burning shall be subject the road works, and burn it
to the prior approval of the at a time when burning is
relevant Government permitted.
authorities, and shall be
carried out in conformance Where burning is not
with all pertinent permitted at any time, or the
regulations. Burning shall Contractor elects not to burn
also be carried out at such unwanted material,
places and at such times and combustible material shall
in such a manner as to be disposed of together with
prevent fire from damaging incombustible material.
vegetation and property
within the road reserve
designated to be preserved,
and from spreading to areas Page 37
FOR INTERNAL USE ONLY in cutting which is immediately
below the subbase or lower
Incombustible material, including subbase of the road pavement
where appropriate the remains of and shoulders.
burning, shall be disposed of in a
safe and tidy manner at solid (c) Common Excavation
waste dumps outside the Site,
unless otherwise approved or Common excavation shall mean
directed by the S.O. The excavation in any materials
Contractor shall be solely which are not rock or artificial
responsible for making the hard materials as defined in
necessary agreements, and paying Sub-Sections 2.2.1 (f) and (g).
expenses and claims arising from
the use of such solid waste (d) Unsuitable Materials
dumps whether on Government
or private land. Unsuitable materials shall
include :-
2.2 EARTHWORKS i) running silt, peat, logs,

stumps, perishable or toxic
2.2.1 Definitions material, slurry or mud, or
(a) Formation Level Cawangan Jalan, Ibu Pejabat JKR, K.L
Formation level means the top

surface of the subgrade.
(b) Subgrade
Subgrade means that part of the

embankment or existing ground
Standard Specification For Road Works classified as unsuitable, unless
otherwise classified by the S.O.
ii) any material
(e) Suitable Materials
- consisting of highly
organic clay and silt; Suitable materials shall mean
those materials other than the
- which is clay having a unsuitable materials defined in
liquid limit exceeding Sub-Section 2.2.1 (d) above.
80% and/or a plasticity
index exceeding 55%; (f) Rock
- which is susceptible to Rock shall mean material found

spontaneous combustion; in ledges or masses in its original
position which would normally
- which has a loss of weight have to be loosened either by
greater than 2.5% on blasting or by pneumatic tools or,
ignition; if excavated by hand, by wedges
and sledge hammers. It shall not
- containing large amounts include material which can be
of roots, grass and other loosened with a track-type tractor
vegetable matter. with mounted and drawn ripper
of the following descriptions :-
Materials that are soft or unstable
merely because they are too wet
or too dry for effective
compaction are not to be Page 38
FOR INTERNAL USE ONLY 0.5 cubic metre.
i) Tractor Unit : Equipment with a 2.2.2 General Requirements

minimum weight of 20 tonnes
and nett horse power rating of The work shall include the
200 brake horse power or more. excavation of all types of material,
The tractor unit is to be in good backfilling, compaction, forming
condition and operated by embankments and slopes, etc., as is
experienced personnel skilled in necessary for the completion of the
the use of ripping equipment; Works up to the formation levels, in
accordance with the lines, grades,
ii) Ripping Unit : The ripper to be dimensions, shapes and typical
attached to the tractor shall be the cross- sections shown on the
most efficient parallelogram type Drawings and to the approval of the
recommended by the tractor or S.O.
ripper manufacturer. The ripper
shall have a single shank in good
working condition with
sharpened cutting point.
Boulders or detached pieces shall only be

regarded as rock if they individually
exceed 0.5 cubic metre. Cawangan Jalan, Ibu Pejabat JKR, K.L
(g) Artificial Hard Material
This shall mean any hard artificial

material which would require the use
of blasting or approved pneumatic
tools for its removal but shall
exclude individual masses less than
Standard Specification For Road Works the Contractor shall at his own cost make
good such areas to the satisfaction of the
The Contractor shall provide where S.O.
necessary temporary water courses,
ditches, drains, pumping or other means of The Contractor shall exercise care in
maintaining the earthworks free from preventing wastage of suitable material
water. Such provision shall include needed for embankment or fill
carrying out the work of forming the construction.
cuttings and embankments in such a
manner that their surfaces have at all times 2.2.3 Roadway Excavation
a sufficient gradient to enable them to shed
water and prevent ponding. 2.2.3.1 Dimensional Tolerances
In pumping out excavations and in the Slopes in cutting shall be

lowering of water tables the Contractor trimmed mechanically to neat
shall pay due regard to the stability of all and even surfaces which shall
structures. have gradients not steeper than
that shown on the Drawings.
Adequate means for trapping silt shall be Widths of excavations shall not
provided on all temporary drainage exceed the dimensions shown on
systems. Similar arrangements shall be the Drawings by more than 300
made for all earthworks including mm, unless otherwise approved
excavations whether for pile trenches, by the S.O.
foundations or cuttings.
Should the surface of completed areas be

damaged by erosion or by any other cause Page 39
FOR INTERNAL USE ONLY good any consequent deficit of
fill material arising there from, at
2.2.3.2 Separation and Stockpiling of his own expense. Unless
Suitable Material designated dump sites have been
shown on the Drawings, the
Where excavation reveals a Contractor shall dispose of
combination of suitable and surplus suitable material at his
unsuitable materials, the own dump areas outside the Site
Contractor shall, wherever the as approved by the S.O. In doing
S.O. considers it practicable, so, the Contractor shall comply
carry out the excavation in such a with statutory requirements such
manner that the suitable materials as payment of royalties, environ
are excavated separately for use mental protection, etc.
in the Works without
contamination by the unsuitable
materials. The Contractor shall
stockpile separately material for
subgrade as specified in Sub-
Section 2.2.7.
2.2.3.3 Removal of Excavated Material

From Site
No excavated material shall be
removed from the Site except on
the direction or with the approval
of the S.O. Should the
Contractor be permitted to
remove suitable materials from
the Site to suit his operational
procedure, then he shall make
Standard Specification For Road Works environmental protection, etc.
Voids created due to removal of
2.2.3.4 Removal of Unsuitable Material unsuitable material shall be
backfilled with suitable material
Unsuitable material shall be compacted to a dry density not
excavated to such depth and over less than that of the surrounding
such area as directed by the S.O. material or that specified for the
respective part of the earthworks
or as directed by the S.O.
B.S. Sieve Size % Passing By
Weight
2.2.3.5 Replacement of Unsuitable
Material Under Standing Water
Crushed Rock or
Gravel
100 Where it is decided by the S.O.
63.0 mm 85 - 100 that replacement of unsuitable
37.5 mm 0 - 20 material shall be done under
20.0 mm 0-5 standing water, voids created due
10.0 mm to removal of unsuitable material
shall be backfilled with hard
Sand
clean crushed rock, natural gravel
10.0 mm 100 or sand having grading within the
5.0 mm 90 - 100 respective limits specified in
1.18 mm 45 - 80 Table 2.1.
300 um 10 - 30
150 um 2 - 10
2.2.3.6 Widening Cuts
and be transported and disposed
The S.O. may instruct the
of in an approved manner. Unless
approval of the S.O. to dump and Contractor or the Contractor
spread the unsuitable materials himself may elect to obtain
within the Site is obtained, the material for the Works by
Contractor shall be responsible widening cuts. In the latter case,
for providing his own dump site the Contractor shall first request
for such unsuitable materials. permission in writing from the
The Contractor shall comply with S.O.
statutory requirements such as
payment of royalties, Page 40
FOR INTERNAL USE ONLY excavations shall be used as far
as is practicable in the Works.
TABLE 2.1 - GRADING LIMITS OF
MATERIALS FOR
REPLACEMENT OF
UNSUITABLE MATERIAL
2.2.3.7 Excavation of Rock
Rock excavation shall be carried

out by methods appropriate to
Site requirements as approved by
the S.O. Where explosives shall
be used, the relevant security
regulations dealing with
purchase, transport, handling,
storage and usage of explosives
shall be complied with.
All material from rock

i) excavated rock shall be broken
Where the rock is of satisfactory down to a maximum particle size
quality, the Contractor may elect to of 400 mm and used as rock fill
crush and screen it to produce as described in Sub-Section 2.2.5;
aggregates required for concrete,
roadbase, subbase, or other purposes. ii) excavated rock shall be broken
Excavated rock needed for earth down to a maximum particle size
work construction which the of 150 mm, blended with suitable
Contractor elects so to use for earth fill material in a proportion
producing select materials shall be not exceeding 1 rock to 1 earth,
replaced at the Contractor's own and used as common fill.
expense by borrow of satisfactory
quality approved by the S.O. The Contractor may only waste
excavated rock with the approval of the
Otherwise, excavated rock shall be S.O. Excavated rock needed for
used in the construction of earthwork construction which the
embankment and fill, to the fullest Contractor elects to waste shall be
practical extent, in either of the two replaced at the Contractor's own expense
following ways :- by borrow of satisfactory quality
approved by the S.O.

FOR INTERNAL USE ONLY 2.2.3.9 Blasting
2.2.3.8 Storage and Handling of Explosives shall be used in

Explosives the quantities and manner
recommended by the
Proper buildings or manufacturers. Blasting shall
magazines, with separate be restricted to such periods
compartments for detonators, as the S.O. may prescribe. If,
in suitable positions for the in the opinion of the S.O.,
storage of explosives in blasting would be dangerous
manner and quantities to be to persons or property or to
approved shall be provided. any finished work, or is being
The prevention of any carried on in a reckless
unauthorised issue or manner, he may prohibit it,
improper use of any explosive and order the rock to be
brought on the Works shall be excavated by other means.
the responsibility of the The use of explosives in large
Contractor and only blasts, i.e. exceeding 9 kg of
experienced and responsible explosive, as in seams, drifts,
men shall be employed to shafts, pits, or large holes, is
handle explosives for the prohibited unless authorised
purpose of the Works. in writing by the S.O. Such
authorisation shall not in any
way relieve the Contractor of Standard Specification For Road Works
his liabilities under the
Conditions of Contract. All necessary precautions shall be
taken to preserve in the soundest
possible condition the materials
below and beyond the lines of all
excavations. Delayed blasting to
Cawangan Jalan, Ibu Pejabat JKR, K.L reduce shock waves shall be used
to avoid damage to concrete and
other works already completed.
As the excavation approaches its
final lines, blasting shall be
carried out by means of parallel
drill holes perpendicular to the
toe of the excavation and parallel
to the finally required face.
2.2.3.10 Safety Measures
When blasting is carried out close

to properties or roads, appropriate
safety rules shall be strictly
adhered to. Where necessary or
as directed by the S.O., the use of
heavy mesh blasting mats shall
be used to ensure that no damage
is caused to persons or property
on or off Site. Special care shall
be taken in wet ground to ensure
that individual explosions are
reduced to such size as to
preclude damage to any buildings
or structures. Plaster shooting
will not be permitted within 400
metres of any building or
structure. If traffic on any road
or railway has to be interrupted
for blasting operations, the
Contractor shall obtain approval
of his schedule for such
interruption from the appropriate
authorities and shall prove to the
S.O. that he has obtained it, prior
to the interruption.
Page 42
The slopes of cuttings shall be
2.2.3.11 Insecure Material cleared of all rock fragments
which move when prised with
a crow-bar. Where, in the Standard Specification For Road Works
slopes of cuttings, layers of
rock and soft material 2.2.4.2 Borrow Pits
alternate and the S.O.
considers that the slope, The Contractor shall be
immediately after dressing, responsible for locating
will not permanently borrow pits. Designated
withstand the effect of borrow pits shown on the
weather, the Contractor shall Drawings only indicate to the
excavate any insecure Contractor potential areas for
material to an approved depth borrow. Whether the
and build up the resulting Contractor obtains materials
spaces with grade 15P/20 from the designated or his
concrete or masonry using own borrow pit, it shall be his
rock similar to the adjoining responsibility to ascertain the
natural rock so as to ensure a suitability of the pit with
solid face. respect to the quantity and
quality of the materials, which
2.2.4 Earth Embankment shall be subject to the
approval of the S.O. The
2.2.4.1 Material Contractor shall pay all
necessary fees, taxes or
Fill materials for use in royalties to the appropriate
forming embankments shall authorities and observe all
be the suitable material relevant regulations. The
obtained from excavation in Contractor shall keep the
cuttings. Where the quantity borrow pits free from ponding
of such materials is water and the excavation neat
inadequate, the Contractor and tidy and shall carry out
shall obtain suitable materials necessary erosion protection
from the designated borrow measures as instructed by the
pits or from his own borrow S.O.
pits which have been
approved by the S.O. 2.2.4.3 Placement of Fill Material
All fill materials shall be

deposited in layers. The loose
depth for each layer of fill
shall be determined from the
trial compaction. Each layer
shall extend over the full
width of the fill area and shall
be compacted in accordance
with the requirements of Sub-
Section 2.2.4.4. Each
compacted layer shall be
Cawangan Jalan, Ibu Pejabat JKR, K.L maintained at all times with a
sufficiently even surface in
order to drain away the
sur face water.
Page 43
FOR INTERNAL USE ONLY constructed on ground with a
cross-slope flatter than 1
Where embankment is to be (vertical) to 10 (horizontal) but
steeper than 1 (vertical) to 30
(horizontal), the foundation Standard Specification For Road Works
material, except where this is
rock, shall be scarified to a depth Compaction shall be
of 100 mm, blended with undertaken to the
embankment fill material and requirements of this Section
compacted as described in Sub- by plant approved by the S.O.
Section 2.2.4.4. All compaction requirements
shall be controlled by means
Where embankment is to be of field density measurement.
constructed against existing
embankment or on ground with a For compaction of
cross-slope of 1 or more (vertical) embankment slope, the
to 10 (horizontal), the foundation Contractor may either extend
shall be excavated in all materials each compacted layer beyond
(including hard rock) to form the design slope surface by at
benches with horizontal and least 600 mm and then trim
vertical faces from which con back to the required slope
struction of the embankment shall angle, or he may employ a
proceed. The benches shall be tow type roller to compact the
contiguous beneath the full width sloping surface.
of the embankment, and shall be
of a suitable width to accomodate (b) Compaction Trials
construction equipment such as
motor-graders, trucks, rollers, etc. The B.S. 1377 Compaction
Scarifying of the horizontal and Test (4.5 kg rammer method)
vertical faces of the benches shall shall be used in determining
not normally be required, and the the moisture versus density
material excavated in forming the relation of soil.
benches may normally be used as
fill in the embankment as The Contractor shall submit to
approved by the S.O. the S.O. for his approval the
proposed method of
2.2.4.4 Compaction compaction for each main
type of material to be used in
(a) General the embankment. This shall
include the type of
All materials used in compaction plant for each
embankments and as fill type of material and the
elsewhere shall be compacted number of passes in relation
as soon as practicable after to the loose depth of material
being placed and spread. to achieve desired
compaction. The maximum
compacted thickness for fill
shall be limited to 300 mm
unless otherwise approved by
the S.O. The Contractor shall
Cawangan Jalan, Ibu Pejabat JKR, K.L carry out field compaction
trials, supplemented by any
necessary laboratory
investigations, as required by
the S.O.
Page 44
FOR INTERNAL USE ONLY procedures proposed by the
Contractor for earthworks and
This shall be done by using the shall satisfy the S.O. that all the
specified requirements regarding
compaction can be achieved. Standard Specification For Road Works
Compaction trials with the main
types of material likely to be moisture content at which each
encountered shall be completed soil type shall be compacted.
before the works with the Water shall be added, or the
corresponding materials will be material aerated and dried to
allowed to commence. Each trial adjust the soil to the proper
area shall be not smaller than moisture content to obtain the
8 m x 15 m. required density. A satisfactory
method and sufficient equipment
(c) Degree of Compaction as approved by the S.O. shall be
used for the furnishing and
The whole of the embankment handling of water.
below the top 300 mm of the
subgrade shall be compacted to If the natural water content of
not less than 90% (for cohesive suitable materials is too high for
material) or 95% (for the proper compaction to be
cohesionless material) of the carried out, the Contractor can
maximum dry density determined either bring down the moisture
in the B.S. 1377 Compaction Test content by aeration or drying or
(4.5 kg rammer method). alternatively replace it with
suitable materials of compactable
(d) Field Density Testing moisture range at his own cost.
Field density tests on each layer 2.2.5 Rock fill Embankment

of compacted earth fill shall be
carried out using the sand Rock used in rock fill
replacement method in embankments shall be of maximum
accordance with B.S. 1377 or by particle size of 400 mm so that it can
using other means of testing of be deposited in horizontal layers,
comparable accuracy approved each not exceeding 500 mm in
by the S.O. compacted depth and extending over
the full width of the embankment
(e) Moisture Control except for any specified external
cover to slopes or new formation
Each layer of earth fill shall be level. The materials shall be spread
processed as necessary to bring and levelled by a crawler tractor
its moisture content to a uniform weighing not less than 15 tonnes.
level throughout the material, Each layer shall consist of
suitable for compaction. The reasonably well graded rock and all
optimum moisture content as large voids shall be filled with
determined by the B.S. 1377 broken fragments before the next
Compaction Test (4.5 kg rammer layer is placed. The top surface and
method) shall be used as a guide side slopes of embankments so
in determining the proper formed shall be thoroughly blinded
with approved fine graded material
Cawangan Jalan, Ibu Pejabat JKR, K.L to seal the surface.
Page 45
FOR INTERNAL USE ONLY between rock fill and earth fill or the
top 300 mm of subgrade of at least
There shall be a transition layer 300 mm compacted thickness. This
shall consist of uniformly graded
crushed rock between 6 mm and 150 Standard Specification For Road Works
mm as approved by the S.O.
2.2.6.2 Surcharge and Staged
Each layer of rock used as rock fill Construction
in embankments shall be
systematically compacted by at least Where indicated in the Contract
12 passes of a vibrating roller with a or directed by the S.O., the
static load per 25 mm width of roll embankment shall be built to
of at least 45 kg or a grid roller with different heights in stages with or
load per 25 mm width of roll of at without surcharge with allowance
least 200 kg or other approved plant. for consolidation time periods in
between stages, all in accordance
2.2.6 Embankment Over Soft Ground with the Contract. Where sur
charge is specified, the
2.2.6.1 Foundation Treatment Contractor shall be responsible
for the provision of surcharge
Prior to forming embankment material and the removal and
over soft ground, the soil over disposal of excess material on
which fill material shall be completion of consolidation or
placed shall be given strength when directed by the S.O.
improvement treatment as
specified and to the details as 2.2.6.3 Settlement Markers
shown on the Drawings or as
directed or approved by the Markers shall be provided and
S.O. Treatment by means of installed by the Contractor in the
replacement of unsuitable positions indicated on the
material shall be as specified Drawings for the purpose of
in Sub-Sections 2.2.3.4 and measuring settlements taking
2.2.3.5. place under the embankments
during and after the construction
The first layer or layers of fill period. The design of markers
materials shall be deposited shall be as shown on the
over the full width of the Drawings and the Contractor
embankment and berms in shall be responsible for supplying
thicknesses and compacted as and installing such markers and
approved by the S.O. The for extending the markers as the
Contractor shall provide work proceeds. Adjustments to
compaction plant suitable for the height of markers shall be
working over soft ground. made when required by the S.O.
Each marker shall be identified
by painting on it the chainage of
its position.
The Contractor shall take all

necessary measures to protect
markers from damage by plant
Cawangan Jalan, Ibu Pejabat JKR, K.L and vehicles at all times and shall
repair any such damage to the
satisfaction of the S.O. Readily
visible barriers shall be installed
around each marker.
Page 46
Joint measurement of
2.2.6.4 Settlement Records settlement shall be taken
weekly while fill is being
placed in the vicinity of the Standard Specification For Road Works
markers. Thereafter, readings
shall be taken fortnightly for a (for cohesionless material) of the
period as directed by the S.O. maximum dry density determined in
The readings shall be the B.S. 1377 Compaction Test (4.5
submitted on an approved kg rammer method). If the S.O. is
printed form to be supplied by fully satisfied that the subgrade in its
the Contractor. natural state possesses a density
exceeding the requirements, then the
For the measurement of the surface of the subgrade shall be
volume that has settled below trimmed and rolled to obtain a
the original level of the smooth finish.
foundation of the
embankment, the measured Where the material in cut area is
settlement of each marker found to be unsuitable for use in the
shall be used for volume top 300 mm of subgrade it shall be
computation following the removed and replaced with suitable
method shown on the material which shall be compacted as
Drawings. indicated above.
2.2.7 Subgrade The subgrade shall be finished in a

neat and workmanlike manner, and
Material for the top 300 mm of the widths of embankments and cuts
subgrade shall have a minimum shall be everywhere at least those
California Bearing Ratio (CBR) specified or shown on the Drawings
as shown on the Drawings when on both sides of the centreline. The
compacted to 95% of the top surface of the subgrade shall
maximum dry density determined have the required shape,
in the B.S. 1377 Compaction superelevation, levels and grades and
Test (4.5 kg rammer method) shall be finished everywhere to with
under 4 days soaked condition. in + 10 mm and minus 30 mm of the
required level.
Throughout the top 300 mm of
subgrade, the material shall be i) Where rock surface extends over
compacted to not less than 95% the whole width of the
(for cohesive material) or 100% formation :-
(for cohesionless material) of the
maximum dry density determined The rock surface shall be
in the B.S. 1377 Compaction Test trimmed to a free draining
(4.5 kg rammer method). profile, at or below formation
levels. No high spot shall
In cut area, the top 300 mm of protrude above the formation
the subgrade shall be scarified levels.
and recompacted to 95% (for
cohesive material) or 100% Any voids or cavities more than
0.5 metre below the formation
Cawangan Jalan, Ibu Pejabat JKR, K.L level shall be filled up with
approved lean concrete having
7-day cube strength greater than
7 N/sq.mm. The rock surface
shall then be brought up to the
formation levels with approved
Page 47
FOR INTERNAL USE ONLY and blinded.
crushed rock or gravel, regulated ii) Where rock outcrop occurs over
part of the formation only:-
The rock outcrop shall be cut
down to a level not less than 300 Turf sods shall be stacked and
mm below the formation level. watered when they cannot be
The surface shall then be brought laid immediately after cutting.
up to level with suitable subgrade
material. The surfaces to be turfed shall
be trimmed and thoroughly
2.2.8 Protective Vegetation for Erosion wetted. The turf shall then be
Control carefully laid to form a complete
and uniform cover as shown on
2.2.8.1 Topsoil the Drawings. Turf laid on slopes
steeper than 1 (vertical) and 3
Topsoil stockpiled for the Works (horizontal) shall be pegged
in accordance with Sub- Sections down with bamboo stakes
2.1.1.3 and 2.1.2.3 shall be spread approximately 250 mm in length.
and lightly compacted to an even Approved fertiliser shall be
thickness of 50 mm as directed applied after placing of turf at
by the S.O. in areas to be turfed suitable times and at rates of
and/or seeded, or used as the S.O. application approved by the S.O.
shall otherwise direct for tree
planting and other purposes. All turf shall be regularly
watered and fertilised to the
2.2.8.2 Turfing satisfaction of the S.O. until
the vegetation is satisfactorily
Turfing shall be carried out as established. Any dead turf
soon as practicable on all earth shall be replaced with new
slopes and other areas as shown turf at the Contractor's own
on the Drawings and/or where expense.
directed by the S.O. The type of
turf shall be as indicated on the
Drawings or other alternative 2.2.8.3 Seeding
type as approved by the S.O. and
shall be free of lallang and Seeding or hydroseeding shall be
essentially free of weeds. carried out as soon as practicable
on slopes and other areas as
Turf shall be obtained in shown on the Drawings and/or
unbroken sods with a substantial directed by the S.O.
amount of topsoil and shall be
approximately 250 mm x 250 The Contractor shall submit to
mm in size and 100 mm thick, the S.O. for his consideration and
from an approved source, and approval, at least four (4) weeks
shall be placed in position as in advance of the proposed work,
soon as practicable after cutting. full details of his proposed
method of seeding or
hydroseeding. The information
Cawangan Jalan, Ibu Pejabat JKR, K.L submitted shall include, but not
necessarily be limited to, a full
description of the following
aspects of the work :-
Page 48
FOR INTERNAL USE ONLY seeded or hydroseeded, including
if appropriate the amount of top
i) the preparation of the areas to be soil to be used and its method of
application;
ii) the details and results of
investigations to determine which xii) the cultivation and after-care of
types of grass and legume are the seeded areas, including rates
compatible with the soil in the and frequencies of watering,
areas to be seeded; fertilising, grass cutting and
general maintenance for at least 1
iii) the types of grass and legume (if year after seeding;
any) and strains of seed to be
used, and the function, root and xiii) the time after seeding required for
growth characteristics of each establishing permanent, dense
type; growth of grasses, which will
require minimal maintenance;
iv) the rates of application of the
grass and legume seeds; xiv) guarantees of the success of the
seeding work.
v) the composition of fertiliser to be
used at the time of seeding and its All grass shall be regularly watered until
rate of application; the vegetation is satisfactorily
established to the satisfaction of the S.O.
vi) the composition of fertiliser to be Any dead grass shall be replaced at the
used after seeding, the times of Contractor's own expense.
application after seeding, and the
rates of application;
vii) the type of mulch to be used and

its method and rate of
application;
viii) the amounts of lime or other

chemicals (if any) to be applied
to improve the soil before,
during and/or after seeding;
ix) the type and amounts of binding

agent to be applied with the
seeds, mulch, fertiliser, etc.,
as appropriate.
x) the proportions and methods of

preparation of the seeding mix;
xi) the equipment and methods to be

used in preparing and placing the
seeding mix and other materials;
Page 49
SECTION 3
DRAINAGE WORKS

SECTION 3 - DRAINAGE WORKS
Page
3.1 GENERAL S3-54

3.2 EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS S3-54
3.2.2 Materials S3-54

3.2.2.1 Excavation S3-54
3.2.2.2 Granular Bedding Material S3-54
3.2.2.3 Concrete Bedding S3-54
3.2.2.4 Ordinary Backfill Material S3-54
3.2.2.5 Granular Backfill Material S3-54
3.2.2.6 Concrete Backfill S3-55
3.2.3 Excavation S3-55
3.2.4 Backfilling with Ordinary or Granular Backfill Material S3-56
3.3 CHANNEL EXCAVATION S3-57
3.4 SURFACE DRAINAGE S3-58
3.4.1 Surface Drainage Types S3-58
3.4.2 Surface Drain Construction S3-58

3.4.2.1 Unlined Drains S3-58
3.4.2.2 Cast In Situ Concrete Drains S3-59
3.4.2.3 Precast Concrete Drain Sections S3-59
3.5 STONE PITCHING S3-60

3.5.2.1 Stone S3-60
3.5.2.2 Cement Mortar S3-60

Page

3.5.3.1 Grouted Stone Pitching S3-60
3.5.3.2 Ungrouted Stone Pitching S3-61
3.6 GABIONS S3-61

3.6.2.1 Wire Mesh Gabions S3-61
3.6.2.2 Polyvinyl Chloride Coating S3-62
3.6.2.3 Stone S3-62
3.7 BRICKWORK S3-63

3.7.2.1 Common Bricks S3-63
3.7.3.1 Brick Laying S3-63
3.7.3.2 Plastering Brickwork S3-64
3.8 SUBSOIL DRAINS S3-64

3.8.2.1 Pipes S3-64
3.8.2.2 Filter Material S3-64
3.8.2.3 Filter Cloth S3-65
3.9 R.C. PIPE CULVERTS S3-66

3.9.2.1 Pipes S3-66
3.9.2.3 Bedding Material S3-66

Page
3.9.3 Excavation and Backfilling for R.C. Pipe Culverts S3-67

3.9.3.2 Backfilling S3-68
3.9.4 Installation of R.C. Pipe Culverts S3-68

3.9.4.1 General S3-68
3.9.4.2 Butt Ended Pipe Culverts with Precast Concrete Collars S3-68
3.9.4.3 Rebated Pipe Culverts S3-69
3.9.4.4 Spigot and Socket Pipe Culverts S3-70
3.10 CORRUGATED METAL PIPE CULVERTS S3-70


3.10.2.1 Pipes S3-70
3.10.2.2 Bitumen Coating S3-71
3.10.2.3 Bolts and Nuts S3-71
3.10.3 Excavation and Backfilling for Corrugated Metal Pipe Culverts S3-72
3.10.4 Installation of Corrugated Metal Pipe Culverts S3-72

3.10.4.1 General S3-72
3.10.4.2 Mortar Lining S3-72
3.11 PRECAST BOX CULVERTS S3-72

3.11.2.1 Precast Box Culverts S3-72
3.11.3 Excavation and Backfilling S3-73

3.11.3.1 Excavation for Precast Box Culverts S3-73
3.11.4 Installation of Precast Box Culverts S3-73
3.12 EXTENSION OF CULVERTS S3-74
3.12.1 Extension of Pipe Culverts S3-74

3.12.2 Extension of Box Culverts S3-74

FOR INTERNAL USE ONLY 3.2 EXCAVATION AND
BACKFILLING FOR DRAINAGE
SECTION 3 - DRAINAGE WORKS WORKS
3.2.1 Description
3.1 GENERAL This work shall consist of excavation

for the construction of surface drains,
This work shall consist of the subsoil drains, cast in site box
construction of surface drains, subsoil culverts, and other drainage
drains, pipe culverts, box culverts, structures, except pipe culverts, not
sumps and other drainage structures in otherwise provided for in this
accordance with this Specification or Specification, and shall include
as directed by the S.O. Drainage works furnishing, placing, compacting and
shall be constructed to the lines, levels, shaping foundation bedding
grades and cross-sections shown on the materials, backfilling excavations
Drawings or as directed by the S.O. against completed structures with
suitable material or granular backfill
where specified, and the removal and
disposal of all excess excavated Standard Specification For Road Works
material, in accordance with this
Specification and as shown on the 3.2.2 Materials
Drawings and as required by the
S.O. 3.2.2.1 Excavation
Excavation and backfill for pipe Material excavated shall be

culverts and precast box culverts classified as common excavation
shall be in accordance with the or rock as defined in Section 2 of
provisions of Sub-Section 3.9. this Specification.
3.2.2.2 Granular Bedding Material
Granular bedding material for the

B.S. Sieve Size % Passing By Weight foundations of structures shall be
Cawangan Jalan, Ibu Pejabat JKR, K.L suitably graded broken rubble,
crushed stone, crushed gravel,
10.0 mm 100 sand or other material as
5.0 mm 90 - 100 specified on the Drawings or as
1.18 mm 45 - 80 required by the S.O.
300 um 10 - 30 3.2.2.3 Concrete Bedding
150 um 2 - 10
Concrete bedding or blinding for
the foundations of structures shall
conform to the requirements of
Section 9 of this Specification
for the class of concrete specified
on the Drawings or required by
the S.O.
3.2.2.4 Ordinary Backfill Material
Ordinary backfill material shall

be suitable material as defined in
B.S. % Passing By Weight Section 2 of this Specification.
Sieve A B C The maximum particle size of the
Size backfill material shall be 50 mm.
37.5mm 100 - - 3.2.2.5 Granular Backfill Material

28.0mm 70 –100 100 -
20.0mm 60 – 90 70 - 100 100 Granular backfill material shall
10.0mm 45 – 75 45 - 75 - be sand, crushed stone, crushed
5.0mm 30 – 60 35 - 65 45 – 75 gravel or a mixture of crushed
2.0mm 20 – 50 25 - 50 30 – 60 and natural aggregates, shall be
425um 10 – 30 10 - 30 15 – 35 essentially free from vegetative
75um 0–2 0–2 0–2 and other organic matter and clay,
and shall not contain lateritic or
concretionary materials.
Page 54
FOR INTERNAL USE ONLY following physical and
mechanical quality requirements:-
The material shall conform to the
i) the fines shall be non-plastic;
ii) sand shall have a gradation
conforming to the envelope 3.2.2.6 Concrete Backfill
shown in Table 3.1;
TABLE 3.1 - GRADING LIMITS FOR SAND Concrete backfill where
BACKFILL
specified shall be of the
grade as shown on the
iii) material other than sand shall Drawings and shall con
have a gradation conforming form to Section 9 of this
to one of the envelopes shown Specification.
in Table 3.2.
3.2.3 Excavation
TABLE 3.2 - GRADING LIMITS FOR
GRANULAR BACKFILL OTHER THAN The Contractor shall notify the S.O.
SAND sufficiently in advance of the
beginning of any excavation so that
cross-section elevations and
measurements may be taken of the
undisturbed ground. The natural
ground adjacent to the structure shall
Cawangan Jalan, Ibu Pejabat JKR, K.L not be disturbed without permission
of the S.O.
Trenches and foundation pits for

structures and structure footings and
underdrains shall be excavated to the
lines, grades and elevations shown
on the Drawings or as directed by
the S.O. Excavations must be kept
free from water and temporary
drains, sumps and pumps shall be
provided when necessary. The rate of
excavation and backfill shall be
approved by the S.O. The elevations
of the bottoms of footings shown on
the Drawings are approximate only
and the S.O. may order in writing
such changes in the dimensions or
elevations of footings as may be
deemed necessary to secure a satis
factory foundation.
Boulders, logs and other

objectionable materials encountered
in excavation shall be removed.
After each excavation is completed

the Contractor shall notify the S.O.
to that effect and no footing,
bedding material or structure shall be
placed until the S.O.
Page 55
FOR INTERNAL USE ONLY to that effect and no footing,

bedding material or structure shall be Standard Specification For Road Works
placed until the S.O. has approved
the depth of excavation and the All excavated material, so far as
character of the foundation material. suitable, shall be utilized as backfill
or embankment. The surplus
Rock and other hard foundation material, whether or not temporarily
material shall be cleared of all loose allowed to be placed within a stream
material and cut to a firm surface, area, shall be finally disposed of in
either level or stepped or serrated, as such a manner as not to obstruct the
specified or shown on the Drawings stream nor otherwise impair the
or directed by the S.O. All seams efficiency or appearance of the
and crevices shall be cleared out and works, nor is it to endanger the
grouted with Portland cement grout partly finished structure.
at the time the footing is placed.
Excavated material suitable for use
All loose and disintegrated rock and as backfill may be deposited by the
thin strata shall be removed. When Contractor in storage piles at points
the footing is to rest on material convenient for rehandling of the
other than rock, special care shall be material during the backfilling
taken not to disturb the bottom of the operation.
excavation, and excavation to final
grade shall be deferred until just Excavated material shall be
before the footing is to be placed. deposited in such places and in such
When, in the opinion of the S.O., the a manner as not to cause damage to
foundation material is soft or mucky highway, services or property either
or otherwise unsuitable, the within or outside the road reserve,
Contractor shall remove the and so as to cause no impediment to
unsuitable material and insert the drainage of the Site or
foundation fill material or concrete surrounding area.
as specified or shown on the
Drawings or directed by the S.O. If 3.2.4 Backfilling with Ordinary or
foundation fill material is required it Granular Backfill Material
shall be placed and compacted in
layers not more than 150 mm thick All spaces excavated under this
or as directed by the S.O. The Specification and not occupied by a
degree of compaction shall be permanent structure shall be
equivalent to that of the surrounding backfilled. Backfill material shall be
foundations. free from large lumps, wood and
other extraneous material.
All excavation surfaces and surfaces
of backfill material against which Backfill not within the embankment
concrete is to be placed shall be areas shall be placed in layers not
even and firm and true to line and more than 250 mm in depth
level. (compacted measurement) and shall
be compacted to a density
comparable with the adjacent
undisturbed material.

FOR INTERNAL USE ONLY areas shall be made with approved
material placed in uniform layers not
Backfill within the embankment to exceed 150 mm in depth
(compacted measurement) and each
layer shall be constructed in Standard Specification For Road Works
accordance with Section 2 of this
Specification except that mechanical Special care shall be taken to prevent
tampers may be used for any unduly high pressures against
compaction. Each layer of backfill the structures.
shall be wetted uniformly as
necessary and compacted to the The placing of embankment and the
same requirements as the adjacent benching of slopes shall continue in
earthwork as specified in Section 2 such a manner that at all times there
of this Specification. Unless will be a horizontal berm of
otherwise approved by the S.O., thoroughly compacted material for a
hand tamping will not be accepted. distance at least equal to the height
of the abutment or wall to be back
In placing backfill and embankment, filled.
the material shall be placed insofar
as possible to approximately the 3.3 CHANNEL EXCAVATION
same height on both sides of the
structure. If conditions require 3.3.1 Description
backfilling appreciably higher on one
side, the additional material on the This work shall consist of excavation
higher side shall not be placed until for waterway channels both inside
permission is given by the S.O. or and outside the road reserve as
until the S.O. is satisfied that the shown on the Drawings or directed
structure has enough strength to by the S.O., and shall include all
withstand any pressure created. required excavation for widening,
training or permanently diverting
Backfill for embankment shall not be rivers, streams and irrigation and
placed behind the walls of box drainage channels other than drains
culverts until the top slab is placed and ditches appurtenant to the
for the required time and not less roadway, except excavation of top
than three days. Backfill and soil for use in the Works and
embankment behind abutments held excavation required for clearing and
at the top by superstructure shall be grubbing. This work shall also
carried up simultaneously behind include the backfilling of old
opposite abutments and side walls. channels, haulage to their points of
utilization in the Works or the
No backfilling shall be placed removal and disposal of all
against any structure until permission excavated materials, the construction
shall have been given by the S.O. of appurtenant bunds, dikes and
Jetting of fill or other hydraulic berms, and the shaping and finishing
methods involving, or likely to of all earthworks involved in the
involve, liquid or semi-liquid construction of channels in accor
pressure shall be prohibited. dance with the required lines, levels,
grades and cross-sections.
3.3.2 Materials
Channel excavation shall be
classified as common excavation or
rock as specified in Section 2 of this
Specification.
Page 57
All suitable materials removed from
3.3.3 Construction Methods channel excavations shall be used for
backfilling waterways to be
abandoned and constructing bunds, Standard Specification For Road Works
dikes and other earth appurtenances
as required. Surplus suitable Sections of channel abandoned
materials shall be used as far as is owing to diversions shall be back
practicable in constructing the filled as directed by the S.O.
roadway. The Contractor shall
provide borrow of satisfactory q
quality and approved by the S.O. 3.4 SURFACE DRAINAGE
should this be necessary to complete
the work. Borrow which is required 3.4.1 Surface Drainage Types
to replace suitable excavated
materials needed for construction Surface drains of the types shown on
which the Contractor elects to waste the Drawings shall be constructed to
shall not be paid for. the lines, levels, grades and cross-
sections as specified or as directed
Excavated unsuitable material, by the S.O. Surface drains shall
suitable material surplus to that include interceptor drains, roadside
needed for construction and suitable drains, embankment toe drains,
material that the Contractor elects to shoulder drains, bench drains, berm
waste, shall be disposed of at drains, median drains, outfall drains,
designated areas in such a manner as cascade drains, etc.
to present a neat appearance and not
obstruct flow in any channels, Any of the above drains may be
ditches or drains, nor cause damage constructed either unlined or lined
to highway works or property, all to using cast in situ concrete, precast or
the satisfaction of the S.O. porous concrete drain sections, or
stone pitching.
During construction, channel
excavations shall be kept drained as 3.4.2 Surface Drain Construction
far as is practicable and the work
shall be carried out in a neat and 3.4.2.1 Unlined Drains
workmanlike manner.
Excavation for unlined drains
All channels and appurtenances shall shall be trimmed to form a
be excavated and constructed to the smooth, firm surface to the
lines, levels, grades and cross- required lines, levels, grades and
sections shown on the Drawings or cross-sections as shown on the
as directed by the S.O. Excavation Drawings or as required by the
beyond the limits required shall not S.O.
be paid for and shall be backfilled at
the Contractor's expense as directed Any areas of over excavation
by the S.O. should he deem it shall be made good to the
necessary. satisfaction of the S.O., all at the
Contractor's expense.
Page 58
Excavation shall be carried
3.4.2.2 Cast In Situ Concrete Drains out to the lines and levels as
specified and as shown on the
Drawings. Templates which Standard Specification For Road Works
may be of timber or steel shall
then be provided to ensure the Ready made precast concrete
thickness and shape of the drain sections may be used
concrete drains. The concrete subject to the approval of the
shall be poured in sections not S.O. Samples of ready made
exceeding 2 m in length and drain sections shall be submitted
shall be carried out between to the S.O. for his approval
end forms in alternate bays. before placing of orders.
Construction joints shall not Notwithstanding any approval
be formed in the inverts. given by the S.O., any defective
or broken drain section shall be
All concrete shall be grade replaced by the Contractor at his
20/20 concrete unless otherwise own expense before or after
specified and shall conform to the laying in position.
requirements of Section 9 of this
Specification. Weep holes shall Precast concrete drain sections
be cast in situ as shown on the shall be laid on concrete bedding
Drawings or as directed by the in trenches excavated to the lines
S.O. and levels as specified and
jointed to produce a neat even
3.4.2.3 Precast Concrete Drain alignment and gradient. The joint
Sections shall be grouted with 1:3 cement
mortar complying with Sub-
Precast concrete block inverts Section 3.5.2.2 and weep holes
shall be of the shapes and shall be provided as shown on the
dimensions as shown on the Drawings or as directed by the
Drawings and shall be of S.O.
grade 20/20 concrete conforming
to the requirements of Section 9 Porous concrete shall comply
of this Specification or of with the requirements of porous
porous concrete unless otherwise concrete for pipes as described in
specified. The precast concrete M.S. 525. Cement and
drain sections shall be aggregates used in the
manufactured using good quality manufacture of the porous
moulds and the finished product concrete drain sections shall con
shall be round and have smooth form to the requirements of
inside surfaces all to the approval Section 9 of this Specification.
of the S.O. Ready made precast
concrete drain sections may be Mass concrete for bases shall be
used subject to the approval of of grade 10/25 concrete or as
the S.O. specified and to the dimensions
and thicknesses as shown on the
Drawings.
Page 59
3.5.1 Description
3.5 STONE PITCHING
This work shall consist of the
construction of all structures or parts Standard Specification For Road Works
of structures to be composed of stone
pitching either grouted or ungrouted 3.5.2.2 Cement Mortar
as shown on the Drawings or as
directed by the S.O. including Cement mortar, unless otherwise
erosion protection pavements and specified, shall contain 1 part
aprons, drain linings, culvert inlets ordinary Portland cement to 3
and outlets, etc. The work shall be parts fine aggregate by volume.
carried out all in accordance with Water shall be added to the mix
this Specification and to the lines, to produce a suitable consistency
levels, grades, dimensions and cross- for the intended use, all to the
sections shown on the Drawings and satisfaction of the S.O. The
as required by the S.O. constituent materials of the
mortar shall comply with the
3.5.2 Materials appropriate requirements of
Section 9 of this Specification.
3.5.2.1 Stone
The ingredients for mortar shall
Stone shall be clean rough quarry be measured in proper gauge
stone, or pit or river cobbles, or a boxes and mixed on a clean
mixture of any of these materials, boarded platform or in an
and shall be essentially free from approved mechanical batch
dust, clay, vegetative matter and mixer.
other deleterious materials.
Individual pieces of stone shall be All mortar shall be used within
approximately cubical or 30 minutes of mixing and no
spherical and shall have least reworking of mortar shall be
dimensions in the range 100 to permitted thereafter.
150 mm and a maximum
dimension of 250 mm, 3.5.3 Construction Methods
maximum, unless otherwise
specified. The stone shall be 3.5.3.1 Grouted Stone Pitching
hard, tough, durable and dense,
resistant to the action of air and Prior to constructing grouted
water, and suitable in all respects stone pitching, the surfaces
for the purpose intended. against which it is to be placed
shall have been finished in
accordance with the appropriate
provisions of this Specification.
Notwithstanding any earlier
approval of these finished
surfaces, any damage to or
deterioration of them shall be
made good to the satisfaction of
the S.O. before grouted stone
pitching is placed.

FOR INTERNAL USE ONLY pitching shall commence at the
lowest part of each structure or
Construction of grouted stone section of a structure and
continue progressively upward.
Long structures such as drain Standard Specification For Road Works
linings and slope protection
pavements shall be constructed in building up the structure to full
sections of practicable length, to thickness is commenced on any
the satisfaction of the S.O. The section of the work, as the con
surface against which the work is struction advances.
to be placed shall be moistened
with clean water a little in The work shall be carried out and
advance of construction, and finished all to the satisfaction of
covered with a layer of cement the S.O.
mortar about 50 mm thick.
Stones shall then be firmly set by 3.5.3.2 Ungrouted Stone Pitching
hand into the mortar, densely
packed against adjacent stones Where shown on the Drawings,
and built up to form a stone ungrouted stone pitching shall be
structure of more or less uniform hand set to provide maximum
thickness which shall nowhere be interlocking effect. The stones,
less than 150 mm (measured per the largest of which shall be used
pendicularly to the surface at the bottom, shall be well
covered). All the while that bedded on a 75 mm layer of
stones are being placed, all voids gravel or aggregate rammed to an
in the structure shall be packed even surface. The whole work
solidly with mortar and stone shall be finished to the
spalls; however the surfaces of satisfaction of the S.O
stones in the exposed faces and
edges shall not be covered with 3.6 GABIONS
mortar. The exposed surfaces
and edges of the structure shall be 3.6.1 Description
constructed such that they have
as large a proportion as This work shall consist of the
practicable composed of stone construction of miscellaneous
faces. Weep holes shall be erosion protection and retaining
provided as shown on the structures to be composed of stone
Drawings or as directed by the filled wire mesh gabions. The work
S.O. shall be carried out all in accordance
with this Specification and as shown
Mortar which has been mixed for on the Drawings and/or as approved
more than 30 minutes shall not be by the S.O.
used in the works. Nor shall
mortar be laid against the 3.6.2 Materials
supporting surface more than 2
minutes before pitching stone and 3.6.2.1 Wire Mesh Gabions
Gabions shall be rectangular

baskets of the required
dimensions as shown on the
Cawangan Jalan, Ibu Pejabat JKR, K.L Drawings or ordered by the S.O.
Unless otherwise specified, they
shall be of the following standard
dimensions :-
Page 61
i) width - 1.00 metre;
ii) length - 1.00, 2.00 or 3.00

metres;
iii) height - 0.50 or 1.00 metre.
Gabions longer than 1.00 m shall

be divided into compartments of
equal length not exceeding 1.00
m by wire mesh diaphragms
securely tied along all edges.
Each gabion or compartment of a
gabion shall be provided with at
least 4 cross-connecting wires if
its height is 0.50 m or less, and
with at least 8 cross-connecting
wires if its height is in the range
0.50 to 1.00 metre.
Gabions shall be fabricated from

steel wire manufactured in
accordance with B.S. 1052 and
galvanised in accordance with
M.S. 407, or such similar
standards as the S.O. shall
approve. The galvanised wire
sizes used shall be in accordance
with Table 3.3.
TABLE 3.3 - GALVANISED WIRE SIZES

FOR GABIONS
Type of Wire Minimum Diameter
Selvage (perimeter) wire 3.50 mm
Mesh wire 2.70 mm
Tying and connecting 2.20 mm

wire

Standard Specification For Road Works than 0.55 mm in thickness.
Gabion mesh shall be triple 3.6.2.3 Stone

twisted and shall have a uniform
hexagonal pattern with openings Stone fill for gabions shall be
of 100 x 120 mm or less. The clean rough quarry stone, or pit
mesh shall be securely tied to or river cobbles, or a mixture of
selvage wires to form rectangular any of these materials, and shall
panels which shall be securely be essentially free from dust,
wired together to form the clay, vegetative matter and other
completed gabion baskets. The deleterious materials. Individual
ties and connections for each pieces of stone shall have least
gabion basket shall comprise not dimensions not less than 20 mm
less than 8% of its total weight, larger than the gabion mesh
and the fabrication shall be all to openings and greatest dimensions
the satisfaction of the S.O. not more than 250 mm. The stone
shall be hard, tough, durable and
3.6.2.2 Polyvinyl Chloride Coating dense, resistant to the action of
air and water, and suitable in all
When specified on the Drawings, aspects for the purpose intended.
all wire used in the fabrication of The material shall be approved
gabions and in the wiring by the S.O.
operation during construction
shall, after galvanising, have
extruded on to it a coating of
polyvinyl chloride (PVC). The Page 62
PVC coating, not inclusive of
galvanising, shall nowhere be less
FOR INTERNAL USE ONLY mass. Finally, the lid of the basket
shall be securely fastened down with
3.6.3 Construction Methods tying wire along all hitherto
unfastened edges, all to the
Prior to placing gabions, the surface satisfaction of the S.O. In no case
on and against which they are to be shall the weight of the finished
constructed shall have been prepared gabion be less than 1300 kg
and finished in accordance with the per cubic metre.
relevant provisions of the appropriate
Sections of this Specification. As a gabion structure is built up,
Notwithstanding any earlier approval backfilling against finished gabions
of these finished surfaces, any shall be carried out as necessary for
damage to or deterioration of them proper progressive construction, all
shall be made good to the in accordance with the relevant
satisfaction of the S.O. before provisions of the appropriate
gabions are placed. Sections of this Specification. Unless
otherwise specified, vertical joints
Each gabion basket shall be put in between gabions shall be staggered
place in its turn, completely in gabion structures in a pattern
fabricated except for the fastening similar to the joints in running bond
down of the lid, stretched to the brickwork.
correct shape and dimensions, and
fastened securely to all contiguous
baskets along each edge with tying
wire. The basket shall then be tightly Cawangan Jalan, Ibu Pejabat JKR, K.L
packed with approved stone by hand
in such a manner that voids are kept
to a practicable minimum and are
uniformly distributed in the stone
Standard Specification For Road Works Cement mortar for brickwork
shall comply with the
3.7 BRICKWORK requirements of Sub-Section
3.5.2.2.
3.7.1 Description
This work shall include the laying of
brickwork to the lines, levels and 3.7.3.1 Brick Laying
grades shown on the Drawings
and/or as directed by the S.O. Brickwork shall be executed with
cement mortar and shall be of the
3.7.2 Materials thickness and bonds as shown on
the Drawings. Bricks shall be
3.7.2.1 Common Bricks kept damp until used and shall be
laid on a full bed of mortar. The
Common bricks shall be sound, brickwork shall be true to line
hard, well burnt, of proper size and plumb, and courses shall be
and clean and shall give a clear kept truly level. The thickness of
ring when struck. They shall be mortar joints shall not exceed 10
Class 3 standard format mm and shall be such that 4
complying with the requirements courses of brickwork forms a
of M.S. 76. Bricks shall be height of 300 mm.
obtained from manufacturers
3.7.2.2 Cement Mortar

Page 63
FOR INTERNAL USE ONLY the S.O. may be added to the mix
in accordance with the
Newly laid brickwork shall be manufacturer's instructions.
protected from the harmful
effects of sunshine, rain, running Ordinary Portland cement and
and surface water and shocks. water shall comply with the
Any brickwork that is damaged appropriate requirements of
shall be taken down and rebuilt Section 9 of this Specification.
and the joints raked out and
pointed as directed by the S.O. Weep holes shall be provided as
Any such remedial work shall be shown on the Drawings or as
at the Contractor's own expense. directed by the S.O.
3.7.3.2 Plastering Brickwork
All exposed brickwork surfaces

shall be plastered. The plaster B.S. Sieve % Passing By
shall be applied in 2 coats Size Weight
generally to a total thickness of
10.0mm 100
20 mm and shall be finished with 5.0mm 90 - 100
a steel trowel for internal surfaces 2.36mm 75 - 100
and with a wooden float for 1.18mm 55 - 90
external surfaces. 600um 35 - 59
300um 8 - 30
150um 0 - 10
Plain plaster shall consist of 1
part masonry cement complying
with M.S. 794 to 3 parts of sand
by volume. where ordinary
portland cement is used,
plasticiser of a type approved by
Standard Specification For Road Works Clay pipes for subsoil drains shall
comply with B.S. 1196.
3.8 SUBSOIL DRAINS
Polyvinyl Chloride (PVC) pipes
3.8.1 Description for subsoil drains shall comply
with Australian Standard
This work shall include the supply Specification 2439 or B.S. 3656.
and installation of subsoil drains
constructed in accordance with this 3.8.2.2 Filter Material
Specification at the locations and in
accordance with the lines, levels and Filter material used in the
grades as shown on the Drawings construction of subsoil drains
and/or as directed by the S.O. shall consist of hard, clean sand
conforming to the grading limits
3.8.2 Materials given in Table 3.4. The material
passing the 425 um sieve shall be
3.8.2.1 Pipes non-plastic when tested in
accordance with B.S. 1377.
Porous concrete pipes for subsoil
drains shall comply with M.S. TABLE 3.4 - GRADING LIMITS FOR
525.

FOR INTERNAL USE ONLY deterioration from ultraviolet and
heat exposure.
3.8.2.3 Filter Cloth
(b) Physical Property
The synthetic filter cloth shall be Requirements
a non-woven type of approved
manufacture having the following The physical properties of the
properties :- filter cloth shall comply with
FILTER MATERIAL
Table 3.5.
(a) Chemical Composition
Requirements TABLE 3.5 - PHYSICAL PROPERTY
REQUIREMENTS FOR FILTER CLOTH
Fibres used in the manufacture of
the engineering fabric shall
consist of a long chain synthetic
polymer, composed of at least
85% by weight of
polypropylene, -ethylene, -
esteramide or -vinylidene
chloride and shall contain
stabilisers and/or inhibitors added
to the base plastic (as necessary)
to make the fabric resistant to
(c) Filtration Requirement
1:3 cement mortar for use in pipe
Equivalent opening size of the joints shall comply with Sub-
filter cloth determined by sieving Section 3.5.2.2.
as described in ASTM D422 shall
be less than the eighty-five 3.8.3 Construction Methods
percentage size of the adjacent
soil. Excavation for subsoil drains shall
be carried out all in accordance with
(d) Permeability Requirement the appropriate provisions of Sub-
Section 3.2.
The equivalent Darcy
Permeability of the filter cloth Filter material as described in Sub-
shall be greater than 10 times Section 3.8.2.2 above shall be placed
the Darcy Permeability of the and uniformly compacted by a
soil to be drained. suitable method approved by the
S.O. to form a firm, even bedding for
Grab Strength 0.9 kN the pipe drain as shown on the
Drawings.
(ASTM D1682)
The pipe sections shall be set firmly
Puncture Strength 0.4 kN against the filter material bedding
(ASTM D3787 - 80a) with the flow lines in the design
position. For pipes with mating
joints, the receiving ends shall be
Burst Strength 2100 kN/sq.m upgrade, and the pipe joints shall be
(ASTM D3786 - 80a) fully mated. For butt jointed pipes
with collars, the pipe sections shall
be fully contiguous, and the collars
properly centred over the joints.

FOR INTERNAL USE ONLY material shall be placed and
uniformly compacted by a suitable
Joints shall be spot mortared as method approved by the S.O. to
necessary to hold the pipe sections form a dense, even surround to the
correctly centred and aligned, but not pipe as shown on the Drawings. Care
so as to unduly restrict the infiltration shall be taken that the pipe is neither
of water through the joints. damaged nor displaced.
Slotted or perforated pipes shall be Backfill shall then be placed and

tightly wrapped in filter cloth such compacted in accordance with the
that the entire length of the mortared appropriate provisions of Sub-
pipe is covered by at least 2 layers of Section 3.2.4.
cloth. All joints in both layers shall
have an overlap of at least 100 mm 3.9 R.C. PIPE CULVERTS
and joints in the outer layer shall be
offset by at least 300 mm from joints 3.9.1 Description
in the inner layer, all to the
satisfaction of the S.O. This work shall comprise the supply
and installation of reinforced
After pipe laying and, if appropriate, concrete pipe culverts, inclusive of
wrapping has been approved by the excavation, backfilling, jointing,
S.O., the remainder of the filter bedding, construction of headwalls,
wingwalls, aprons and sumps and Standard Specification For Road Works
channel protection works, all in
accordance with this Specification 3.9.2 Materials
and the details shown on the
Drawings. 3.9.2.1 Pipes
Reinforced concrete pipes shall

M.S. 881 and shall be supplied
Cawangan Jalan, Ibu Pejabat JKR, K.L by manufacturers approved by
the S.O.
Rebated pipes of diameter 600

mm and above shall be internally
rebated.
Collars shall be precast with

grade 25 concrete and shall be
suitably reinforced all
in accordance with Section 9 of
this Specification. The width of
the collar shall be not less than
150 mm and the minimum
thickness shall be 50 mm.
Rubber rings for spigot and

socket pipes shall comply with
the requirements of Type 2 as
specified in B.S. 2494.
1:3 cement mortar for jointing of

reinforced concrete pipes shall
Sub-Section 3.5.2.2.
3.9.2.3 Bedding Material
Type A bedding shall consist of

grade 20/20 concrete complying
with Section 9 of this
Specification.
Type B bedding shall consist of

clean, natural sand or gravelly
sand of suitable gradation and
quality, approved by the S.O.
The material shall have a
maximum particle size of not
more than 12 mm.
Page 66
FOR INTERNAL USE ONLY Pipe Culverts
3.9.3 Excavation and Backfilling for R.C. 3.9.3.1 Excavation

(a) General Standard Specification For Road Works
Unless otherwise directed by Where rock or other hard

the S.O., prior to construction unyielding foundation
of a pipe culvert, the earth material is encountered in the
works at the required location trench, it shall be excavated to
shall have been constructed a depth below the bottom of
to a level at least 600 mm pipe design levels of at least
above the top of culvert 300 mm or 12.5 mm per 300
design levels or to the top of mm of fill to be placed over
subgrade levels, whichever is the top of the pipe, whichever
lower. is greater, up to a maximum
of 75% of the internal
Pipe culverts specified to be diameter of the pipe. The
constructed in trench hard material so excavated
conditions shall be excavated shall be replaced with suitable
in accordance with Sub- material uniformly compacted
Section 3.9.3.1 (b) below. in layers of not more than 150
mm compacted thickness to
Where drainage conditions or provide satisfactory support
other circumstances so for the pipe, all to the
require, the S.O. may direct satisfaction of the S.O.
the Contractor to construct the
pipe culvert without first (c) Open Ground Method
constructing the earthworks to
the level specified above, in Where existing ground levels
which case excavation and are above top of bedding
foundation preparation shall material design levels and
be in accordance with Sub- firm foundation materials are
Section 3.9.3.1 (c) below. encountered, excavation and
foundation preparation shall
(b) Trench Method be similar to that described
in the trench method above.
The trench to receive a culvert Otherwise a firm foundation
pipe shall be of sufficient plane shall be prepared, which
width and depth to enable the shall be essentially free
placing of bedding material draining along the line of the
and construction of pipe joints culvert, by trimming the
in accordance with this existing ground, or such fill as
Specification, and the bottom it is necessary to place and
of the trench shall be trimmed compact, over a width
to a suitably smooth plane sufficient to permit
surface which shall be kept satisfactory construction of
free from water, all to the the pipe bedding, all to the
satisfaction of the S.O. satisfaction of the S.O. Hard
materials shall be excavated
Cawangan Jalan, Ibu Pejabat JKR, K.L from the pipe foundation over
a width equal to the outside
diameter of the pipe to the
same depth as specified in the
trench method, and shall be
replaced with suitable
Page 67
FOR INTERNAL USE ONLY in layers of not more than 150
mm compacted thickness to
material uniformly compacted provide satisfactory support
for the pipe, all to the
satisfaction of the S.O. Standard Specification For Road Works
Where soft or unstable soil is Heavy plant and equipment shall

encountered in the foundation, not operate within 1.5 m of any
it shall be excavated over a pipe culvert until backfilling and,
width of at least 1.5 times the where appropriate, pavement
outside diameter of the pipe construction has advanced to a
on each side of the culvert stage which provides at least 600
centre-line to the depth mm of cover to the culvert.
directed by the S.O., and Subject to the approval of the
replaced with suitable S.O., light compaction equipment
material uniformly may be operated above pipe
compacted in layers of not culverts after a minimum of 300
more than 150 mm mm of cover has been placed and
compacted thickness to compacted.
provide satisfactory support
for the pipe, all to the 3.9.4 Installation of R.C. Pipe Culverts
satisfaction of the S.O.
3.9.4.1 General
3.9.3.2 Backfilling
The type, size and class of pipe to
Backfilling against reinforced be installed at each location shall
concrete pipe culverts and their be as shown on the Drawings or
appurtenant structures shall be as directed by the S.O. Culverts
carried out in accordance with the shall not be installed at any
construction methods described location until the type of pipe, the
in Sub-Section 3.2.4, using exact location, the lines, levels
material conforming to the and grades, the length of pipe and
requirements of Sub-Section details of inlet and outlet
3.2.2.5. Special care shall be structures have been confirmed
taken to properly compact by the S.O. In addition, special
backfill against the undersides of requirements recommended by
culvert pipes without disturbing the manufacturer with respect to
or damaging the pipes and joints. assembly and installation shall be
Backfill shall be built up evenly complied with.
on both sides of each pipe culvert
along its entire length. Especially where elliptically
reinforced pipe sections are used,
care shall be taken to ensure that
the loading axes are positioned
exactly vertically.
3.9.4.2 Butt Ended Pipe Culverts with

Precast Concrete Collars
The pipes shall be laid on Type A

Cawangan Jalan, Ibu Pejabat JKR, K.L bedding in conformity with the
dimensions shown on the
Drawings. Before placing any
concrete bedding, the pipes shall
be assembled complete with
precast concrete collars to the
Page 68
FOR INTERNAL USE ONLY concrete spacing blocks of the same
class of concrete as the bedding
correct levels and grades on precast material and of sufficient size to
eliminate any risk of settlement of
the pipes before or during Standard Specification For Road Works
concreting.
Following pipe assembly and
All joints shall be fully mortared mortaring up as above, the
with 1:3 cement mortar before remainder of the cradle shall be
concreting of the cradle, all to the cast monolithically, all to the
satisfaction of the S.O. The concrete satisfaction of the S.O.
cradle shall be cast as one monolithic
unit. Alternatively, part of the Where vertical construction joints
concrete cradle below the underside in the concrete cradle are
of the pipe may be constructed unavoidable due to circumstances
monolithically at least 24 hours on Site, transfer bars shall be
before the assembly and mortaring provided to the satisfaction of the
up of the pipe sections and collars, S.O.
on condition that shear connectors
are provided across horizontal Special care shall be taken when
construction joints to the satisfaction placing the concrete cradle to
of the S.O. avoid the entrapment of air
underneath the pipe. To
During installation, the ends of the eliminate this possibility,
pipes shall be butted and the collar concrete shall be placed to one
centred about the joint using wedges side of the pipe only until such
or other approved means. The time as the level of the concrete
annular shall be completely filled surface rises above the underside
with 1:3 cement mortar with only of the pipe on the side remote
sufficient water added to ensure from that on which concrete is
adequate workability and the wedges being placed. The concrete shall
removed before finally fairing the then be brought up at the same
joint. Special care shall be taken to level on both sides of the pipe.
ensure that excess cement mortar is
neatly cleaned off. For pipes over 3.9.4.3 Rebated Pipe Culverts
900 mm in diameter the jointing
space shall be filled from inside the The pipes shall be laid on Type A
pipe after completion of bedding in conformity with the
embankment construction using 1:3 dimensions shown on the
cement mortar. When installed, the Drawings.
clearance between the outer
diameter of pipe and the inner The method of construction shall
diameter of collar shall be at least follow that described in Sub-
20 mm. Section 3.9.4.2 for butt ended
pipe culverts except for the
exclusion of precast concrete
collars.
The rebated joint shall be

internally flush and fully
mortared with 1:3 cement mortar,
all to the satisfaction of the S.O.

The pipes shall be laid on Type
3.9.4.4 Spigot and Socket Pipe Culverts B bedding in conformity with the
dimensions shown on the
Drawings. The bedding material Standard Specification For Road Works
shall be accurately shaped by a
template to fit the lower part of Care shall be taken to see that the
the pipe exterior for a height of at rubber ring is adequately
least 10% of the outside diameter compressed to seal the joint. All
of the pipe. Gaps shall be left in pipes shall be laid to the
the bedding material and recesses satisfaction of the S.O.
dug in the earth foundation of
sufficient width and depth to 3.10 CORRUGATED METAL PIPE
accomodate the socket without it CULVERTS
resting on the bottom of the
recess. The widths of the 3.10.1 Description
recesses in the foundation and the
bedding shall both exceed the This work shall comprise the supply
width of the socket by more than and installation of bolted, corrugated
50 mm. metal pipe culverts inclusive of
excavation, backfilling, jointing,
Jointing of the pipes shall be bedding, construction of headwalls,
carried out strictly in accordance wingwalls, aprons and sumps and
with the manufacturer's recom channel protection works, all in
mendations, all to the satisfaction accordance with this Specification
of the S.O. and the details shown on the
Drawings.
Concrete pipes as specified above
shall be laid true to line and level, 3.10.2 Materials
each pipe being separately boned
between sight rails. Pipes shall 3.10.2.1 Pipes
be laid in an upstream direction
with the sockets towards the inlet The pipe sections shall be
and shall rest on even fabricated from zinc-coated
foundations for the full length of (galvanised) steel sheets
the barrel. Rubber ring joints conforming to AASHTO M218
shall be installed strictly in or from structural plates
accordance with the conforming to AASHTO M167
manufacturer's instructions. Prior depending on the pipe size
to jointing, rubber rings and requirements.
jointing surfaces shall be cleaned
of all contaminants except for The dimensions of the pipes shall
specified lubricants. The spigot conform to AASHTO M36. All
of each pipe shall be inserted pipes shall be clearly identified
concentrically in the socket of the by marking on each section the
one previously laid, and the pipe following information :-
then adjusted and fixed in its
correct position with the spigot i) name of manufacturer;
correctly entered in the socket. ii) diameter of pipe;
iii) gauge number;
Cawangan Jalan, Ibu Pejabat JKR, K.L iv) date of manufacture.
The above markings shall have

been marked by the
manufacturer.
Page 70
FOR INTERNAL USE ONLY the S.O. the material test
certificates from the manufacturer
The Contractor shall submit to showing the chemical
composition and mechanical
properties of the base metal and Standard Specification For Road Works
the amount of zinc coating for
every lot of pipes supplied. The For pipe material conforming to
S.O. may order further tests in the AASHTO M218 (corrugation 68
sections supplied to Site at the mm pitch x 13 mm depth) with
rate of not more than 1 in 100. diameters of 1500 mm or smaller,
12 mm diameter bolts shall be
All costs on such tests shall be used. Bolt holes along
borne by the Contractor. circumferential seams shall have
spacings of not more than 314
3.10.2.2 Bitumen Coating mm.
Where specified, the pipe For pipe material conforming to

sections or plates shall be coated AASHTO M167 (corrugation
with an approved bitumen 150 mm pitch x 50 mm depth)
coating at the factory by the hot- with diameters of 1500 mm or
dip process for Type A as larger, 19 mm diameter bolts
specified in AASHTO M190. shall be used. Four bolt holes per
Before coating, any damage to 300 mm of longitudinal seam
the galvanising shall be made shall be provided and these shall
good in a manner approved by be staggered in rows 51 mm a
the S.O. apart with holes in one row in the
trough and holes in the other row
3.10.2.3 Bolts and Nuts in the crest of the corrugation.
Bolt holes in the circumferential
All bolts and nuts shall be of high seams shall have spacings of not
strength carbonated steel meeting more than 254 mm.
the provisions of ASTM A449
and ASTM A563 Grade `C' Notwithstanding the above, the
respectively. The galvanising on Contractor shall satisfy the S.O.
bolts and nuts must meet the as to the adequacy of all bolted
requirements of ASTM A153. connections.
Diameters of bolt holes in the 3.10.2.4 Cement Mortar

longitudinal seams, except those
at the plate corners, shall not 1:3 cement mortar shall comply
exceed the bolt diameter by more with the requirements of Sub-
than 3 mm. The bolt holes in the Section 3.5.2.2.
circumferential seams, including
those at the plate corners, shall 3.10.2.5 Bedding Material
not exceed the bolt diameter by
more than 6 mm. The minimum Corrugated metal pipe culverts
distance from the centre of a hole shall be bedded on Type B
to the edge of a plate shall be bedding as specified in Sub-
1.75 times the diameter of the Section 3.9.2.3.
bolt.
Page 71
FOR INTERNAL USE ONLY Corrugated Metal Pipe Culverts
3.10.3 Excavation and Backfilling for Unless otherwise directed and/or

approved by the S.O., the pipe
culvert shall be laid in a trench Standard Specification For Road Works
excavated in accordance with
Sub-Section 3.9.3.1 (b). placed along the entire length
of the culvert. The lining
Where the open ground method shall be constructed after
is approved, the work shall completion of earthworks and
comply with Sub-Section wingwalls.
3.9.3.1 (c).
3.11 PRECAST BOX CULVERTS
3.10.4 Installation of Corrugated Metal
Pipe Culverts 3.11.1 Description
3.10.4.1 General This work shall comprise the supply

and installation of precast box
The culvert sections shall be culverts inclusive of excavation,
assembled, strutted, and backfilling, jointing, bedding,
protected during construction construction of headwalls,
in accordance with the wingwalls, aprons and sumps and
manufacturer's instructions. channel protection works, all in
Special attention shall be accordance with this Specification
given to the sequence of and the details shown on the
tightening bolts and the Drawings.
specified torque to be applied
during assembly. After 3.11.2 Materials
assembly the bitumen coating
shall, where damaged, be 3.11.2.1 Precast Box Culverts
repaired and made good with
further application of the Precast box culverts shall be of
bitumen coating. approved manufacture complying
with Australian Standard
Specification 1597 Part 1, or any
3.10.4.2 Mortar Lining equivalent alternative standard
acceptable and approved by the
For corrugated metal pipe S.O.
culverts of 1800 mm diameter
or more, or where directed by 3.11.2.2 Cement Mortar
the S.O. for pipes of smaller
diameters, a 1:3 cement 1:3 cement mortar for jointing of
mortar lining shall cover the precast box culvert sections shall
inverts of the pipes to a conform to the requirements of
thickness of 25 mm above the Sub-Section 3.5.2.2.
crest of the corrugations over
a minimum of one third of the 3.11.2.3 Bedding Material
circumference centrally
Precast box culverts shall be
bedded on Type B bedding as
Cawangan Jalan, Ibu Pejabat JKR, K.L specified in Sub-Section 3.9.2.3.
Page 72
3.11.3.1 Excavation for Precast Box
3.11.3 Excavation and Backfilling Culverts
Unless otherwise directed by Standard Specification For Road Works
the S.O., prior to construction
of a precast box culvert, the Backfill shall be built up
earthworks at the required evenly on both sides of each
location shall have been box culvert along its entire
first constructed to a level at length.
least 600 mm above the top
of the culvert design levels or Unless otherwise approved by
to the top of subgrade levels, the S.O., heavy plant and
whichever is lower, and the equipment shall not operate
precast box culvert shall then within 2.0 m of any precast
be constructed in a trench box culvert until backfilling
excavated in accordance with and, where appropriate,
Sub-Section 3.9.3.1 (b). pavement construction has
advanced to a stage which
Where drainage conditions or provides at least 300 mm of
other circumstances so cover to the culvert.
require, the S.O. may direct
the Contractor to construct 3.11.4 Installation of Precast Box
the precast box culvert Culverts
without first constructing the
earthworks to the level The type and size of precast box
specified above, in which culvert to be installed at each
case excavation and location shall be as shown on the
foundation preparation shall Drawings or as directed by the
be in accordance with Sub- S.O. Precast box culverts shall
Section 3.9.3.1 (c). not be installed at any location
until the exact location, the lines,
3.11.3.2 Backfilling levels and grades, the length of
culvert and details of inlet and
Backfilling against precast outlet structures have been con
box culverts and their firmed by the S.O. In addition,
appurtenant structures shall special requirements
be carried out in accordance recommended by the
with the construction manufacturer shall be complied
methods described in Sub- with.
Section 3.2.4, using material
conforming to the Precast box culverts shall be
requirements of Sub-Section laid on Type B bedding as
3.2.2.5. Special care shall be specified in Sub-Section 3.9.4 in
taken to properly compact conformity with the dimensions
backfill without disturbing or shown on the Drawings. Where
damaging the precast box specified on the Drawings or
culvert sections. directed by the S.O., Type B
bedding shall be laid on a layer of
crushed aggregate of maximum
Cawangan Jalan, Ibu Pejabat JKR, K.L particle size not exceeding 50
mm.
Page 73
FOR INTERNAL USE ONLY with 1:3 cement mortar, all to the
satisfaction of the S.O. In
All joints shall be fully mortared addition, a 3 mm layer of 1:3
cement mortar shall be spread on
top of the legs of the invert in Standard Specification For Road Works
order to ensure uniform bearing
between the invert and lid. 3.12.2 Extension of Box Culverts
Lifting holes shall be filled with The existing wingwalls, aprons

1:3 cement mortar. and concrete bedding shall be
demolished wherever indicated
on the Drawings to expose the
3.12 EXTENSION OF CULVERTS existing box culvert on the side(s)
to be extended. The end of the
existing box culvert to be
3.12.1 Extension of Pipe Culverts extended shall then be wire-
brushed or some other means
The existing wingwalls, aprons and employed to give a clean sur
concrete bedding shall be face.Extension joints shall be
demolished wherever indicated on formed as shown on the
the Drawings to expose the existing Drawings by injecting Thioflex
pipe culvert on the side(s) to be 600 - Gun Grade (manufactured
extended. The end of the existing by Expandite) or its equivalent to
pipe culvert to be extended shall then a thickness of not less than 25
be wire-brushed or some other mm in the 15 mm wide gap
means employed to give a clean pipe between the existing box culvert
end. and the new box culvert section.
The remaining space in the gap
Extension joints shall be formed as shall then be filled with Flexcell
shown on the Drawings by injecting Expansion Filler.
Thioflex 600 - Gun Grade
(manufactured by Expandite) or its Bakau piles shall be installed as
equivalent to a thickness of not less shown on the Drawings, unless
than 25 mm in the 15 mm wide gap otherwise directed by the S.O.
between the existing pipe and the
new pipe. The remaining space in
the gap shall then be filled with
Flexcell Expansion Filler.
Bakau piles shall be installed as

shown on the Drawings, unless
otherwise directed by the S.O.

SECTION 4
FLEXIBLE PAVEMENT

SECTION 4 - FLEXIBLE PAVEMENT
Page
4.1 UNBOUND PAVEMENT COURSES S4-78
4.1.1 Lower Subbase S4-78

4.1.1.1 Description S4-78
4.1.1.2 Materials S4-78
4.1.1.3 Construction Methods S4-78
4.1.2 Subbase S4-79

4.1.3 Gravel Surfacing S4-81

4.1.4 Crushed Aggregate Roadbase S4-83

4.2 BITUMINOUS PAVEMENT COURSES S4-85
4.2.1 Bitumen Prime Coat S4-85

4.2.1.3 Equipment S4-85
4.2.2 Bituminous Tack Coat S4-88

4.2.3 Bituminous Surface Dressing S4-90


Page
4.2.4 Asphaltic Concrete S4-99

4.2.4.3 Asphaltic Concrete Mix Design S4-102
4.2.5 Bituminous Macadam S4-116

4.3 SHOULDERS S4-119


4.3.2.1 Earth Shoulders S4-119
4.3.2.2 Gravel Shoulders S4-119
4.4 HORIZONTAL ALIGNMENT, SURFACE LEVELS AND

SURFACE REGULARITY OF PAVEMENT COURSES S4-120
4.4.1 Horizontal Alignment S4-120
4.4.2 Surface Levels of Pavement Courses S4-120
4.4.3 Surface Regularity S4-121

FOR INTERNAL USE ONLY and cross-sections shown on the
Drawings and/or as required by
SECTION 4 - the S.O.
FLEXIBLE PAVEMENT
4.1.1.2 Materials
Lower subbase material shall be

4.1 UNBOUND PAVEMENT
inorganic soil, sand, gravel,
COURSES
weathered or fragmented rock, or
a mixture of any of these
materials, essentially free from
4.1.1 Lower Subbase
vegetative and other organic
matter and expansive clay
4.1.1.1 Description
minerals. It shall have a
maximum particle size of 75 mm
This work shall consist of
or less, and shall have a CBR
furnishing, placing, compacting
value not less than that shown on
and shaping lower subbase
the Drawings when compacted to
material on a prepared and
95% of the maximum dry density
accepted subgrade in accordance
determined in the B.S. 1377
with this Specification and the
Compaction Test (4.5 kg rammer
lines, levels, grades, dimensions
method) and soaked for 4 days
under a surcharge of 4.5 kg. Standard Specification For Road Works
4.1.1.3 Construction Methods accordance with the provisions of

Sub-Section 2.2.7.
Prior to placing any lower Notwithstanding any earlier
subbase material, the underlying approval of finished subgrade,
subgrade (particularly the top 300 any damage to or deterioration of
mm of the subgrade) shall have the subgrade shall be made good
been shaped and compacted in to the satisfaction of the S.O.
before lower subbase is
Cawangan Jalan, Ibu Pejabat JKR, K.L constructed.
Lower subbase shall be placed

over the full width of the
formation to the required
thickness as shown on the
Drawings or directed by the S.O.
in one layer or more, each layer
not exceeding 200 mm
compacted thickness. Where two
or more layers are required they
shall be of approximately equal
thickness and none shall be less
than 100 mm compacted
thickness.
Each layer of lower subbase shall

be processed as necessary to
bring its moisture content to a
uniform level throughout the
material suitable for compaction,
and shall then be compactedEaE
using suitable compaction
equipment approved by the S.O.
to not less than 95% of the
maximum dry density determined
in the B.S. 1377 Compaction Test
(4.5 kg rammer method).
Compaction shall be carried out
in a longitudinal direction along
the roadbed, and shall generally
begin at the outer edge and
progress uniformly towards the
crown on each side in such a
manner that each section receives
equal compactive effort, all to the
Page 78
FOR INTERNAL USE ONLY finished in a neat and workman
like manner, and shall have an
The lower subbase shall be average thickness over any 100
metre length not less than the
required thickness. The top Standard Specification For Road Works
surface of the lower subbase shall
have the required shape, i) the liquid limit shall be not
superelevation, levels and grades, more than 25%;
and shall be everywhere within
the tolerances specified in Sub- ii) the plasticity index shall be
Section 4.4. not more than 6;
4.1.2 Subbase iii) the aggregate crushing value

when tested in accordance
4.1.2.1 Description with M.S. 30 shall be not
more than 35;
furnishing, placing, compacting iv) unless otherwise specified on
and shaping subbase material on the Drawings or directed by
a prepared and accepted subgrade the S.O., the material shall
or lower subbase in accordance have a CBR value of 30 or
with this Specification and the more when compacted to
lines, levels, grades, dimensions 95% of the maximum dry
and cross-sections shown on the density determined in the B.S.
Drawings and/or as required by 1377 Compaction Test (4.5 kg
the S.O. rammer method) and soaked
for 4 days under a surcharge
4.1.2.2 Materials of 4.5 kg;
Subbase material shall be a v) the gradation shall conform

natural or prepared aggregate to one of the envelopes
comprising crushed rock, shown in Table 4.1 with the
weathered or fragmented rock, fraction passing the B.S. 75
gravel or crushed gravel, sand, or um sieve not greater than 2/3
a mixture of any of these of the fraction passing the
materials. It shall have a small B.S. 425 um sieve.
proportion of plastic or
non-plastic fines and shall be
essentially free from vegetative
and other organic matter,
expansive clay minerals and
lumps of clay. The material
shall conform to the following
physical and mechanical quality
requirements :-
B.S. % Passing By Weight
Sieve Page 79
Size A B C D E F
50.0 mm 100 100 - - - -

25.0 mm - 79-95 100 100 100 100
9.5 mm 30-65 40-75 50-85 60-100 - -
4.75 mm 25-55 30-60 35-65 50-85 55-100 70-100
2.00 mm 15-40 20-45 25-50 40-70 40-100 55-100
425 um 8-20 15-30 15-30 25-45 20-50 30-70
75 um 2-8 5-20 5-20 5-20 6-20 8-25
TABLE 4.1 - GRADATION LIMITS FOR SUBBASE MATERIAL
4.1.2.3 Construction Methods

Prior to placing any subbase

material, the underlying subgrade
(particularly the top 300 mm of the
subgrade) or lower subbase shall
have been shaped and compacted in
accordance with the provisions of
Sub-Section 2.2.7 or Sub-Section
4.1.1.3 as appropriate.
Notwithstanding any earlier
approval of finished subgrade or
lower subbase, any damage to or
deterioration of the subgrade or
lower subbase shall be made good
to the satisfaction of the S.O. before
subbase is constructed.
Subbase shall be placed with

equipment approved by the S.O.
over the full width of the formation
to the required thickness as shown
on the Drawings or directed by the
S.O. in one layer or more, each
layer not exceeding 200 mm
or more layers are required they
shall be of approximately equal
thickness and none shall be less
than 100 mm compacted thickness.
Each layer of subbase shall be

processed as necessary to bring
its moisture content to a uniform
level throughout the material
suitable for compaction, and shall out in such a manner that each
then be compacted using suitable section receives equal compactive
compaction equipment approved effort, all to the satisfaction of the
by the S.O. to not less than 95% S.O.
of the maximum dry density
determined in the B.S. 1377 Throughout the placing,
Compaction Test (4.5 kg rammer adjustment of moisture content
method). Compaction shall be and compaction of subbase
carried out in a longitudinal material, care shall be taken to
direction along the carriageway, maintain a uniform gradation of
and shall generally begin at the the material and prevent its
outer edge and progress separation into coarse and fine
uniformly towards the centre on parts, all to the satisfaction of the
each side, except on S.O.
superelevated curves where
rolling shall begin at the lower
edge and progress uniformly
towards the higher edge. In all
cases compaction shall be carried
Page 80
The subbase shall be finished in a

neat and workmanlike manner;
its width shall be everywhere at
least that specified or shown on
the Drawings on both sides of the
centre-line; and its average
thickness over any 100 metre
length shall be not less than the
required thickness. The top
surface of the subbase shall have
the required shape,
superelevation, levels and grades,
and shall be everywhere within
the tolerances specified in Sub-
Section 4.4.
4.1.3 Gravel Surfacing

% Passing By Weight
B.S. Sieve 4.1.3.1
Size Description
A B C D
This work shall c
onsist 37.5 mm 100 100 100 100 of
45 - 75 55 - 85 60 - 100 - furnishing, placin
12.5 mm
g, com pacting
4.75 mm 30 - 60 35 - 65 50 - 85 55 - 90
and shaping grav
2.00 mm 20 - 45 25 - 50 40 - 70 40 - 70
el surf acing
425 um 15 - 30 15 - 30 25 - 45 20 - 50
material on a pre
pared a 75 um 8 - 20 8 - 20 8 - 20 8 - 25 nd
accepted subgrad
e or lo wer
subbase in accordance with this
Specification and the lines, levels,
grades, dimensions and
cross-sections shown on the
the S.O.
4.1.3.2 Materials
Gravel surfacing material shall be

a natural or prepared soil-
aggregate mixture comprising
gravel and sand size particles
together with a small proportion
of plastic fines, and shall be
essentially free from vegetative
and other organic matter,
expansive clay minerals and
lumps of clay. The material shall
conform to the following physical
and mechanical quality
requirements :-
i) the liquid limit shall be not

more than 35%;
ii) the plasticity index shall be in

the range 4 to 10;
iii) the aggregate crushing value

with M.S. 30 shall be not
more than 35;
iv) the gradation shall conform

to one of the envelopes
shown in Table 4.2 with the
fraction passing the B.S. 75
um sieve not greater than 2/3
of the fraction passing the
B.S. 425 um sieve.
TABLE 4.2 - GRADATION LIMITS FOR GRAVEL SURFACING

FOR INTERNAL USE ONLY Material with a maximum
particle size of 37.5 mm, while
otherwise not conforming to the Standard Specification For Road Works
gradation specification but
satisfying the other requirements, uniform level throughout the
shall be acceptable provided that material suitable for compaction,
it shall have a CBR value of 30 and shall then be compacted
or more when compacted to 95% using suitable compaction
of the maximum dry density equipment approved by the S.O.
determined in the B.S. 1377 to not less than 95% of the
Compaction Test (4.5 kg rammer maximum dry density determined
method) and soaked for 4 days in the B.S. 1377 Compaction Test
under a surcharge of 4.5 kg. (4.5 kg rammer method).
4.1.3.3 Construction Methods in a longitudinal direction along
the carriageway, and shall
Prior to placing any gravel generally begin at the outer edge
surfacing material, the underlying and progress uniformly towards
subgrade (particularly the top 300 the centre on each side, except on
mm of the subgrade) or lower superelevated curves where
subbase shall have been shaped rolling shall begin at the lower
and compacted in accordance edge and progress uniformly
with the provisions of Sub- towards the higher edge. In all
Section 2.2.7 or Sub-Section cases compaction shall be carried
4.1.1.3 as appropriate. out in such a manner that each
Notwithstanding any earlier section receives equal compactive
approval of finished subgrade or effort, all to the satisfaction of the
lower subbase, any damage to or S.O.
deterioration of the subgrade or
lower subbase shall be made Throughout the placing,
good to the satisfaction of the adjustment of moisture content
S.O. before gravel surfacing is and compaction of gravel
constructed. surfacing material, care shall be
taken to maintain a uniform
Gravel surfacing shall be placed gradation of the material and
to the required width and prevent its separation into coarse
thickness as shown on the and fine parts, all to the
Drawings or directed by the S.O. satisfaction of the S.O.
not exceeding 200 mm The gravel surfacing shall be
compacted thickness. Where two finished in a neat and
or more layers are required they workmanlike manner; its width
shall be of approximately equal shall be everywhere at least that
thickness and none shall be less specified or shown on the
than 100 mm compacted Drawings on both sides of the
thickness. centre-line; and its average
Each layer of gravel surfacing length shall be not less than the
shall be processed as necessary to required thickness and its
bring its moisture content to a minimum thickness at any point
shall be not less than the required
Cawangan Jalan, Ibu Pejabat JKR, K.L thickness minus 20 mm.
Page 82
The top surface of the gravel

surfacing shall have the required
shape, superelevation, levels and
grades, and shall be everywhere
within 10 mm of the required
plane or such higher,
approximately parallel plane, as
the S.O. shall approve.
4.1.4 Crushed Aggregate Roadbase
4.1.4.1 Description

furnishing, placing, compacting
and shaping crushed aggregate
roadbase material on a prepared
and accepted subgrade or lower
subbase or subbase in accordance
with this Specification and the
lines, levels, grades, dimensions
and cross-sections shown on the
the S.O.
4.1.4.2 Materials
Crushed aggregate roadbase

material shall be crushed rock, or
crushed gravel, or a mixture of
crushed and natural aggregates,
which is hard, durable, clean and
essentially free from clay and
other deleterious materials. B.S. Sieve % Passing By Weight
Size
The material shall conform to the
Type I Type II
following physical and
mechanical quality requirements:- 50.0 mm 100 100
37.5 mm 95 - 100 85 - 100
i) the plasticity index shall be not
28.0 mm - 70 - 100
more than 6; 60 - 80 60 - 90
20.0 mm
10.0 mm 40 - 60 40 - 65
ii) the aggregate crushing value 5.0 mm 25 - 40 30 - 55
when tested in accordance with 2.36 mm 15 - 30 -
M.S. 30 shall be not more than 2.00 mm - 20 - 40
30; 600 um 8 – 22 -
425 um - 10 - 25
iii) the flakiness index when tested in 75 um 0–8 2 - 10
accordance with M.S. 30 shall be
not more than 30;

iv) not less than 80% of particles

retained on the B.S. 4.75 mm
sieve shall have at least one
fractured face;
v) the weighted average loss of

weight in the sodium sulphate
soundness test (5 cycles)
with AASHTO Test Method
T 104 shall be not more than
12%;
vi) the material shall have a CBR

value of not less than 80 when
compacted to 95% of the
maximum dry density
determined in the B.S. 1377
Compaction Test (4.5 kg
rammer method) and soaked
for 4 days under a surcharge
of 4.5 kg;
vii)the gradation shall comply

with the envelope shown in
Table 4.3 for the type
specified.
TABLE 4.3 - GRADATION LIMITS FOR

CRUSHED AGGREGATE ROADBASE
Page 83
FOR INTERNAL USE ONLY Drawings or directed by the S.O.
4.1.4.3 Construction Methods not exceeding 200 mm
Prior to placing any crushed or more layers are required they
aggregate roadbase material, the shall be of approximately equal
underlying subgrade or lower thickness and none shall be less
subbase or subbase shall have than 100 mm compacted
been shaped and compacted in thickness. Spreading shall be
accordance with the provisions of done by a mechanical spreader
the appropriate Section of this approved by the S.O. or, if
Specification. Notwithstanding approved by the S.O., by motor
any earlier approval of finished grader.
subgrade or lower subbase or
subbase, any damage to or Prior to spreading, crushed
deterioration of the subgrade or aggregate roadbase shall be
lower subbase or subbase shall be processed as necessary to bring
made good to the satisfaction of its moisture content to a uniform
the S.O. before crushed aggregate level throughout the material
roadbase is constructed. suitable for compaction. Spread
material shall be maintained at
Crushed aggregate roadbase shall the correct moisture content for
be placed to the required width proper compaction by sprinkling
and thickness as shown on the with water or drying as may be
necessary, and shall be Standard Specification For Road Works
compacted using suitable
compaction equipment approved of the maximum dry density
by the S.O. to not less than 95% determined in the B.S. 1377
Compaction Test (4.5 kg rammer
Cawangan Jalan, Ibu Pejabat JKR, K.L method).

in a longitudinal direction along
the carriageway, and shall
generally begin at the outer edge
and progress uniformly towards
the centre on each side, except on
superelevated curves where
rolling shall begin at the lower
edge and progress uniformly
towards the higher edge. In all
cases compaction shall be carried
out in such a manner that each
section receives equal compactive
effort, all to the satisfaction of the
S.O.
Throughout the placing,

adjustment of moisture content
and compaction of crushed
aggregate roadbase material, care
shall be taken to maintain a uni
form gradation of the material
and prevent its separation into
coarse and fine parts, all to the
The crushed aggregate roadbase

shall be finished in a neat and
workmanlike manner; its width
shall be everywhere at least that
specified or shown on the
Drawings on both sides of the
centre-line; and its average
length shall be not less than the
required thickness. The top
surface of the crushed aggregate
roadbase shall have the required
within the tolerances specified in
Sub-Section 4.4.2.
Page 84
FOR INTERNAL USE ONLY COURSES
4.2 BITUMINOUS PAVEMENT 4.2.1 Bitumen Prime Coat

4.2.1.1 Description Standard Specification For Road Works
This work shall consist of the (a) Power Broom

careful and thorough cleaning of
the surface of a prepared and The power broom shall be a
accepted crushed aggregate rotary type specifically
roadbase, and the furnishing and designed for sweeping road
application to the cleaned surfaces, and shall be
roadbase surface of a bituminous approved by the S.O.
priming material, all in
accordance with this (b) Compressed Air Blower
Specification and the lines,
dimensions and cross-sections The compressed air blower
shown on the Drawings and/or as shall comprise a portable air
required by the S.O. compressor of 3 cu.m/min. in
capacity at 0.7 N/sq.mm
4.2.1.2 Materials delivery pressure with a
suitable hose and nozzle for
The bituminous priming material blowing clean a road surface
shall be either cut-back bitumen after power brooming, and
or bitumen emulsion as stated in shall be approved by the S.O.
the Bill of Quantities.
(c) Pressure Distributor for
Cut-back bitumen shall be grade Bituminous Material
RC-70 or MC-70 conforming to
the requirements of M.S. 159. The distributor shall be a
purpose built model of
Bitumen emulsion shall be slow recognised manufacture and
setting, grade SS-1 or SS-1K, shall be approved by the S.O.
conforming to the requirements It shall conform to the
of M.S. 161, as appropriate to the requirements described
type of roadbase material to be hereunder.
primed and approved by the S.O.
The distributor shall have a
4.2.1.3 Equipment suitable capacity and shall be
equipped with a gas or oil
The equipment used by the fired heating system capable
Contractor shall include a power of heating a full charge of
broom, a compressed air blower, bituminous material to
a self-propelled pressure l80°C. The heating system
distributor for bituminous shall be such that overheating
material, and as necessary, of the bituminous material
equipment for storing and heating will not occur and shall be of
bituminous material. a type in which flames from
the burner do not come into
direct contact with the casing
Cawangan Jalan, Ibu Pejabat JKR, K.L of the tank containing the
bituminous material. The
tank shall be insulated in such
a manner that when filled
with bituminous material at
l80°C and not heated,
Page 85
FOR INTERNAL USE ONLY less than 3°C per hour. A
thermometer shall be provided to
the drop in temperature shall be measure continuously the
temperature of the bituminous
material in the tank and shall be Standard Specification For Road Works
so arranged that the highest
temperature in the tank is 0.25 to 8.0 litres/sq.m at normal
measured. The tank shall be distributor operating speeds, such
fitted with an accurately that deviation from the prescribed
calibrated dipstick or contents rate of application shall not
gauge, and the pipe for filling the exceed 10%.
tank shall be fitted with an easily
replaceable filter. The distributor shall be equipped
with a hand spraying system.
The distributor shall run on
pneumatic tyred wheels of such The meters for the `fifth wheel'
width and number that the load tachometer system and the
produced on the road surface bituminous material pumping
when the vehicle is fully charged flow rate, pumping pressure and
shall not exceed l2 kg/mm of tyre temperature shall be located in
width. The vehicle shall be such a manner that the vehicle
equipped with a `fifth wheel' driver can easily read them while
tacheometer system to accurately operating the distributor. The
measure its forward speed during spray bar shall be controlled by a
spraying operations. second operator riding at the rear
of the vehicle in such a position
The distributor shall be equipped that all the discharge sprays are in
with a full circulation type spray his good view.
bar with nozzles from which the
bituminous material is sprayed on All measuring equipment on the
to the road surface uniformly distributor shall have been
over the full spraying width. The recently calibrated, and accurate
spraying width shall be variable and satisfactory records of the
in increments of not more than calibrations shall be submitted to
100 mm up to a maximum of 5.0 the S.O. If in the course of the
metres. The spraying pump shall work the rates of application of
be driven by a separate power bituminous material are found to
unit and shall be equipped with be inaccurate, the distributor shall
an accurate pressure gauge and be withdrawn from the Works
an accurate flow rate gauge or and recalibrated to the
meter. On the suction side the satisfaction of the S.O. before
pump shall be fitted with an being returned to service.
easily replaceable filter. The
spray bar and pump shall be so The S.O. may require such
designed that bituminous material performance tests as he considers
at even temperature and uniform necessary to check that the
pressure may be sprayed uni distributor is operating
formly over the spraying width at satisfactorily. As directed by the
controlled rates in the range S.O., the Contractor shall make
the distributor and its equipment
Cawangan Jalan, Ibu Pejabat JKR, K.L available for such tests and shall
supply all necessary assistance,
materials, tools, testing apparatus,
etc., all at the Contractor's own
expense.
Page 86
FOR INTERNAL USE ONLY for Bituminous Material
(d) Storage and Heating Facilities Tanks for storage of

bituminous material shall
have a capacity suited to the Standard Specification For Road Works
proposed rate of utilisation of
the material and the method Notwithstanding any earlier
and frequency of its delivery approval of finished crushed
to the Works, all to the satis aggregate roadbase, any
faction of the S.O. The tanks damage to or deterioration of
and, where necessary, barrel the roadbase shall be made
decanters shall be equipped good to the satisfaction of the
with heating systems which S.O. before prime coat is
provide for effective and applied.
positive control of the
temperature of the bituminous Immediately prior to applying
material at all times up to the the bituminous material, the
temperature required for full width of the surface to be
utilisation. The method of treated shall be swept using a
heating shall be such that power broom followed by a
neither flames nor the compressed air blower and, if
products of combustion shall necessary, scraped using hand
come into direct contact with tools to remove all dirt, dust
the bituminous material or the and other objectionable
casing of its immediate material, all to the satisfaction
container, and such that no of the S.O.
portion of the bituminous
material shall be subject to (c) Application of Bituminous
overheating. Material
4.2.1.4 Construction Methods The bituminous priming

material shall be sprayed on
(a) General Conditions to the cleaned roadbase
surface by means of a
Bitumen prime coat work pressure distributor. Any
shall only be carried out in areas inaccessible to the
dry, warm weather when the distributor spray bar shall be
surface to be treated is treated using the distributor's
essentially dry. hand spraying system. The
rate or rates of application
(b) Surface Preparation and shall be as directed by the
Cleaning S.O. based on the results of
test applications, but shall
Prior to applying the prime usually be in the range 0.5 to
coat, the crushed aggregate 1.0 litre/sq.m. The
roadbase shall have been temperature of cut-back
shaped and compacted in bitumen shall be maintained
accordance with the in the range 50°C to 70°C
provisions of Sub-Section during spraying operations.
4.1.4.3. For bitumen emulsions, the
Cawangan Jalan, Ibu Pejabat JKR, K.L spraying temperature shall be
in the range 25°C to 45°C.
Page 87
FOR INTERNAL USE ONLY prevent the bituminous
material from flowing on the
If necessary, in order to sprayed surface, the pre
scribed prime coat shall be
applied in two separate Standard Specification For Road Works
spraying operations. Where
the condition of the treated The Contractor shall maintain
surface indicates that it is the prime coat, all to the
necessary, bituminous satisfaction of the S.O., until
material additional to that the overlying pavement
prescribed shall be applied as course is constructed, which
the S.O. shall direct. shall not be within 24 hours
after the application of the
Prime coat shall be distributed bituminous priming material
uniformly over the surface to nor within such longer period
be treated without streaking; as is required, in the opinion
the quantities applied shall not of the S.O., for the prime coat
deviate by more than 10% to achieve maximum
from those prescribed. Areas penetration of the roadbase
with insufficient bituminous and become fully cured.
material shall be resprayed as
necessary to make up the 4.2.2 Bituminous Tack Coat
deficiency, all to the
satisfaction of the S.O. 4.2.2.1 Description
The surfaces of structures, This work shall consist of the

road furniture and trees careful and thorough cleaning of
adjacent to the areas being the surface of a prepared and
sprayed shall be protected in accepted bituminous or bitumen
such a manner as to prevent primed pavement course, and the
their being spattered or furnishing and application to the
marred by bituminous cleaned surface of a bituminous
material. Bituminous material tack coat prior to the construction
shall not be discharged into of an overlying bituminous
road drains, gutters, etc. pavement course, all in
accordance with this
(d) Curing and Opening to Traffic Specification and the lines,
dimensions and cross-sections
Prime coat shall normally be shown on the Drawings and/or as
left undisturbed for at least 24 required by the S.O.
hours after application and
shall not be opened to traffic 4.2.2.2 Materials
until, in the opinion of the
S.O., it has penetrated the Bituminous tack coat material
roadbase and cured shall be rapid setting bitumen
sufficiently so that it will not emulsion of grade RS-1 or RS-
be picked up by the wheels of 1K conforming to the
vehicles. requirements of M.S. 161.
4.2.2.3 Equipment
The equipment shall be as
specified in Sub-Section 4.2.1.3.
Page 88
(a) General Conditions
Bituminous tack coat shall
only be applied to a clean, Standard Specification For Road Works
dry, bituminous or bitumen
primed surface. (c) Application of Bituminous
Material
Bituminous tack coat shall
only be applied as far in The bituminous tack coat
advance of the construction of shall be sprayed on to the
the overlying bituminous cleaned bituminous or
pavement course as is bitumen primed surface by
necessary to achieve a satis means of a pressure
factory degree of tackiness distributor. Any areas
before the overlying material inaccessible to the distributor
is placed, all to the spray bar shall be treated
satisfaction of the S.O. using the distributor's hand
spraying system. The rate or
(b) Surface Preparation and rates of application shall be as
Cleaning directed by the S.O. based on
the results of test applications,
Prior to applying bituminous but shall usually be in the
tack coat, the surface to be range 0.25 to 0.55 litres/sq.m.
treated shall have been The temperature of the
prepared in accordance with bituminous material shall be
the appropriate Sections of maintained in the range 25°C
this Specification. to 45°C during spraying
Notwithstanding any earlier operations.
approval of this surface, any
damage to it or deterioration Tack coat shall be distributed
of it shall be made good uniformly over the surface to
before tack coat is applied. be treated without streaking;
the quantities applied shall not
Immediately prior to applying deviate by more than 10%
bituminous tack coat, the full from those prescribed. Areas
width of the surface to be with bituminous material in
treated shall be swept using a excess of these limits shall
power broom followed by a have the excess removed at
compressed air blower, and if the Contractor's expense, and
necessary, scraped using hand areas with insufficient
tools, to remove all dirt, dust bituminous material shall be
and other objectionable resprayed as necessary to
material, all to the satisfaction make up the deficiency, all to
of the S.O. the satisfaction of the S.O.
The surfaces of structures,

road furniture and trees
adjacent to the areas being
sprayed shall be protected in
Cawangan Jalan, Ibu Pejabat JKR, K.L such a manner as to prevent
their being spattered or
marred by bituminous
material. Bituminous material
shall not be discharged into
road drains, gutters, etc.
Page 89
FOR INTERNAL USE ONLY tack coat at all times, and the
Contractor shall maintain the
Traffic shall be kept off the tack coat, all to the
satisfaction of the S.O., until
the overlying pavement Standard Specification For Road Works
course is constructed.
Penetration graded bitumen
4.2.3 Bituminous Surface Dressing shall be 80-100 grade con
forming to M.S. 124.
4.2.3.1 Description
Cut-back bitumen shall be
This work shall consist of the grade RC-70 or MC-70
careful and thorough cleaning of conforming to M.S. 159.
the surface of a prepared and
accepted bituminous or bitumen Bitumen emulsion shall be
primed pavement course, and the rapid setting of grade RS-
furnishing and placing on the 1, RS-1K, RS-2, RS-2K or
cleaned surface of one or two RS-3K conforming to M.S.
applications of bituminous 161. The grade of emulsion
material and cover aggregate, all selected shall be anionic or
in accordance with this cationic as appropriate to the
Specification and the lines, type of rock from which the
dimensions and cross-sections cover aggregate is derived,
shown on the Drawings and/or as and shall be approved by the
required by the S.O. When one S.O.
application of bituminous
material and cover aggregate is (b) Additives for Bituminous
placed the term `single Material
bituminous surface dressing'
(SBSD) shall apply, and when An adhesion and anti-
two applications of bituminous stripping agent shall be added
material and cover aggregate are to the bituminous material if
placed, the term `double the S.O. shall so direct or
bituminous surface dressing' approve. The additive shall be
(DBSD) shall apply. of a type approved by the
S.O. and the required quantity
4.2.3.2 Materials of additive shall be
thoroughly mixed with the
(a) Bituminous Material bituminous material in
accordance with the
Bituminous binder for manufacturer's instructions or
bituminous surface dressing as directed by the S.O. for
shall be penetration graded such time as is necessary to
bitumen, or cut-back bitumen, produce a homogenous
or bitumen emulsion as mixture.
shown on the Drawings or
otherwise specified. (c) Aggregates for Bituminous
Surface Dressing
For single bituminous surface

Cawangan Jalan, Ibu Pejabat JKR, K.L dressing the cover aggregate
shall be nominal 20 mm, 14
mm, 10 mm or 6 mm size
chippings as shown on the
Drawings and/or directed by
the S.O.
Page 90
FOR INTERNAL USE ONLY surface dressing the cover
aggregate for the first
For double bituminous application of bituminous
material and cover aggregate
shall be nominal 20 mm size Standard Specification For Road Works
chippings, and the cover
aggregate for the second iii) the weighted average loss
application of bituminous of weight in the sodium
material and cover aggregate sulphate soundness test (5
shall be nominal 10 mm size cycles) when tested in
chippings. accordance with AASHTO
Test Method T 104 shall
Cover aggregates shall be be not more than 12%;
screened, crushed stone and
shall comprise clean, dry, iv) the flakiness index when
hard, tough, sound, angular tested in accordance with
and cubical chippings free M.S. 30 shall be not more
from vegetative and other than 25;
organic matter, clay and other
deleterious substances, and v) the polished stone value
containing few, if any, flaky when tested in accordance
or elongated particles. Dusty with M.S. 30 shall be not
chippings shall be washed less than 40;
clean, all to the satisfaction of
the S.O. Cover agregates vi) the gradation shall con
shall conform to the following form to the appropriate
physical and mechanical envelope shown in Table
requirements :- 4.4.
i) using the type of 4.2.3.3 Equipment

bituminous material to be
used in the Works, treated The Contractor shall provide all
with additive if so the plant and equipment
required, the coated area in necessary for executing the work
the coating and stripping in accordance with this
test for bitumen aggregate Specification, and shall furnish
mixtures, AASHTO Test the S.O. with such details of
Method T 182, shall not particular items of equipment,
be less than 95%; e.g. manufacturer, model type,
capacity, weight, etc., as the S.O.
ii) the aggregate crushing shall require.
value when tested in
accordance with M.S. 30 The equipment shall include a
shall be not more than 30; power broom, a compressed air
blower, a self-propelled pressure
distributor for bituminous
material, all necessary equipment
for storing and heating
bituminous material, aggregate
spreading equipment, a suitable
number of tip-trucks and a self-
propelled pneumatic tyred roller.
% Passing By Weight
B.S. Page 91
Sieve
Nominal Nominal Nominal Nominal
Size
20 mm 14 mm 10 mm 6 mm
Chippings Chippings Chippings Chippings
25.0 mm 100 - - -
20.0 mm 85 - 100 100 - -
14.0 mm 0 - 20 85 - 100 100 -
10.0 mm - 0 - 20 85 - 100 100
6.3 mm - - 0 - 20 85 - 100
4.75 mm 0-5 0-5 0 - 10 0 - 25
2.36 mm 0-2 0-2 0-2 0 - 10
TABLE 4.4 - GRADATION LIMITS FOR BITUMINOUS SURFACE DRESSING
(a) Power Broom (e) Aggregate Spreading

Equipment
The power broom shall be
as specified in Sub-Section Aggregates shall be placed
4.2.1.3(a). using mechanical
spreaders of a type
(b) Compressed Air Blower approved by the S.O. The
The compressed air spreaders shall be capable
blower shall be as of applying aggregate
specified in Sub-Section uniformly over the full
4.2.1.3 (b). width of the area being
treated and shall have
(c) Pressure Distributor for controls to regulate the
Bituminous Material rate of spread as required
by this Specification, all to
The distributor shall be as the satisfaction of the S.O.
specified in Sub-Section
4.2.1.3(c). (f) Tip-Trucks
(d) Storage and Heating The Contractor shall

Facilities for Bituminous provide a suitable number
Material of tip-trucks of a type
approved by the S.O.,
Storage and heating capable of spreading
facilities for bituminous aggregate in accordance
material shall be as with this Specification.
specified in Sub-Section
4.2.1.3 (d).
(g) Pneumatic Tyred Roller In operation, the ballasted

weight and the tyre
The pneumatic tyred roller inflation pressure shall be
shall be of recognised adjusted to meet the
manufcature and shall be requirements of each
approved by the S.O. It particular operation. Each
shall conform to the tyre shall be kept inflated
requirements described at the specified pressure
hereunder. such that the pressure
difference between any
The pneumatic tyred roller two tyres shall not exceed
shall be self-propelled and 0.04 N/sq.mm. Means
capable of being reversed shall be provided for
without backlash; it shall checking and adjusting
be equipped with power tyre pressures at all times
steering and dual controls at the place of the works.
allowing operation from
either the left or right side. The Contractor shall
provide the S.O. with a
The roller shall have nine calibration chart for the
wheels equipped with roller showing the
smooth treaded tyres all of relationship between the
the same size and quantity or depth of ballast
construction, and capable and total weight, and also
of operating at inflation a chart showing the
pressures of up to 0.9 relationship between
N/sq.mm. Five wheels wheel load, tyre inflation
shall be on the driven axle pressure and contact
and four on the steering pressure.
axle, all equally spaced on
both axles and arranged so 4.2.3.4 Construction Methods
that the tyres on the
steering axle track midway (a) General Conditions
between those on the
driven axle with a small Bituminous surface dressing
overlap. The roller shall be shall only be carried out in
equipped with water tanks, dry, warm weather when the
sprinkler systems and pads surface to be treated is dry.
of coconut matting to keep Work shall be discontinued
all tyres evenly wetted when rain appears imminent
during operation. and during periods of strong
wind.
The roller shall be
equipped with means of The S.O. may order the
adjusting its total weight discontinuation of work on
by ballasting so that the account of adverse weather,
load per wheel can be unsatisfactory condition of
varied in the range 1.0 to materials, equipment or
2.0 tonnes.

surface to be treated, or such

other conditions as he shall
consider detrimental to the
work.
(b) Surface Preparation and

Cleaning
Prior to constructing a
bituminous surface dressing,
the surface to be treated shall
have been prepared in
accordance with the
appropriate Sections of this
Specification.Notwithstanding
any earlier approval of this
surface, any damage to or
deterioration of it shall be
made good before surface
dressing is commenced.
Immediately prior to
commencing surface dressing,
the full width of the surface to
be treated, together with an
additional 300 mm width on
each side, shall be swept
using a power broom
followed by a compressed air
blower and, if necessary,
scraped using hand tools to
remove all loose particles,
dirt, dust and other
objectionable material, all to
the satisfaction of the S.O. Nominal Size Rate of Application of
of Aggregate Penetration Graded
In double bituminous surface Bitumen
dressing construction, the
surface of the first application
of bituminous material and 20 mm 2.0 - 3.0 litre/sq.m
cover aggregate shall be
similarly made good and 14 mm 1.5 - 2.2 litre/sq.m
cleaned, immediately prior to
commencing the second 10 mm 1.0 - 1.5 litre/sq.m
application.
Standard Specification For Road Works 0.7- 1.0 litre/sq.m
6 mm
(c) Application of Bituminous

Material
The bituminous material for a

single bituminous surface
dressing or for each
material and cover aggregate
of a double bituminous
surface dressing, shall be
sprayed on to the cleaned
surface to be treated by means
of a pressure distributor. Any
areas inaccessible to the
distributor spray bar shall be
treated using the distributor's
hand spraying system.
The rate or rates of

application shall be as
directed by the S.O. based on
the results of laboratory tests
and/or test applications but for
penetration graded bitumen
shall usually be in the
appropriate range given in
Table 4.5.
TABLE 4.5 - RATES OF APPLICATION Bituminous Material Spraying Temperature

OF PENETRATION GRADED BITUMEN
80-100 penetration 150 oC to 165o C

grade bitumen
o o
Cut-back bitumen 50 C to 65 C
grade
Cawangan Jalan, Ibu Pejabat JKR, K.L RC-70 or MC-70
o o
25 C to 45 C
Bitumen emulsions
Page 94
The rates of application

for cut-back bitumens and
bitumen emulsions shall
be commensurately higher
depending on their residual
bitumen contents.
The temperature of the

bituminous material shall
be maintained during
spraying operations within
the appropriate range
given in Table 4.6.
The bituminous material

shall be distributed
uniformly over the surface
to be treated without
streaking; the quantities
applied shall not deviate
by more than 10% from
those prescribed. The rate
of application shall be
checked for each spraying
run by measuring the
volume of bituminous
material in the distributor
before and after spraying
and the area treated.
Adjustments shall be made
as necessary to ensure that
the prescribed rate of
application is maintained
in subsequent runs.
Spraying shall be
discontinued immediately
if any defect develops in
the distributor, and it shall
not be resumed until the
fault has been rectified to
the satisfaction of the S.O.
The spraying of bituminous

material over any portion of
the surface to be treated shall
not be carried out more than
two minutes in advance of
placing the cover aggregate
on that portion at the specified
rate; an the progress of
spraying the bituminous
material shall be restricted as
necessary to comply with
this requirement.
TABLE 4.6 - SPRAYING TEMPERATURE

FOR BITUMINOUS
Bituminous materials
Bituminous materials shall
not be heated to spraying
temperatures too soon in
advance of requirements.
Any bituminous material
which has been heated to
spraying temperature for
more than ten hours or
which has been overheated
shall be rejected.
In cases where the Provision shall be made

bituminous material is for a volume of
applied in lanes there shall bituminous material of at
be a small overlap of least 10% of the capacity
bituminous material at the of the distributor, or such
joints between lanes equal other quantity as the S.O.
in width to the edge strip shall direct, to remain in
of the sprayed area which the distributor tank at the
does not receive the full completion of each spraying
rate of application of run, in order to avoid air
bituminous material. For entrapment within the
double bituminous surface bitumen spraying system.
dressing, joints in the
second application of The surfaces of structures,
bituminous material shall road furniture and trees
be offset from those in the adjacent to the areas being
first application by 150 - sprayed shall be protected
300 mm for longitudinal in such a manner as to prevent
joints and by at least 1.0 their being spattered or
metre, where possible, for marred by bituminous
transverse joints. material. Bituminous material
shall not be discharged into
Each spraying run shall road drains, gutters, etc.
commence and terminate
on lengths of building (d) Application of Cover
paper placed across the Aggregate
full spraying width
immediately before and Before each spraying run
after the section to be of bituminous material
sprayed. Sufficient building commences, sufficient
paper shall be aggregate to provide full
placed so that the distributor cover at the prescribed rate
may be started and stopped of application over the
with the spray bar over paper, entire area to be sprayed
and so that the correct shall have been loaded in
distributor road speed and rate trucks at the Site of the
of spraying can be maintained Works in readiness for
over the entire length of the spreading.
section to be sprayed, all to
the satisfaction of the S.O. Immediately following
Immediately after use and the application of the
before application of cover bituminous material, the
aggregate, the building clean, dry cover aggregate
paper shall be removed shall be uniformly spread over
and disposed of in a manner the bituminous material using
approved by the S.O. mechanical spreaders

The aggregate shall be placed

as quickly as practicable after
the application of bituminous
material on all parts of the
area to be covered, and for no
portion of the surface to be
treated shall there be a delay
of more than two minutes
between the application of the
bituminous material
and the spreading of
the aggregate.
The trucks feeding the

aggregate to the mechanical
spreaders shall operate
backward during aggregate
spreading in order that the
wheels of the spreaders and
trucks shall not run on
uncovered bituminous
material.
The rate of application of

cover aggregate shall be as
directed by the S.O. based on
the results of laboratory tests
and/or tests applications, but
shall usually be in the
appropriate range given in
Table 4.7
TABLE 4.7 - RATES OF APPLICATION OF

COVER AGGREGATE
Nominal Rate of Application

Size of Aggregate Cawangan Jalan, Ibu Pejabat JKR, K.L
The rate of application shall

20 mm 17 – 27 kg/sq.m be checked for each spraying
run from measurements of the
14 mm 12 – 18 kg/sq.m quantities of aggregate in the
trucks and the area treated, or
10 mm 8 – 12 kg/sq.m by sampling and measuring
the aggregate spread on the
6 mm 5 – 8 kg/sq.m road. Any bare or
insufficiently covered areas
shall be made good by hand
spreading as quickly as
possible. Aggregate in excess
of the rate prescribed shall be
evenly distributed over the
surface or removed as quickly
as possible, all to the
In cases where the surface

dressing is constructed in
lanes, the edge of the
aggregate spread adjacent to
an untreated lane shall
coincide with the edge of the
sprayed area which receives
the full rate of application of
the bituminous material. This
will leave a narrow strip of
bituminous material of partial
thickness which shall be
overlapped by the bituminous
material spray and aggregate
spread of the adjacent lane.
Immediately following the

spreading of the aggregate to
the satisfaction of the S.O.,
the aggregate shall be rolled
with a pneumatic tyred roller
approved by the S.O. to
embed the aggregate in the
bituminous material. Rolling
shall commence as quickly as
practicable after the
application of the bituminous
material and aggregate on all
parts of the area to be
covered, and for no portion
of the surface to be treated
shall there be a delay of more
Page 97
FOR INTERNAL USE ONLY dressing and progress
uniformly towards the centre
than 3 minutes between the on each side, except on super
application of the bituminous elevated curves where rolling
material and the shall begin at the lower edge
commencement of rolling. and progress uniformly
towards the higher edge.
The pneumatic tyred roller Consecutive roller passes
shall be ballasted to an shall generally overlap by
operating weight of 9 - 10 about one half of the roller's
tonnes and its tyre inflation width.
pressure shall be 0.53
N/sq.mm for surface dressing When, in the opinion of the
work. Rolling shall be S.O., the bituminous material
continued for as long as is has hardened sufficiently to
necessary to thoroughly prevent the dislodgement of
embed the aggregate in the embedded aggregate by the
bituminous material, all to the action of the power broom, all
satisfaction of the S.O. loose aggregate shall be swept
from the treated surface using
Rolling shall generally begin the power broom and
at the outer edge of surface compressed air blower and
disposed of to the satisfaction Standard Specification For Road Works
of the S.O. Where the
dressing so prepared is the shall then proceed as soon as
first application of a double is practicable.
bituminous surface dressing,
construction of the second (e) Opening to Traffic
material and cover aggregate Bituminous surface dressing
shall normally not be opened
Cawangan Jalan, Ibu Pejabat JKR, K.L to traffic until such time as,
in the opinion of the S.O., the
surfacing shall have
developed sufficient strength
to withstand normal traffic
forces without dislodgement
of the aggregate. This will
usually be not less than 24
hours after the completion of
rolling. Where it is necessary
to allow earlier use of the
finished surface to facilitate
the movement of traffic,
vehicles may be allowed to
run on the work after rolling
has been completed, provided
that speeds are restricted to 30
km per hour or less and sharp
turning movements are
prohibited. The finished
surface shall subsequently
have to be closed
temporarily to enable the
loose aggregate to be swept
off and disposed of as
described in Sub-Section
4.2.3.4 (d).
Ideally, the first application of

bituminous material and cover
aggregate of a double
bituminous surface dressing
should not be opened to
traffic before construction of
the second application.
However, where it is
necessary to facilitate the
movement of traffic, the first
application may be opened to
traffic prior to construction of
the second application.
Nevertheless, traffic
movement on the completed
Page 98
FOR INTERNAL USE ONLY to a practicable minimum and
the second application shall
first application shall be kept be constructed as soon as is
practicable after the
completion of the first. Standard Specification For Road Works
organic matter, and other

4.2.4 Asphaltic Concrete deleterious substances. They
shall conform to the following
4.2.4.1 Description physical and mechanical quality
requirements :-
furnishing, placing, shaping and i) the aggregate crushing value
compacting asphaltic concrete when tested in accordance
binder course and/or wearing with M.S. 30 shall be not
course on a prepared and more than 30;
accepted bituminous or bitumen
primed pavement course, and ii) the weighted average loss of
shall include the careful and weight in the sodium sulphate
thorough cleaning of surfaces soundness test (5 cycles)
which are to be covered without when tested in accordance
receiving a bituminous tack coat. with AASHTO Test Method T
The work shall be carried out all 104 shall be not more than
in accordance with this 12%;
Specification and the lines,
levels, grades, dimensions and iii) the flakiness index when
cross-sections shown on the tested in accordance with
Drawings and/or as required by M.S. 30 shall be not more
the S.O. than 30;
4.2.4.2 Materials iv) the water absorption when

tested in accordance with
(a) Aggregates M.S. 30 shall be not more
than 2%;
Aggregate for asphaltic
concrete shall be a mixture of v) the polished stone value when
coarse and fine aggregates tested in accordance with
and, if necessary, mineral M.S. 30 shall be not less than
filler. The individual aggregates 40 (only applicable to
shall be of sizes suitable for aggregates for wearing
blending to produce the required course).
gradation of the combined
aggregate, all to the satisfaction Fine aggregates shall be clean
of the S.O. natural sands, screened quarry
fines, or mining sand. Mining
Coarse aggregates shall be sand shall be thoroughly washed
screened crushed hard rock, before use. Other types of fine
angular in shape and free from aggregate may be used subject to
dust, clay, vegetative and other the approval of the S.O.
Cawangan Jalan, Ibu Pejabat JKR, K.L Fine aggregates shall be non-
plastic and free from clay, loam,
aggregations of material,
vegetative and other organic
matter, and other deleterious
substances.
Page 99
They shall conform to the

following physical and
mechanical quality requirements:-
i) the weighted average loss of

weight in the sodium sulphate
soundness test (5 cycles)
with AASHTO Test Method T
104 shall be not more than
12%;
ii) the water absorption when

tested in accordance with
M.S. 30 shall be not more
Notwithstanding compliance with

the requirements of this
Specification, limestone
aggregates shall no
t be permitted
Mix Type Wearing Course Binder Course
for use in wearing
course. Mix ACW 20 ACB 28
Designation
The gradation of th
e combined
B.S. Sieve % Passing by weight
37.5 mm 100 coarse and fine ag
gregates,
28.0 mm 100 80 - 100 together with ordin
ary Portland
20.0 mm 76 - 100 72 - 93 cement added as a
n adhesion and
anti-
14.0 mm 64 - 89 58 - 82
stripping agent a nd, if
necessary, any othe
10.0 mm 56 - 81 50 - 75
r mineral
filler, shall confor
m to the 5.0 mm 46 - 71 36 - 58
appropriate envelop
e shown in 3.35 mm 32 - 58 30 - 52
Table 4.8
1.18 mm 20 - 42 18 - 38 than 2%.
425 um 12 - 28 11 - 25
TABLE 4.8 - GRA
D 150 um 6 - 16 5 - 14 ATION LIMITS F
O R ASPHALTIC C
O 75 um 4-8 3-8 NCRETE
FOR INTERNAL USE ONLY lime, hydraulic cement, or such other
suitable material as the S.O. shall
The gradation envelopes in the approve. At the time of mixing with
above Table are purposely wider bitumen it shall be sufficiently dry to
than the tolerances for good flow freely and shall be essentially
works control of asphaltic free from agglomerations. Not less
concrete mixes. For each type of than 70% by weight shall pass the
mix required in the Works, the B.S. 75 um sieve.
Contractor shall establish a job
mix formula gradation which (c) Bituminous Material
shall consist of a single definite
percentage passing for each sieve Bituminous binder for asphaltic
size in the above Table and shall concrete shall be penetration graded
produce a smooth curve within bitumen of 80-100 grade conforming
and essentially parallel to the to M.S. 124.
appropriate gradation envelope.
This job mix formula gradation, (d) Anti-Stripping Agent
with the allowable tolerances for
a single test as specified in Sub- Ordinary Portland cement shall be
Section 4.2.4.3 (c), then becomes added to the combined aggregate for
the job control envelope and this asphaltic concrete to serve as an
job control envelope must be
totally within the limits of the Cawangan Jalan, Ibu Pejabat JKR, K.L
appropriate gradation envelope in
the above Table.
(b) Mineral Filler
Mineral filler shall be finely

divided mineral matter such as
rock dust, limestone dust, hydrated
Standard Specification For Road Works to the complete satisfaction of the S.O.
that the aggregates will perform
adhesion and anti-stripping agent. The satisfactorily in service with the
amount of cement added for this specified bitumen binder. Such tests
purpose shall be 2% by weight of the shall be carried out in accordance with
combined aggregate. (Additional AASHTO Test Method T 182, or such
cement may also be added, if necessary, other test methods as the S.O. shall
to serve as filler.) direct or approve. When AASHTO Test
Method T 182 is used, the coated area at
Ordinary Portland cement for this the end of the mixture's period of
purpose shall conform to the immersion in water shall be not less
requirements of M.S. 522 and shall be than 95%.
dry, free flowing and free from
agglomerations at the time of use. Where, in the opinion of the S.O.,
ordinary Portland cement does not per
Notwithstanding the use of ordinary form satisfactorily as an anti-stripping
Portland cement as an anti-stripping agent, the Contractor may propose to
agent as specified above, the Contractor use another adhesion and anti-stripping
shall be responsible for ensuring that the agent in addition to, or wholly or
bitumen binder adheres satisfactorily to partially instead of, the ordinary
the aggregate and does not strip from it Portland cement specified above. Such
during the service life of the asphaltic agent shall be of a type approved
concrete. by the S.O. and shall be thoroughly
mixed with the bituminous binder,
Accordingly, the Contractor shall
carry out bitumen stripping tests with
the proposed aggregates to demonstrate Page 101
all in accordance with the

manufacturer's instructions. In such a
case, the agent shall be added to the
bitumen binder used in the bitumen
stripping tests in the appropriate amount
and manner.
Aggregate which does not perform

satisfactorily in the bitumen stripping
tests, using the approved adhesion and
anti-stripping agent when appropriate,
shall not be used in asphaltic concrete.
ACW14 - Wearing Course 5.0 – 7.0 % 4.2.4.3 Asphaltic Concrete Mix Design
ACW14 - Binder Course 4.5 - 6.5 %
(a) Job Mix Formulae
ACB 28 - Binder Course 4.0 - 6.0%
After obtaining supplies or
production (as applicable) of all
aggregates consistent as to gradation
and other qualities, the Contractor
shall propose a job mix formula for
each class of mix required in the
Works. In order to attain optimum
quality of the mixtures, the job mix
formula for each class shall be
prepared on the basis of testing
several trial gradations within the
limits set in Table 4.8 at an
appropriate range of bitumen
contents. As a guide to the testing
range of bitumen contents, the design
bitumen content will usually be in
the appropriate range given in Table
4.9.
TABLE 4.9 - DESIGN BITUMEN

CONTENTS
A sample of each trial mix (i.e. each

combination of trial gradation and
bitumen content) shall be subject to a
comprehensive Marshall method test
and analysis as follows :-
i) preparation of specimens for the

standard stability and flow test in
accordance with AASHTO Test
Method T 245 using the 75
blows/face compaction standard;
ii) determination of the bulk

specific gravity of the specimens
in accordance with AASHTO
Test Method T 166;
iii) determination of the stability and

flow values in accordance with
AASHTO Test Method T 245;
iv) analysis of the density and

voids parameters to determine
the percentage of voids in the
compacted aggregate, the
percentage of voids in the
compacted aggregate filled with
bitumen, and hence the
percentage of air voids in the
compacted mix.
For each trial mix conforming to a

proposed job mix formula, the
parameters of the above tests and
analyses shall conform to the
requirements of the appropriate type
of mix as given in Table 4.10.

TABLE 4.10 - TEST AND ANALYSIS PARAMETERS

FOR ASPHALTIC CONCRETE
Parameter Wearing Course Binder Course
Stability S > 500 kg > 450kg
Flow F > 2.0 mm > 2.0mm
Stiffness S/F > 250 kg/mm > 225 kg/mm
Air voids in mix 3.0% - 5.0% 3.0% - 7.0%
Voids in aggregate
filled with bitumen 75% - 85% 65% - 80%
Air voids shall be defined as the gravity on an oven dried basis of

small pockets of air between the the
coated aggregate particles in a coarse and fine aggregate fractio
compacted asphaltic concrete mix. ns
The portion of the bitumen absorbed (separated by the ASTM # 10 sie
into the aggregate particles must ve
therefore be allowed for when or B.S. 2.0 mm sieve) as determ
calculating the air voids. For ined
combined aggregate with a water in accordance with AASHTO Te
absorption of not more than 2.0%, st
the absorbed bitumen may be Method T 84 and T 85 as applic
estimated on the basis that the able.
absorption of bitumen will be
approximately 20% of the water
absorption.
Voids in the aggregate of a mix shall

be calculated on the basis of the
weighted average bulk specific Cawangan Jalan, Ibu Pejabat JKR, K.L
The Marshall density of an asphaltic
concrete mix is defined as the ii) the proportions for cold batching
average density of a set of three (3) the aggregates;
test specimens moulded for the
standard stability and flow test in iii) the mixing plant screen sizes, the
accordance with AASHTO Test smallest of which shall generally
Method T 245 using the 75 blows be not more than 3.2 mm;
per face compaction standard.
iv) the gradation analysis of the
The Contractor shall submit to the aggregate in each of the mixing
S.O. full details of his proposed job plants' hot bins and of the mineral
mix formula for each class of mix filler (including any ordinary
required in the Works including :- Portland cement added as
anti-stripping agent);
i) the gradation analysis of each
aggregate to be used in the mix;
Page 103
FOR INTERNAL USE ONLY laying and compacting equipment
conforms to the requirements of this
v) the job mix formula gradation of Specification, and that the proposed
the combined aggregate and mixes are satisfactory. The trial areas
filler; shall not be part of the Contract Works
but shall be provided by the Contractor
vi) the proportions for combining the at his own expense. They shall be
hot bin aggregates and filler; approved by the S.O.
vii)the bitumen content (by weight of

total mix);
viii)the dry and wet mixing times if a
batch plant is to be used, or the
mixing time if a continuous mix
plant is to be used;
ix) the full results of the

comprehensive Marshall method
tests and analyses as described
above for each trial mix used in
determining the job mix formula.
The S.O. may require changes of any

of the factors in each proposed job
mix formula and further tests and
analyses in order to attain optimum
quality of the asphaltic concrete
mixes.
(b) Plant Trials
After having received the S.O.'s

preliminary approval of his proposed
job mix formulae, the Contractor
shall arrange to mix, lay and compact
asphaltic concrete conforming to the
proposed formula for each class of mix
required in the Works. A minimum of
10 tonnes of each mix shall be placed
in trial areas to demonstrate to the
satisfaction of the S.O. that the mixing,
Standard Specification For Road Works Modifications to a job mix formula may
only be made with the approval of the
As directed by the S.O., comprehensive S.O. Should the S.O. at any time have
sampling and testing of each class of reason to believe that the materials and
ParameterPermissible Variation % By Weight of Total
Mix
Bitumen. + 0.2%
Fractions of combined
aggregate passing 5.0 mm
and larger sieves. + 5.0%
aggregate passing 3.35 mm + 4.0%
and 1.18 mm sieves.
aggregate passing 425 um + 3.0%
and 150 um sieves.
Fraction of combined
aggregate passing 75 um + 2.0%
sieve.
mix shall be carried out to check for methods of mixing and laying are
satisfactory compliance with its job mix different from those approved, he shall
formula, and for a satisfactory degree of so advise the Contractor, and may order
compaction. that asphaltic concrete works be
discontinued pending further trials and
As a result of the plant trials, the S.O. testing.
may require amendments to the job mix
formulae, further tests and analyses,
and possibly additional plant trials
before finally approving the mixes for
full scale production and use in the
Works.
(c) Compliance with the Job Mix Formulae
The S.O.'s final approval of the job mix

formulae shall bind the Contractor to
furnish asphaltic concrete mixes
meeting the precise gradations and
bitumen contents specified in these
formulae within the tolerances set
forth in Table 4.11.
Page 104
TABLE 4.11 - TOLERANCES FOR ASPHALTIC CONCRETE MIXES

4.2.4.4 Equipment
The Contractor shall provide all the blower as specified in Sub-Sections

plant and equipment necessary for 4.2.1.3 (a) and 4.2.1.3 (b) respectively.
executing the work in accordance
with this Specification and shall (b) Asphalt Mixing Plant
furnish the S.O. with such details of
particular items of equipment, e.g. The asphalt plant shall be either a
manufacturer, model type, capacity, batch plant or a drum mix plant or a
weight, operating features, etc., as continuous mix plant of recognized
the S.O. shall require. manufacture and shall be approved by
the S.O. It shall conform to the
(a) Road Cleaning Equipment requirements described hereunder.
Road cleaning equipment will be The mixing plant shall have a capacity
required where asphaltic concrete is suited to the Works and sufficient to
to be laid on a surface which is not enable the paver to operate more or less
to receive a tack coat. The continuously when paving at normal
equipment shall be the same as that speeds at the required thicknesses. The
required for preparing a surface for plant shall be so designed as to enable
a tack coat, and shall include a consistent production of asphaltic
power broom and compressed air

FOR INTERNAL USE ONLY accurate to within 0.5% of the
maximum load that may be required.
concrete mixes within the tolerances Scale dials and pointers shall be easily
prescribed in this Specification, all to read from their operator's normal
the satisfaction of the S.O. position without significant parallax
errors. Scales shall be substantially
Scales for all weigh boxes or hoppers constructed so that they shall maintain
shall be of the springless dial type, their accuracy after initial adjustment.
The Contractor shall furnish not less
than ten 25 kg test weights at the plant Standard Specification For Road Works
for checking, adjusting and calibrating
scales. The plant shall be provided with
accurate mechanical means for
Tanks for storage of bitumen shall have uniformly feeding the aggregates into
a capacity suited to the proposed rate of the dryer so that uniform production and
utilization of the material and the temperature of the heated aggregates
method and frequency of its delivery to will be obtained. A separate feed bin
the Works, all to the satisfaction of the with an adjustable gate opening shall be
S.O. The tanks shall be provided with provided for each aggregate to be
means of measuring the volume of their included in the combined aggregate for
contents at all times and of drawing off the mix; normally four bins will be
samples of the contents. The bitumen required. The feed bins and gates shall
feeding system shall provide for be so constructed and equipped that they
continuous circulation of hot binder shall be readily accessible for calibrating
through the system and back into the at all times, and shall provide for a
feed tank. The end of the return line continuous and uniform flow of each
discharging into the feed tank shall aggregate required in the mix.
always be kept submerged in the
bitumen in the tank in order to prevent The plant shall have a rotary drum dryer
oxidation of the returning hot binder. of satisfactory design for drying and
The storage tanks, and where necessary heating the combined aggregate so that
barrel decanters, and all elements of the its temperature will be at the required
bitumen feeding system shall be level at the time it is mixed with the
equipped with heating systems or bitumen. The burner shall be so
insulating jackets as necessary to designed that complete combustion of
provide for effective and positive control the fuel will be obtained, and the
of the temperature of the bitumen at all aggregate will remain clean and not
times up to the temperature required for become coated with soot or oil.
utilisation. . The method of heating
shall be such that neither flames nor the The plant shall be equipped with four
products of combustion shall come into (or more) screens, the smallest of which
direct contact contact with the bitumen shall generally be not more than 3.2
or the casing of its immediate container, mm. The screens shall have a normal
and such that no portion of the bitumen capacity slightly in excess of the
shall be subject to overheating. maximum output of the mixing plant.
Cawangan Jalan, Ibu Pejabat JKR, K.L The screens shall be readily accessible
for inspection.
The plant shall include four (or more)

storage bins for screened aggregates,
each with a capacity of not less than
twice the pugmill dead load capacity.
The bins shall be arranged so as to
provide separate dry storage for each
screened fraction of the aggregate. Each
bin shall be provided with an overflow
pipe of such size and location as to
prevent any backing up of material into
other bins. Each bin shall be so
constructed that representative aggregate
samples can be readily obtained, and
Page 106
FOR INTERNAL USE ONLY aggregate level. Separate dry storage
shall be provided for mineral filler, and
shall have means for observing the the plant shall be satisfactorily equipped
to feed filler into the mixer.
Satisfactory means by either weighing
or metering shall be provided to obtain the truck loading area, which shall be
the prescribed amount of bitumen in the kept free from drippings from the mixer.
mix within the specified tolerance.
Means shall be provided for checking Special Requirements for Batch Plants
the quantity or flow rate of binder
entering the mixer. Suitable means shall Each storage bin for screened aggregate
be provided for maintaining the shall be provided with a bottom outlet
prescribed temperature of the bitumen in gate so constructed as to prevent leakage
the pipelines, weigh bucket or flow when closed. These gates shall have a
meter, and spray bars. quick and complete closing action.
An armoured thermometer with a The plant shall be equipped with a

range of 30 oC to 200 oC shall be fitted weigh box or hopper for accurately
in the bitumen feed line at a suitable weighing out aggregate from each of the
location near the discharge valve at the screened aggregate storage bins. The
mixer unit. Suitable dial-scale mercury weigh box or hopper shall be
actuated thermometers, electric suspended from its scale's lever
pyrometers or other thermometric mechanism and shall be sufficiently
instruments shall be fitted at the large to hold a full batch equal to the
discharge chute of the dryer and in each pugmill capacity without hand raking or
hot aggregate storage bin to indicate the spilling of the aggregate. The discharge
temperatures of the heated aggregates. gate shall be so constructed as to allow
rapid and complete emptying of the
The plant shall be equipped with a dust weigh box or hopper into the mixer, and
collector so constructed as to waste the prevent leakage when closed.
material collected or feed it uniformly to
the heated aggregate. The plant shall be equipped with a
binder weigh bucket which shall be
The plant shall be equipped with charged through a fast acting non-drip
adequate and safe stairways to the valve in the binder feed pipe located
mixing platform and sampling locations, directly over the bucket. The bucket
and guarded ladders and cat-walks shall shall be suspended from its scale's lever
provide access to all other positions as mechanism and shall have a capacity
necessary for proper operation, sufficient to weigh out binder up to 20%
inspection and maintenance of the plant, of the weight of the pugmill dead load
all to the satisfaction of the S.O. All capacity. The bucket shall have a
gears, pulleys, chains, sprockets and discharge mechanism which shall
other dangerous moving parts shall be provide for rapid and complete
properly guarded and protected. Ample emptying of the bucket in a thin uniform
and unobstructed space shall be sheet or multiple sprays over the full
provided on the mixing platform, and length and width of the mixer. The
clear and unobstructed passage shall be dicharge mechanism shall not leak or
maintained at all times in and around drip when closed.
Cawangan Jalan, Ibu Pejabat JKR, K.L The batch mixer shall be a suitable
twinshaft pugmill, with a capacity of at
least 500 kg of asphaltic concrete,
capable of producing a thoroughly
homogeneous mixture. The clearance of
the paddle blades from all fixed and
Page 107
FOR INTERNAL USE ONLY more than 20 mm. If the pugmill is not
enclosed it shall be equipped with a dust
moving parts of the mixer shall be not hood to prevent loss of fines from the
mixture. The discharge gate shall be so
constructed as to allow rapid and Standard Specification For Road Works
complete emptying of the mixer, and
prevent leakage of any mix constituent producing an accurate and continuous
when closed. blend of the individual aggregate sizes
from the cold feed compartment.
The mixer shall be equipped with an
accurate time lock system for The drum mixer shall be of an inclined,
controlling the operations of a complete oil-fired and parallel flow type in which
mixing cycle. It shall lock the aggregate the aggregates and exhaust gases flow in
weigh box or hopper gate after charging the same direction. The drum mixer
the mixer with aggregate, until the length to diameter ratio shall be such as
closing of the mixer gate at the to ensure efficient drying and intimate
completion of the mixing cycle; it shall mixing of aggregate, filler and binder
lock the binder weigh bucket discharge over the full range of rated operating
mechanism during the dry mixing and efficiencies. A bypass chute shall be
wet mixing periods. (The dry mixing incorporated for sampling of cold
period is defined as the interval of time aggregate.
between the opening of the aggregate
weigh box or hopper gate and the start Freshly mixed material shall be
of discharging the binder weigh bucket. delivered and stored in a surge silo
The wet mixing period is defined as the through a proper conveyor system.
interval of time between the start of
discharging the binder weigh bucket and Special Requirements for Continuous
the opening of the mixer gate.) The dry Mix Plants
and wet mixing periods shall both be
adjustable in increments of not more Each storage bin for screened aggregate
than 5 seconds from zero to not less than shall be provided with an accurately
120 seconds total for dry and wet controlled variable orifice gate
mixing. discharging on to an aggregate feed
mechanism. The discharge orifice shall
Special Requirements for Drum Mix be rectangular with one dimension
Plants variable by means of an adjustable and
lockable gate, which shall have an
The cold material feeder unit shall indicator showing the distance it is open.
consist of not less than 5 compartments These gates shall be used for accurately
with suitable heaped capacity proportioning the screened aggregates
appropriate for the plant. Each bin shall for the mix.
be provided with a control gate and
measuring feeder suitable for accurate The plant shall have means of
blending of the aggregates on to the cold calibrating the aggregate bin discharge
feed collecting conveyor. The cold feed gate openings by weighing test samples
system shall incorporate a device for obtained by diverting the aggregate fed
moisture compensation capable of out of each bin into a suitable test box.
Test boxes shall have a capacity of not
less than 100 kg each.
Cawangan Jalan, Ibu Pejabat JKR, K.L The plant shall have satisfactory means
of effecting positive interlocking control
between the flow of screened aggregates
from the storage bins and the flow of
binder from the meter or other
proportioning device. This control shall
Page 108
FOR INTERNAL USE ONLY mechanical means or another positive
method satisfactory to the S.O.
be accomplished by interlocking
The continuous mixer shall be a suitable
twin-shaft pugmill with an adjustable Standard Specification For Road Works
dam and paddles with reversible blade
pitch for adjusting the volume of (c) Tip-Trucks
mixture held in the pugmill. The
clearance of the paddle blades from all The Contractor shall provide a suitable
fixed parts of the mixer shall be not number of tip-trucks of a type approved
more than 20 mm. The binder shall be by the S.O. for transporting asphaltic
fed into the mixer through a spray bar concrete from the mixing plant to the
directed on to the aggregate across the paving works. The trucks shall have
full width of the pugmill at the feed end. trays with smooth, flat beds and sides,
The discharging mixture shall pass over and shall have load capacities of not less
the dam into a hopper with a discharge than 5 tonnes. Prior to loading, the
gate so constructed as to allow rapid and inside of each truck tray shall be lightly
complete emptying of the hopper, and and evenly coated with a soap or
prevent leakage of the mix when closed. detergent solution, or such other liquid
The mixer shall be equipped with a as the S.O. shall approve, to prevent
permanent gauge for measuring the adhesion of the asphaltic concrete. The
depth of mixture in the pugmill and a trucks shall be equipped with covers of
manufacturer's calibration plate showing canvas or other suitable material to
the volume of mixture in the pugmill at protect the asphaltic concrete.
each increment of depth.
(d) Asphalt Paver
The mixing time shall be determined
using the formula :- The asphalt paver shall be of recognized
manufacture and shall be approved by
Mixing time (seconds) = the S.O. It shall conform to the
Dead weight of mix in pugmill (kg) requirements described hereunder.
Pugmill output (kg per second)
The paver shall be self-propelled and
and for a given output it may be varied capable of reverse as well as forward
slightly by adjusting the depth (and travel. It shall be equipped with a
hence weight) of the mixture held in the hopper at the front designed to receive
pugmill by varying the dam height, the the paving mixture from tip-trucks, and
configuration of the paddle blades, or shall have a mechanical distribution
both. However for substantial system for spreading the mixture evenly
adjustments of the mixing time, in order and without segregation over the surface
to maintain the depth at a level to be paved in front of a screeding and
compatible with efficient mixing, i.e. so compacting unit which shall be
that the paddle tips just break out of the equipped with a suitable heating device.
mixture at the height of their action, the The screeding and compacting
rate of feed of materials to the mixer mechanism shall be capable of
(and hence output) should be changed. confining the edges of the material
being laid without the use of stationary
side forms, shall be adjustable to strike
off the mixture to the thickness and
cross-section shape required, and shall
Cawangan Jalan, Ibu Pejabat JKR, K.L be controlled by an automatic levelling
device to produce an even carpet of
bituminous mixture with a uniform sur
face texture free from indentations,
ridges, tear marks or other irregularities.
Page 109
FOR INTERNAL USE ONLY bituminous mixture in paving widths in
the range 2.5 to 3.75 m and of finishing
The paver shall be capable of laying the the pavement layer true to the required
lines, grades, levels, dimensions and
cross-sections, subject to compaction by Standard Specification For Road Works
rolling, all to the satisfaction of the S.O.
(e) Rollers (a) General Conditions
A pneumatic tyred roller and two steel Asphaltic concrete paving work
wheeled tandem rollers shall be shall only be carried out in dry
provided. However, a three wheeled weather when the surface to be
steel roller may be substituted for one of covered is dry, or if so specified,
the tandem rollers if the S.O. shall so has received a bituminous tack
approve. All rollers shall be of coat which shall have achieved a
recognized manufacture and shall be satisfactory degree of tackiness,
approved by the S.O. all to the satisfaction of the S.O.
All laying, rolling and finishing
The pneumatic tyred roller shall be as work shall be carried out during
specified in Sub-Section 4.2.3.3 (g). daylight hours, unless the Contractor
Steel wheeled rollers shall conform to shall have provided suitable flood-
the requirements described hereunder. lighting for the job site, to the
Steel wheeled rollers shall be self-
propelled and capable of being reversed The S.O. may order the
without backlash; they shall be equipped discontinuation of work on account
with power steering and dual controls of adverse weather, unsatisfactory
allowing operation from either the left or condition of materials, equipment or
right side. They shall be equipped with surface to be paved, or such other
water tanks, sprinkler systems and conditions as he shall consider detri
scraper blades to keep all wheels evenly mental to the work.
wetted and clean during operation.
(b) Surface Preparation and Cleaning
Each steel wheeled roller shall be
ballasted so that its total operating Prior to constructing an asphaltic
weight is in the range 8 to 10 tonnes and concrete pavement layer, the surface
its driven roll (or rolls) shall exert a to be covered shall have been
rolling force of not less than 3.5 prepared in accordance with the
tonnes/metre of roll width. The appropriate Sections of this
Contractor shall provide the S.O. with a Specification. Notwithstanding any
calibration chart for each roller showing earlier approval of this surface, any
the relationships between the quantity or damage to or deterioration of it shall
depth of ballast and total weight and be made good before asphaltic
rolling force. concrete paving work is commenced.
If the surface to be covered is not to

be provided with a bituminous tack
coat, then immediately prior to
commencing asphaltic concrete
Cawangan Jalan, Ibu Pejabat JKR, K.L paving, it shall be swept using a
power broom followed by a
compressed air blower and, if
necessary, scraped using hand tools
to remove all loose particles, dirt,
dust and other objectionable
Page 110
FOR INTERNAL USE ONLY S.O.
material, all to the satisfaction of the If the surface to be covered is to be

provided with a bituminous tack coat,
then this shall be applied all in Standard Specification For Road Works
accordance with the provisions of Sub-
Section 4.2.2. Ordinary Portland cement and/or
other mineral filler to be used in the
(c) Aggregate Handling and Heating mix shall be stored separately and
kept completely dry. Its rate of feed
Each aggregate to be used in the into the plant shall be accurately
asphaltic concrete mixes shall be stored controlled by weight or volumetric
in a separate stockpile near the mixing measurement, all to the satisfaction
plant. Stockpiles of sand and other fine of the S.O.
aggregates shall be kept dry using
waterproof covers and other means as (d) Heating of Bitumen
necessary. In placing the aggregates in
the stockpiles and loading them into the The binder shall be heated so that
mixing plant's cold aggregate feed bins, when delivered to the mixer it shall
care shall be taken to prevent be at a temperature in the range
segregation or uncontrolled combination 140ºC to 160ºC.
of materials of different gradation.
Segregated or contaminated materials (e) Mixing Asphaltic Concrete
shall be rescreened or rejected for use in
the Works and removed from the mixing The mixing plant shall be so
plant site. coordinated and operated as to
consistently produce asphaltic
The aggregates shall be fed into the concrete mixes within the tolerances
dryer at a uniform rate proportioned in prescribed in this Specification, all
accordance with the appropriate job mix to the satisfaction of the S.O.
formula. The rate of feed for each
aggregate shall be maintained within
10% of the rate prescribed, and the Mixing in Batch Plants
total rate of feed shall be such that
the plant's screens shall never be For each batch the screened hot
overloaded. aggregates shall be weighed out into
the aggregate weigh hopper in
The aggregates shall be dried and heated accordance with the proportions
so that when delivered to the mixer they prescribed in the appropriate job mix
shall be at a temperature in the range formula; the sequence of weighing
150ºC to 170ºC. out shall commence with the largest
sized aggregate and progress down
Immediately after heating, the to the fines, unless the S.O. shall
aggregates shall be screened into four otherwise approve. Mineral filler
(or more) fractions which shall be shall be weighed out into the filler
separately stored in the hot aggregate weigh hopper, where this is
storage bins in readiness for mixing. provided, or added last to the
aggregate weigh hopper, in
accordance with the job mix formula
proportions.
The hot binder shall be weighed out
into the binder weigh bucket in
ccordance with the proportions
prescribed in the job mix formula.
Page 111
FOR INTERNAL USE ONLY discharged into the pugmill and
mixed dry for the dry mixing time
The hot aggregates and filler shall be prescribed in the job mix formula,
which shall usually be in the range 5
to 10 seconds. The hot binder shall Standard Specification For Road Works
then be added and wet mixing per
formed for the wet mixing time shall be as prescribed in the job mix
prescribed in the job mix formula; formula; this shall be sufficient so
this shall be sufficient so that all that all particles of aggregate are
particles of aggregate are uniformly uniformly coated with bitumen, and
coated with bitumen, and shall shall usually be 45 seconds or more
usually be 45 seconds or more for for dense graded mixtures.
dense graded mixtures.
The plant shall be so adjusted as to
The volume of each batch shall be maintain the level of mixture in the
such that the tips of the pugmill pugmill such that the tips of the
paddle blades just break out of the paddle blades just break out of the
mixture at the height of their action. mixture at the height of their action.
After the completion of wet mixing, (f) Transportation of Asphaltic

each batch of asphaltic concrete shall Concrete
be discharged from the pugmill
either into a storage hopper or Asphaltic concrete shall be
directly into a truck for hauling to transported from the mixing plant to
the paving site. Care shall be taken the site of the paving works in loads
that no segregation of the mix of not less than 5 tonnes using
occurs. tip-trucks as specified in
Mixing in Continuous Mix Plants Sub-Section 4.2.4.4 (c). Except

where asphaltic concrete is to be
The screened hot aggregates and hand laid, it shall be discharged
filler shall be fed continuously from directly into the paver hopper, as
their storage bins in accordance with required, from the tip-trucks. Care
the proportions prescribed in the shall be taken in the truck loading,
appropriate job mix formula, hauling and unloading operations to
combined in the plant, and fed prevent segregation of the mix.
continuously into the mixer. The hot During transportation, the asphaltic
binder shall be sprayed on to the concrete shall be protected from
combined aggregate as it enters the contamination by water, dust, dirt
pugmill at the rate required to and other deleterious materials.
achieve the bitumen content pre
scribed in the job mix formula. The The temperature of asphaltic
materials shall then be carried concrete immediately before
through the pugmill and in the unloading from the truck either into
process be thoroughly mixed by the paver hopper or on to the road
the action of the paddles and dis for hand spreading shall be not less
charged over the dam into the stor than 125ºC. Any load which has
age hopper. The mixing time (as cooled below the specified
defined in Sub-Section 4.2.4.4 (b) temperature in the truck shall be
rejected for use in the Works and
Cawangan Jalan, Ibu Pejabat JKR, K.L removed from the Site of the Works.
(g) Laying Asphaltic Concrete
The sequence of laying operations

shall be planned in advance by the
Contractor and approved by the S.O.
Page 112
FOR INTERNAL USE ONLY have a compacted thickness of not
less than twice the nominal
Generally each paving layer shall maximum aggregate size of the
mixture, and not more than 100 mm.
Where applicable, e.g. on Standard Specification For Road Works
superelevated sections and on
carriageways with cross-slope in one and before laying restarts after each
direction only, laying shall interruption of the paving operation.
commence along the lower side of
the carriageway and progress to the As far as is practicable, the paver
higher side. Laying shall not be shall be operated continuously and
carried out in a downhill direction the supply of bituminous mix shall
along any section of road. be regulated so as to enable
continuous paving. Transverse joints
As far as is practicable, laying shall in a paving lane shall be kept to a
be carried out using a paver practicable minimum, and
approved by the S.O. Hand-casting intermittent stopping and restarting
of bituminous mix on to the machine of the paver shall be avoided as far
finished surface shall be kept to the as is practicable.
practicable minimum necessary for
correcting blemishes and Care shall be taken that no
irregularities. In any areas bituminous mix is placed on
inaccessible to the paver, laying shall expansion joints at bridges,
be carried out by hand methods inspection covers for utilities ducts,
using rakes, lutes and other hand drainage and sewerage manholes and
tools, all to the satisfaction of the the like, and that catchpits, drainage
S.O. All laying of bituminous mix openings through kerbs, etc., remain
shall be such that after compaction properly open and serviceable.
by rolling the specified course or During laying operations, such areas
layer thickness and surface profile and openings shall be protected by
shall be achieved. Care shall be suitably shaped and secured boards
taken to achieve a uniform surface or other materials approved by the
texture free from indentations, S.O., and compaction of mix in the
ridges, tear marks or other immediately surrounding or adjacent
irregularities, and to prevent areas shall be completed by hand
segregation of the mix. methods, all to the satisfaction of
the S.O. Alternatively, bituminous
At the commencement of initial mix shall be laid and compacted by
rolling the temperature of asphaltic hand methods as necessary around
concrete shall be not less than surfacing discontinuities of these
110ºC. Material which has cooled types, all to the satisfaction of the
below the specified temperature S.O.
before laying shall not be used and
shall be removed from the Site of the (h) Construction Joints
Works. The Contractor shall provide
accurate thermometers at the paving Existing bituminous surfacing which
site at all times, and shall check the new bituminous mix is to adjoin
temperature of asphaltic concrete in shall be cut back to present a
the paver hopper at regular intervals straight, vertical edge not less than
25 mm deep and a smooth transition
Cawangan Jalan, Ibu Pejabat JKR, K.L section not less than 0.5 metre long
against which to lay the new
material. The specified thickness of
the new surfacing shall be built up
gradually from the vertical joint to
avoid any bumps or ridges across the
carriageway.
Page 113
FOR INTERNAL USE ONLY joints are required in a layer of
bituminous mix under construction,
Where longitudinal or transverse the material first laid and compacted
shall be cut back to a vertical face for
the full thickness of the layer on a Standard Specification For Road Works
line satisfactory to the S.O. before
the adjacent area is paved. Initial (or breakdown) rolling shall
be carried out with an approved steel
At all construction joints, a thin wheeled tandem roller or three
uniform coating of bitumen emulsion wheeled steel roller. The principal
of grade RS-1 or RS-1K shall be heavy rolling shall be carried out
brushed on to the vertically cut joint with an approved pneumatic tyred
faces some 10 to 15 minutes before roller immediately following the
laying the next section of bituminous initial rolling; the pneumatic tyred
mix commences to ensure good roller shall be ballasted to an
Type of Pavement Required Compacted operating weight of not less than 15
Layer Density
tonnes and its tyre inflation pressure
Wearing course 98 - 100% Marshall shall be not less than 0.7 N/sq.mm.
density The final rolling shall be carried out
Binder course 95 - 100% Marshall with an approved steel wheeled
density tandem roller and shall serve to
eliminate minor surface irregularities
bonding. Also, all contact surfaces left by the pneumatic tyred roller.
of kerbs, gutters, manholes,
catchpits, etc., shall be similarly All rollers shall operate in a
treated with a coating of bitumen longitudinal direction along the
emulsion before bituminous mix is carriageway with their driven wheels
placed against them. towards the paver. Rolling shall
generally commence at the lower
Construction joints in a layer of edge of the paved width and progress
bituminous mix shall be offset from uniformly to the higher edge, except
those in any immediately underlying that where there is a longitudinal
bituminous layer by at least 100 mm construction joint at the higher edge,
for longitudinal joints and at least 0.5 this shall be rolled first ahead of the
metre, where possible, for transverse normal pattern of rolling. Generally,
joints. successive roller passes shall overlap
by half the width of the roller, and
(i) Compaction of Asphaltic the points at which the roller is
Concrete reversed shall be staggered.
However, when operating on
For each layer of asphaltic concrete, gradients in excess of 4%, the
compaction by rolling shall breakdown roller shall not pass over
commence as soon after laying as the any previously unrolled mix when
material will support the rollers operating in the downhill direction.
without undue displacement;
nevertheless the temperature of In all cases, compaction shall be
asphaltic concrete at the carried out in such a manner that
commencement of rolling shall be each section receives equal
not less than 110ºC. compactive effort, all to the
In any areas inaccessible to the
rollers, proper compaction shall be The steel wheeled rollers shall
carried out using vibrating plate operate at speeds of not more than 5
compactors, hand tampers or other km/hr and the pneumatic tyred
suitable means, all to the satisfaction rollers shall operate at speeds of
of the S.O. not more than 8 km/hr. No roller or

heavy vehicle shall be allowed to

stand on newly laid bituminous mix
before compaction has been
completed and the material has
thoroughly cooled and set. Rolling
shall continue as long as is necessary
to achieve the appropriate
Care shall be taken to prevent over-

compaction of
requirement as asphaltic
follows :-concrete.
Within 24 hours of laying and

compacting the bituminous mix, the
Contractor shall cut core samples of
not less than 100 mm nominal
diameter at locations selected by the
S.O. The rate of sampling shall be 1
sample per 500 sq.m of mix laid, but
not less than 2 samples for the work
completed in each paving session.
These core samples shall be used by
the S.O. to determine the thickness
of the compacted layer of mix and
the compacted density of the
material in accordance with either
ASTM Test Method D 1188 or
ASTM Test Method D 2726,
whichever is applicable.
(j) Finished Asphaltic Concrete
Asphaltic concrete binder and

wearing courses shall be finished in a
neat and workmanlike manner; their
widths shall be everywhere at least
those specified or shown on the
Drawings on both sides of the
centre-line; ;

the average thickness over any 100

metre length shall be not less than
the required thickness, and the
minimum thickness at any point
shall be not less than the required
thickness minus 5 mm.
The top surface of a wearing or

binder course shall have the required
within the tolerances specified in
Sub-Section 4.4.
(k) Opening to Traffic
Asphaltic concrete shall not be

opened to traffic until compaction
has been completed and the material
has thoroughly cooled and set in the
opinion of the S.O. This will usually
be not less than 4 hours after the
commencement of rolling. Where it
is necessary to allow earlier use of
the finished surface to facilitate the
movement of traffic, vehicles may
be allowed to run on the work after
rolling has been completed,
provided that speeds are restricted
to 30 km/hr or less and sharp turning
movements are prohibited.
Type of Pavement Required Compacted

Layer Density
Bound roadbase 90 - 100% Marshall
Page 11 density
5
Levelling course 90 - 100% Marshall
density
4.2.5 Bituminous Macadam Binder course 95 - 100% Marshall
density
4.2.5.1 Description Wearing course 98 - 100% Marshall
density
This work shall consist of furnishing,
placing, shaping and compacting
bituminous macadam roadbase
and/or levelling course and/or binder
course and/or wearing course on a
prepared and accepted bituminous or
bitumen primed pavement course,
and shall include the careful and
thorough cleaning of surfaces which
are to be covered without receiving a
bituminous tack coat. The work shall
be carried out all in accordance with
this Specification and the lines,
levels, grades, dimensions and cross-
sections shown on the Drawings
and/or as required by the S.O.
4.2.5.2 Materials
The materials for bituminous

macadam (aggregates, mineral filler,
bituminous binder and anti-stripping
agent) shall comply with all the
requirements of Sub-Section 4.2.4.2,
except for the combined gradation
requirements.
For each bituminous macadam mix,

the gradation of the combined coarse
and fine aggregates, together with
ordinary Portland cement added as
an adhesion and anti-stripping agent
and, if necessary, any other mineral
filler, shall conform to the
appropriate envelope given in Table
in accordance with Table 4.12.
Where the characteristics of the

aggregates require a binder content
other than that given in the above
Table, the revised target binder
content shall be agreed between the
Contractor and the S.O. and the same
tolerances shall apply.

4.2.5.3 Equipment
The equipment shall be all as

4.12. The binder
specified content shall
in Sub-Section also be
4.2.4.4.
All the provisions of Sub-Section

4.2.4.5 for the construction of
asphaltic concrete pavement courses
shall apply as appropriate to the
construction of bituminous macadam
pavement courses with the
following variations and additions.
(a) Aggregate Heating
The aggregates shall be dried and

heated so that when delivered to the
mixer they shall be at a temperature
in the range 140 oC to 160 oC.
(b) Rolling Temperature
The temperature of bituminous

macadam at the commencement of
rolling shall be not less than 100 oC.
(c) Compacted Density
The compacted density of

bituminous macadam shall be as
follows :-
Page 116
FOR INTERNAL USE ONLY the required thickness. The top
surface of bituminous macadam
The Marshall density of a roadbase shall have the required
bituminous macadam mix is defined shape, superelevation, levels and
as the average density of a set of grades, and shall be everywhere
three test specimens moulded in the within the tolerances specified in
same way as asphaltic concrete Sub-Section 4.4.2.
specimens are prepared for the
standard stability and flow test in
Method T 245 using the 75 blows
per face compaction standard. The
bulk specific gravity of the
specimens shall be determined in
Method T 166.
The Marshall density of each mix

shall be determined using a sample
(or samples) taken from the mixing
plant soon after the commencement
of preparing each mix for the Works.
(Note : Stability and flow tests are
not normally required for bituminous
macadam mixes.)
(d) Finished Bituminous Macadam
Bituminous macadam roadbase shall

be finished in a neat and
workmanlike manner; its width shall
be everywhere at least that specified
or shown on the Drawings on both
sides of the centre-line; and its
average thickness over any 100
metre length shall be not less than
Standard Specification For Road Works wearing courses shall be finished in a
neat and workmanlike manner; their
Bituminous macadam levelling widths shall be everywhere at least
course shall be finished in a neat and those specified or shown on the
Mix Type Bound Bound Levelling Binder Binder Wearing Wearing

Roadbas Roadbase Course Course Course Course Coursex
e
Mix BMR40 BMR28 BML10 BMB28 BMB20 BMW14 BMW20
Designatio
n
B.S. Test % by Weight
Sieve Passing
50.0 mm 100 - - - - - -
37.5 mm 95 - 100 100 - 100 - - -
28.0 mm 70 - 94 90 - 100 - 90 - 100 100 - 100
20.0 mm - 71 - 95 - 71 - 95 95 - 100 100 95 - 100
14.0 mm 56 - 76 56 - 80 100 58 - 82 65 - 85 95 - 100 65 - 85
10.0 mm - - 85 - 100 - 52 - 72 70 - 90 52 - 72
6.3 mm 44 - 60 44 - 60 30 - 60 44 - 60 39 - 55 45 - 65 39 - 55
3.35 mm 32 - 46 31 - 45 15 - 25 32 - 46 32 - 46 30 - 45 32 - 46
1.18 mm - - - - - 15 - 30 -
300 mm 7 - 21 7 - 21 - 7 - 21 7 - 21 - 7 - 21
75 mm 2-9 2-8 2-6 2-8 2-8 3-7 2-8
Binder 3.5 " 4.0 " 5.1 " 4.7 " 4.7 " 5.0 " 4.9 "
Content
      
0.5% 0.5% 0.5% 0.6% 0.6% 0.5% 0.5%
workmanlike manner; its dimensions Drawings on both sides of the
shall be as specified or shown on the centre-line; the average thickness
Drawings or as directed by the S.O., over any 100 metre length shall be
all to the satisfaction of the S.O. The not less than the required thickness,
top surface of bituminous macadam and the minimum thickness at any
levelling course shall have the point shall be not less than the
required thickness minus 5 mm. The
required shape,, superelevation, top surface of a wearing or binder
levels and grades, and shall be every course shall have the required shape,
where within the tolerances for superelevation, levels and grades,
binder course specified in Sub- and shall be everywhere within the
Section 4.4. tolerances specified in Sub-Section
4.4.
Bituminous macadam binder and

TABLE 4.12 - GRADATION LIMITS AND BINDER CONTENTS

FOR BITUMINOUS MACADAM

FOR INTERNAL USE ONLY 4.3.2.2 Gravel Shoulders
4.3 SHOULDERS Gravel shoulder material shall

conform to the requirements for
4.3.1 Description gravel surfacing material set forth
in Sub-Section 4.1.3.2.
This work shall consist of furnishing,
compacting and shaping earth or 4.3.3 Construction Methods
gravel shoulder material on a
prepared and accepted subbase or Shoulders shall be constructed in
lower subbase or subgrade, all in stages or in one operation as directed
accordance with this Specification or approved by the S.O., but in no
and the lines, levels, grades, instance shall a shoulder be built up
dimensions and cross-sections shown to a level higher than that part of the
on the Drawings and/or as required abutting carriageway structure which
by the S.O. has been completed and accepted.
For paved shoulders, the bituminous Prior to placing any shoulder

surfacing and underlying pavement material, the underlying subbase or
courses shall be constructed as lower subbase or subgrade shall have
described in the appropriate Sections been shaped and compacted in
of this Specification. accordance with the provisions of
4.3.2 Materials
4.3.2.1 Earth Shoulders
Earth shoulder material shall

be suitable material as
described in Sub-Section 2.2.1.
Each layer of shoulder material shall
Sub-Section 4.1.2.3, and the abutting be processed as necessary to bring its
carriageway structure course or moisture content to a uniform level
courses shall likewise have been throughout the material suitable for
shaped and compacted in accordance compaction, and shall then be
with the provisions of the compacted using suitable
appropriate Sub-Section or Sub- compaction equipment approved by
Sections of this Specification. the S.O. to not less than 95% of the
Notwithstanding any earlier approval maximum dry density determined in
of the underlying and abutting the B.S. 1377 Compaction Test (4.5
pavement courses, any damage to or kg rammer method). Compaction
deterioration of these underlying shall be carried out in a longitudinal
and abutting pavement courses shall direction along the shoulder and
be made good to the satisfaction of shall generally begin at the outer
the S.O. before shoulder construction edge and progress uniformly towards
proceeds. the carriageway, except on
superelevated curves where rolling
Shoulders shall be placed to the shall begin at lower edge and
required width and thickness as progress uniformly towards the
shown on the Drawings or directed higher edge.
by the S.O. in one layer or more,
each layer not exceeding 200 mm
compacted thickness at the point of Page 119
maximum thickness. Where two or
more layers are required they shall
be of approximately equal shape and Pavement Course Tolerance
thickness, and none shall be less than
100 mm compacted thickness at the
Wearing Course + 5 mm
point of maximum thickness.
Binder Course + 5 mm
In all cases, compaction shall be + 0 mm
Roadbase
carried out in such a manner that - 20 mm
each section receives compactive
effort appropriate to its thickness, all
Subbase and Lower + 10 mm
to the satisfaction of the S.O.
Subbase - 20 mm
Throughout the placing, adjustment
of moisture content and compaction
of shoulder material, care shall be
taken to maintain a uniform
gradation of the material and prevent
its seperation into coarse and
seperate parts, all to the satisfaction
of the S.O.
Where shown on the Drawings or

directed by the S.O., earth shoulders
shall be turfed in accordance with
Sub-Section 2.2.8.2.
Shoulders shall be finished in a neat

and workmanlike manner. The total
width of carriageway and shoulder
shall be everywhere at least that
specified or shown on the Drawings
on both sides of the centre-line. The
top surface of each shoulder shall
have the required shape,
superelevation, levels and grades,
shall be everywhere within 10 mm
of the required plane, and shall
provide a flush joint with the
carriageway surface and shall be
uniformly free draining away from
the carriageway, all to the
4.4 HORIZONTAL ALIGNMENT,

SURFACE LEVELS AND
SURFACE REGULARITY OF
PAVEMENT COURSES
4.4.1 Horizontal Alignment
The horizontal alignment shall be

determined from the centre-line of
the pavement surface shown on the
Drawings. The edges of the
pavement as constructed and all
other parallel construction lines shall

be correct within a tolerance of + 50

mm and minus 0 mm from the
centre-line, except for kerbs, channel
blocks and edge lines which shall be
laid with a smooth alignment within
a tolerance of + 25 mm and minus
0 mm from the centre-line.
4.4.2 Surface Levels of Pavement Courses
The design levels of pavement

courses shall be calculated from the
vertical profile, crossfall and
pavement course thicknesses shown
on the Drawings. The level of any
point on the constructed surface of a
pavement course shall be the design
level subject to the appropriate
tolerances given in Table 4.13.
TABLE 4.13 - TOLERANCES IN SURFACE

LEVELS OF PAVEMENT COURSES
The combination of permitted

tolerances in the levels of different
pavement courses shall not result in a
pavement thickness less than that
shown on the Drawings. Each
pavement course shall have an
average thickness not less than that
shown on the Drawings.
Page 120
4.4.3 Surface Regularity
The regularity of surfaces shall be

within the relevant limits given in
Table 4.14.
A longitudinal irregularity is a
variation in profile of the road
surface as measured by the rolling
straight-edge or wedge and
straight-edge device. The
permissible number of such
longitudinal irregularities is indicated
Longitudinal Direction Transverse

Direction
Maximum Permissible Number Maximum

Class of of Surface Irregularities Permissible
Surface Depth of
Regularity Transverse
Depth Exceeding 4 Depth Exceeding 7 mm Irregularities
mm
over over over over
traverse traverse traverse traverse
length length length length
of 300 m of 75 m of 30 m of 75 m
Class SR1 20 9 2 1 4 mm
Class SR2 40 18 4 2 8 mm
Class SR3 60 27 4 3 12 mm
No longitudinal irregularity exceeding 10 mm shall be permitted for Class SR1

Surface Regularity and no longitudinal irregularity exceeding 15 mm shall be
permitted for Class SR2 and Class SR3 Surface Regularities.
The class of Surface Regularity for each portion of the Works shall be as stated
on
the Drawings or in the Bills of Quantities.
in Table 4.14.
The traverse length of 300 m and its

associated maximum permissible
number of irregularities shall apply
wherever the continuous length of
the completed carriageway is 300 m
or more, whether or not it is
constructed in shorter lengths.
Where the total length of pavement

is less than 300 m the measurements
shall be taken on 75 m lengths.
The transverse regularity of a newly

laid surface shall be measured with a
3 m straight-edge and shall have no
greater depression under the
straight-edge than that shown in
Table 4.14
TABLE 4.14 - TOLERANCES FOR SURFACE IRREGULARITIES

SECTION 5
PORTLAND CEMENT
CONCRETE PAVEMENT
SECTION 5 - PORTLAND CEMENT CONCRETE PAVEMENT
Page
5.1 DESCRIPTION S5-125
5.2 MATERIALS S5-125
5.2.1 Cement S5-125
5.2 2 Aggregate S5-125
5.2.3 Joint Filler S5-125
5.2.4 Joint Sealants and Seals S5-125
5.2.5 Waterproof Membrane S5-126
5.2.6 Curing Materials S5-126
5.3 PRODUCTION OF CONCRETE S5-128
5.3.1 Concrete S5-128
5.3.2 Equipment S5-128
5.4 CONSTRUCTION S5-128
5.4.1 Preparation of Subgrade or Subbase S5-128
5.4.2 Construction by Machine S5-128

5.4.2.1 Fixed Forms, Rails and Guide Wires For Machine Construction S5-128
5.4.2.2 Construction by Fixed Form Paving Machine S5-129
5.4.2.3 Construction by Slip Form Paving Machine S5-131
5.4.3 Construction by Hand-Guided Method S5-132
5.4.4 Manual Construction S5-132

5.4.4.1 Side Forms for Manual Construction S5-133

Page
5.5 JOINTS S5-133
5.5.1 Transverse Expansion Joints S5-133
5.5.2 Transverse Contraction Joints S5-134

5.5.2.1 Planes of Weakness S5-134
5.5.2.2 Load Transfer Assemblies S5-135
5.5.3 Longitudinal Joints S5-135
5.5.4 Transverse Construction Joints S5-135
5.5.5 Sealing Joints S5-135
5.5.6 Concrete Saw S5-136
5.6 SURFACE TEXTURE S5-136
5.6.1 Texture of Running Surfaces S5-136
5.6.2 Measurement of Texture Depth : Sand Patch Method S5-137

5.6.2.1 Apparatus S5-137
5.6.2.2 Method S5-137
5.7 ROUNDING OF EDGES S5-137
5.8 CURING S5-137
5.9 REMOVING FORMS S5-138
5.10 OPENING TO TRAFFIC S5-139
5.11 TREATMENT OF MANHOLES AND GULLIES S5-139
5.12 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND

SURFACE REGULARITY S5-139
SECTION 5 - PORTLAND CEMENT 5.2.4 Joint Sealants and Seals

CONCRETE PAVEMENT
Joint sealants shall consist of hot or
cold-poured compounds or pre
5.1 DESCRIPTION formed seals as indicated on the
Drawings and shall comply with the
This work shall consist of constructing a following requirements :-
Portland cement concrete pavement with
or without reinforcement in accordance (a) Hot-Poured Sealants
with this Specification, including all
relevant requirements of Section 9, Hot-poured sealants shall comply
and in conformity with the lines, with the requirements of B.S. 2499
levels, grades, dimensions and for Type A2 sealants.
crosssections shown on the Drawings.
Portland cement concrete shall consist
of a mixture of Portland cement, fine
aggregate, coarse aggregate and water, (b) Cold-Poured Sealants
with or without admixture.
Cold-poured sealants shall comply
with the performance requirements
5.2 MATERIALS for the Normal type of sealant given
in B.S. 5212.
All materials shall conform to the
relevant requirements in Section 9 of The sealant shall be composed of a
this Specification. In addition the curing agent and a base resin, which
following requirements shall also be shall be in such proportions as
complied with. recommended by the manufacturer
to provide a fast cure if the material
5.2.1 Cement is mixed and applied by special
machines, or a retarded cure if mixed
Cement shall be ordinary Portland by hand. It shall cure within 1 hour
cement unless otherwise shown on and remain active for not less than 4
the Drawings or directed by the S.O. hours. The sealant shall be applied
after the curing period of the primer
5.2 2 Aggregate and within the period that the primer
remains active.
Coarse aggregate to be used for at
least the top 50 mm of the slab shall Materials to be mixed and applied by
have a polished stone value of not hand shall be supplied in separate
less than 40. containers and shall be mixed in the
correct proportions using a powered
5.2.3 Joint Filler stirrer or mixer or any other method
The expansion joint filler shall
AASHTO M153 or M213.

FOR INTERNAL USE ONLY (c) Gunning Grade Sealants
Gunning grade sealants consisting of Standard Specification For Road Works
two-part poly-sulphide-based sealing
compounds shall comply with B.S. It shall have test certificates from an
4254. Alternatively, poly-urethane- approved testing laboratory to show
based sealing compounds may be that the compound has a curing
used provided their performance is efficiency of 90%.
not inferior to B.S. 4254 material.
The curing compound shall contain
(d) Preformed Compression Seals sufficient flaked aluminium in finely
divided dispersion to produce
Preformed compression seals shall complete coverage of the sprayed
be made from natural rubber and surface with a metallic finish. The
shall conform to the requirements curing compound shall not react
contained in Table 5.1. chemically with the concrete to be
cured and shall not crack, peel or
5.2.5 Waterproof Membrane disintegrate within 2 weeks after
application.
Plastic sheeting shall have a
minimum thickness of 125 um and
shall be of a quality as approved by
the S.O.
5.2.6 Curing Materials
The exposed surface of concrete

pavements shall be cured
immediately after the surface
treatment by the application of one
of the following curing materials :-
(a) White Pigmented Liquid

Membrane-Forming Compound
White pigmented liquid membrane-

forming compound shall conform to
the requirements of AASHTO
M148, Type 2.
(b) Aluminised Curing Compound
Aluminised curing compound

shall be stable and impervious to
evaporation of water from the
concrete surface within 60
minutes after application.
Page 126
TABLE 5.1 - SPECIFICATION FOR PREFORMED NATURAL RUBBER COMPRESSION

SEALS
Property. Units Requirement
Hardness. IRHD 55 + 5
Tensile Strength, minimum. MPa 15
Elongation at break, minimum. % 400
Compression Set, 24 hours at

o
100 C, maximum. % 40
Ageing Resistance, maximum

change from unaged values after
o
72 hrs + 0 hrs at 100 C :-
- 2 hrs
- hardness IRHD 0 to + 10
- tensile strength % - 20
- elongation at break. % - 25
Ozone Resistance, 20%

elongation, 96 hours at - No cracking
o
140 C, 50 pphm.
Change in Volume after

immersion in water for 7 days at % 0 to + 5
laboratory temperature,
maximum.
Recovery of Finished Seals,

under 50% deflection, after % 85
o
72 hrs + 0 hrs at 100 C.
- 2 hrs
Note : All tests are in accordance with ISO Standards.

FOR INTERNAL USE ONLY 5.3 PRODUCTION OF CONCRETE
5.3.1 Concrete Standard Specification For Road Works
Concrete shall be of the grade shown Prior to the placing of concrete, all
on the Drawings and shall comply of the required joint assemblies such
with the relevant requirements of as dowel bars, tie bars, etc., shall be
Section 9 of this Specification. installed in accordance with the
requirements of Sub-Section 5.5. In
5.3.2 Equipment one-layer construction, the slab
reinforcement shall also be installed
All equipment used such as batching and fixed in accordance with the
plant and mixers shall comply with relevant requirements of Section 9.
the relevant requirements of Section
9 of this Specification. In two-layer construction, the
thickness of the top layer shall be not
less than 50 mm or twice the
5.4 CONSTRUCTION maximum size of the coarse
aggregate, whichever is the greater,
5.4.1 Preparation of Subgrade or Subbase and shall be at least 15 mm thicker
than the depth of the groove former,
Prior to placing concrete pavement, if used. Placement of reinforcement
the underlying subgrade or subbase and concreting of the top layer shall
shall have been shaped and be done immediately, and in any
compacted in accordance with the case not more than 30 minutes, after
provisions of Sub-Sections 2.2.7 or the completion of the bottom layer.
4.1.2 as appropriate and the
waterproof membrane laid as 5.4.2.1 Fixed Forms, Rails and Guide
required in the Drawings. Wires For Machine Construction
Notwithstanding any earlier approval
of finished subgrade or subbase, any (a) Fixed Forms and Rails
damage to or deterioration of the
subgrade or subbase shall be made All forms and rails shall be made
good to the satisfaction of the S.O. of steel and be sufficiently robust
before the waterproof membrane is and rigid to support the weight
laid and the concrete pavement and pressure caused by the
constructed. paving equipment. Side forms
for use with wheeled paving
5.4.2 Construction by Machine machines shall incorporate metal
rails firmly fixed at a constant
The concrete slab shall be height below the top of the forms.
constructed either by fixed form or
by slip form paving plant in a The forms shall be secured by
continuous process in either one or using not less than three pins for
two layers, as approved by the S.O. each 3 m length, having one pin
fixed at each side of every joint.
Forms shall be tightly joined
together by a locked joint, free
from play or movement in any
direction.

FOR INTERNAL USE ONLY immediately before each use.
The rails or running surfaces shall
Forms shall be cleaned and oiled be kept clean in front of the
wheels of any paving machines.
The forms shall be straight within Standard Specification For Road Works
a tolerance of 3 mm in 3 m.
form paving plant. (Each guide
The forms shall be bedded on wire shall be at a constant height
low moisture content cement above and parallel to the required
mortar and set to the pavement edges of the slab within a vertical
surface level as described in the tolerance of ±3 mm. In addition,
Contract within a tolerance of ±3 one of the wires shall be at a con
mm. The bedding shall not stant horizontal distance from the
extend under the slab. There required edge of the pavement
shall be no vertical step between within a lateral tolerance of ±10
the ends of adjacent forms greater mm.
than 3 mm. The horizontal
alignment for forms shall be to The guide wires shall be
the required alignment of the supported from stakes not more
pavement edge as described in than 8 m apart by connectors
the Contract within a tolerance of capable of fine horizontal and
±10 mm. The mortar or vertical adjustment. The guide
concrete bedding shall be broken wire shall be tensioned on the
out after use. stakes so that a 500 gramme
weight shall produce a deflection
Prior to concreting, the forms of not more than 20 mm when
shall be approved by the S.O. suspended at the mid-point
between any pair of stakes. The
Forms shall not be removed ends of the guide wires shall be
earlier than 6 hours after the anchored to fixing points which
completion of the construction of shall be not closer to the edge of
the slab. Care shall be taken to the slab than the row of stakes
prevent damage to the concrete and in no circumstances shall a
and any projecting tie bars during guide wire be anchored to a
the removal of the forms. If the stake.
removal of forms results in any
damage to the concrete the period The stakes and guide wires shall
of 6 hours shall be increased to be checked and approved by the
that which is necessary to avoid S.O. prior to concreting.
further damage and the
Contractor shall make good the 5.4.2.2 Construction by Fixed Form
damaged areas. Paving Machine
b) Guide Wires A fixed form paving train shall

consist of separate powered
Unless otherwise agreed by the machines which spread, compact
S.O., a guide wire shall be and finish the concrete in a
provided along each side of the continuous operation.
slab to be constructed by slip
Concrete shall be discharged
Cawangan Jalan, Ibu Pejabat JKR, K.L without segregation into a hopper
spreader which is equipped with
the means to control its rate of
deposition on to the subbase or
on to the lower layer. . The con
crete shall be spread in each layer
Page 129
FOR INTERNAL USE ONLY uniform uncompacted density
over the whole area of the slab.
without segregation and to a The deposited concrete shall be
struck off to the necessary level
by the underside of the hopper as Standard Specification For Road Works
it is traversed across the
spreading machine. The machine The regulation and finishing of
shall be capable of being rapidly the surface of the slab shall be
adjusted for changes in average carried out by a machine which
and differential surcharge incorporates twin oblique
necessitated by changes in slab oscillating finishing beams which
thickness or crossfall. shall be readily adjustable for
both height and tilt. The beams
Prior to being compacted, the shall weigh not less than 170 kg
surface level of each loose spread per linear metre, be of rectangular
layer shall be adjusted to the section and span the full width of
correct surcharge by means of the slab. The leading beam shall
rotating strike off blades or a be vibrated. The beams shall be
screw device. supported on a carriage, the level
of which shall be controlled by
The concrete shall be compacted the average level of not less than
by vibration or by a combination four points evenly spaced over at
of vibration and mechanical least 3.5 m of the supporting rail,
tamping so as to comply with beam, or slab, on each side of the
Sub-Section 5.3.1 throughout the slab that is being constructed.
full depth of the slab. Poker The final regulation and surface
vibrators shall be used adjacent to finishing of the slab shall be
the side forms and the edge of carried out after any wet forming
previously constructed slabs. of joint grooves. After the final
regulation and before texture is
The initial regulation and finish applied, any excess concrete on
to the surface of the slab shall be top of the groove former shall be
effected by means of a beam removed.
oscillating transversely or
obliquely to the longitudinal axis When a concrete slab is
of the pavement. This beam shall constructed in more than one
be readily adjustable for both width, flanged wheels on the
height and tilt. paving machines shall not be run
directly on the surface of any
Joint grooves shall be constructed completed part of the slab. The
in compliance with Sub-Section second or subsequent slabs shall
5.5. The concrete shall be be constructed either by
recompacted around the former supporting machines with flanged
by a hand held vibrating plate wheels on flat- bottom section
compactor drawn along or on rails weighing not less than 15
each side of the joint, prior to kg/m laid on the surface of the
regulation of the surface by the completed slab, or by replacing
diagonal finishing beam. the flanged wheels on that side of
the machine by smooth flangeless
wheels. Before flangeless wheels
Cawangan Jalan, Ibu Pejabat JKR, K.L or rails are used, the surface
regularity of the slab over which
they are to pass shall comply
with Sub-Section 5.4.1 and its
surface shall be thoroughly
cleaned and brushed to remove
Page 130
FOR INTERNAL USE ONLY wheels or rails shall be positioned
sufficiently far from the edge of
all extraneous matter. Flangeless the slab to avoid damage to that
edge.
5.4.2.3 Construction by Slip Form
Paving Machine guide wires by at least one sensor
attached to the paver. The
A slip form paving train shall alignment and level of ancillary
consist of powered machines machines for finishing, texturing
which spread, compact and finish and curing of the concrete shall
the concrete in a continuous be automatically controlled
operation. relative to the guide wires or to
the surface and edge of the slab.
A slip form paving machine shall
compact the concrete by internal Slip form paving machines shall
vibration and shape it between have vibration of variable output,
sliding side forms or over fixed with a maximum energy output
side forms by means of either a of not less than 2.5 kW per metre
conforming plate or by vibrating of slab per 300 mm depth of slab
and oscillating finishing beams. for a laying speed of up to 1.5 m
per minute or pro rata for higher
The concrete shall be deposited speeds. The machines shall be of
without segregation in front of sufficient mass to provide
the slip form paver across its adequate reaction on the traction
whole width and to a height units to maintain forward
which at all times is in excess of movements during the placing of
the required surcharge. The concrete in all situations.
deposited concrete shall be struck
off to the necessary average and Joint grooves shall be constructed
differential surcharge by means in compliance with Sub-Section
of a strike-off plate or a screw 5.5. The concrete shall be
auger device extending across compacted around the former by
the whole width of the slab. The a separate vibrating plate
equipment for striking off the compactor with twin plates. The
concrete shall be capable of being groove former shall be
rapidly adjusted for changes in compacted to the correct level by
the average and differential sur another vibrating float which may
charge necessitated by changes in be included with the transverse
slab thickness or crossfall. joint finishing beam. In addition
a hand held vibrating float, at
The level of the conforming plate least 1 m wide, shall be drawn
and finishing beams shall be over the surface along the joint.
controlled automatically from the Any excess concrete on top of the
guide wires by sensors attached groove former shall be removed
at the four corners of the slip before the surface is textured.
form paving machine. The Where a concrete surface slab is
alignment of the paver shall be constructed in more than one
controlled automatically from the width or where the edge needs to
be matched for level to another
Cawangan Jalan, Ibu Pejabat JKR, K.L section of surface slab, and the
surface levels at the edges are not
achieved, paving shall be carried
out over separate fixed side forms
supporting the edge to the
required levels.
Page 131
FOR INTERNAL USE ONLY Method
5.4.3 Construction by Hand-Guided Areas to be constructed by hand-

guided method shall be agreed with
the S.O. The slabs shall be Standard Specification For Road Works
constructed in one layer. Dowel
bars, tie bars and reinforcement, if Details of joints shall be as shown on
specified, shall be fitted in position the Drawings. Joint grooves shall be
as shown on the Drawings. constructed in compliance with Sub-
Section 5.5. Any irregularities at wet
The concrete shall be spread formed joint grooves shall be
uniformly without segregation or rectified by means of a vibrating
varying degrees of precompaction, float at least 1.0 m wide drawn
by conveyor, chute or by other along the line of the joint. The
means approved by the S.O. The whole area of the slab shall be
concrete shall be struck off by a regulated by two passes of a
screed so that the average and scraping straight edge not less than
differential surcharge is sufficient to 1.8 m wide or by a further
ensure that after compaction the application of a twin vibrating
surface is to the required level. finishing beam. Any excess concrete
on top of the groove former shall be
The concrete shall be compacted by removed before the surface is
vibrating finishing beams. In textured.
addition, internal poker vibration
shall be used for slabs thicker than The surface shall be brush-textured
200 mm and may be used for lesser as described in Sub-Section 5.6.
thicknesses. When used, the pokers
shall be at points not more than 500 The concrete shall be cured in
mm apart over the whole area of the compliance with Sub-Section 5.8.
slab, and adjacent to the side forms
or the edge of a previously 5.4.4 Manual Construction
constructed slab.
Areas to be constructed by manual
The surface shall be regulated and method shall be agreed with the S.O.
finished to the level of the top of the The slabs shall be constructed in one
forms or adjacent slab or pavement layer. Dowel bars, tie bars and
layer by using twin vibrating reinforcement, if specified, shall be
finishing beams. The beams shall be fixed in position as shown on the
metal with a contact face at least 50 Drawings.
mm wide and a vibrating unit having
a minimum centrifugal force of 4 kN The concrete shall be spread
with a frequency recommended by uniformly without segregation or
the manufacturer or an equivalent varying degrees of pre-compaction,
compactive effort. The vibrating by conveyor, chute or by other
beams shall be moved forward at a means approved by the S.O. The
steady speed of 0.5 m to 1 m per concrete shall be struck off by a
minute whilst vibrating over the screed so that the average and
compacted surface to produce a differential surcharge is sufficient to
smooth finish. ensure that after compaction the
surface is to the required level.
The concrete shall be compacted by
internal poker vibrator or other
means approved by the S.O. The
vibrations shall be at points not more
than 500 mm apart over the whole
Page 132
FOR INTERNAL USE ONLY side forms or the edge of a
previously constructed slab.
area of the slab, and adjacent to the
The surface shall be regulated and
finished to the level of the top of the Standard Specification For Road Works
forms or adjacent slab or pavement
layer by using an approved portable As soon as surplus water has risen to
hand screed. The screed shall be at the surface, the pavement shall be
least 600 mm longer than the width given a broomed finish.
of the slab to be struck off and
compacted. It shall be of approved 5.4.4.1 Side Forms for Manual
shape, sufficiently rigid to retain its Construction
shape and constructed either of metal
or of other material shod with metal. All side forms shall be made of
steel and be sufficiently robust
Compaction shall be attained by and rigid to withstand
raising and dropping the screed in construction forces. Timber
successive positions until the forms shall only be used for work
required compaction and reduction which is less than 200 m in
of surface voids is secured. length.
The screed shall then be placed on The forms shall comply with
the forms and slid along them, with other requirements of Sub-
out lifting, in a combined Section 5.4.2.1 as appropriate.
longitudinal and transverse shearing
motion moving always in the 5.5 JOINTS
direction in which the work is
progressing. If necessary, this shall Joints shall be constructed as specified
be repeated until the surface is of herein and/or as directed or approved by
uniform texture, true to grade and the S.O. Before any joint materials are
contour, and free from porous areas. set in place, the underlying pavement
course at those locations shall have been
After the concrete has been struck approved by the S.O.
off and compacted, it shall be further
smoothed, screeded and compacted Preformed expansion joint filler shall be
by means of a longitudinal hand float placed around each structure which
or other equipment as approved by extends into or through the pavement
the S.O. over the full interface with the concrete
pavement slab before concrete is placed.
Details of joints shall be as shown on
the Drawings. Joint grooves shall be 5.5.1 Transverse Expansion Joints
constructed in compliance with Sub-
Section 5.5. Any irregularities at wet The components for each transverse
formed joint grooves shall be expansion joint shall be assembled in
rectified by suitable means approved advance and placed in position as a
by the S.O. unit.
The concrete shall be cured in Each assembly shall consist of an

compliance with Sub-Section 5.8. installing template, preformed joint
filler of the required dimensions in a
Cawangan Jalan, Ibu Pejabat JKR, K.L single piece, dowel bars and sleeves
of the required sizes and lengths at
the required locations, and spacing
and supporting elements for the
dowel bars, as shown on the
Drawings.
Page 133
FOR INTERNAL USE ONLY metal plate of adequate rigidity
approved by the S.O., cut to the
The installing template shall be required depth and crown of the slab
and having a length 10 mm less than
the required length of the joint. It Standard Specification For Road Works
shall be slotted from the bottom as
necessary to permit removal. Stakes for supporting the installing
Suitable means shall be provided on template shall be of a cross-section
the template for facilitating its and length satisfactory to the S.O.
removal.
5.5.2 Transverse Contraction Joints
One half length of each dowel bar
shall be thoroughly coated with a Transverse contraction joints shall
200 pen bitumen blended with consist of planes of weakness created
creosote oil or other material as by forming or cutting grooves in the
approved by the S.O. A dowel surface of the pavement and, when
sleeve shall be fitted on to the coated shown on the Drawings, shall
end of each dowel. include load transfer dowel bar
assemblies.
The dowel supports shall be
constructed so as to hold dowels in 5.5.2.1 Planes of Weakness
correct alignment, both vertically and
horizontally, subject to a tolerance of (a) Sawn Grooves
not more than 1 in 100.
When sawn grooves are specified
When assembled, the top of the they shall be sawn in the con
installing template shall be about 5 crete after its initial set.
mm above the top of the preformed
filler. The filler shall be vertical and Grooves shall be at right angles
shall be in a plane at right angles to to the centre line of the
the centre line of the road, subject to pavement, shall be true to line
a tolerance of not more than 1 in and shall have the width and
500. depth shown on the Drawings.
The joint assembly shall be placed so All joints shall be sawn before
that the installing template is on the uncontrolled shrinkage cracking
side of the filler remote from pouring takes place but not until the
operations. The top of the filler shall concrete has hardened to the
be 10 mm below the required con extent that tearing and ravelling is
crete surface, and the bottom shall not excessive, usually 4 to 24
rest on or extend slightly into the hours after placing. If extreme
underlying pavement course. The conditions exist which make it
assembly and its installation shall impracticable to prevent erratic
have been approved by the S.O. cracking by early sawing, formed
before any concrete is placed against grooves shall be used.
it.
Any procedure for sawing joints
that results in premature and
uncontrolled cracking shall be
revised immediately by adjusting
Cawangan Jalan, Ibu Pejabat JKR, K.L the sequence of cutting the joints
or the time interval involved
between the placing of the con
crete or the removal of the curing
medium and cutting of the joints.
Page 134
When formed grooves are
(b) Formed Grooves specified, they shall be made
by depressing an approved
tool or device into the soft, Standard Specification For Road Works
freshly laid concrete. The
tool or device shall remain in When adjacent lanes of pavement
place until the concrete has are constructed separately, steel side
attained its initial set and then forms shall be used which will form
be removed without a key along the longitudinal joint as
disturbing the adjacent shown on the Drawings.
concrete. The line, width and
depth shall be as shown on 5.5.4 Transverse Construction Joints
the Drawings.
Concreting operations shall be
5.5.2.2 Load Transfer Assemblies planned such that transverse
construction joints shall be
Load transfer assemblies for constructed at designed transverse
transverse contraction joints expansion or contraction joints.
shall be as shown on the
Drawings. They shall be of Transverse construction joints shall
similar construction to the be keyed or butt joints formed by
assemblies for transverse placing suitable bulkheads approved
expansion joints except that by the S.O.
no joint filler shall be
required and, consequently, no When there is an interruption of
installing template shall be more than 30 minutes in the
used. concreting operations, a transverse
construction joint shall be
5.5.3 Longitudinal Joints constructed. As far as is practicable,
this construction joint shall be
Longitudinal joints shall be formed at a designed transverse
constructed as shown on the expansion or contraction joint.
Drawings.
When this is not possible, transverse
Planes of weakness shall be created construction joints shall be
by forming or cutting grooves as constructed at least 3 metres from all
previously specified. transverse expansion or contraction
joints. In such cases, tie bars 12 mm
Tie bars across a longitudinal joint in diameter and 1 metre long at 600
shall be placed perpendicular to the mm centres shall be placed at the
joint and shall be rigidly supported transverse construction joints. Wire
as shown on the Drawings. The bars fabric or bar mat reinforcement shall
shall not be painted or coated with extend across all such transverse
bitumen or other material. construction joints.
5.5.5 Sealing Joints
Joints shall be sealed as soon after

completion of the curing period as
Cawangan Jalan, Ibu Pejabat JKR, K.L feasible and before the pavement is
opened to traffic, including
construction traffic. Immediately
prior to sealing, each joint shall be
thoroughly cleaned of all foreign
material, including membrane curing
Page 135
FOR INTERNAL USE ONLY be clean and surface dry when the
seal is applied.
compound, and the joint faces shall
The sealing material shall be applied
in accordance with the dimensions Standard Specification For Road Works
shown on the Drawings or as
directed by the S.O. units and power to complete the
sawing with a water-cooled diamond
Sealing material to be applied hot edge saw blade, or an abrasive
shall be stirred during heating so that wheel, to the required dimensions
localized overheating does not occur. and at the required rate. The
The pouring shall be done in such a Contractor shall provide at least one
manner that the material will not be stand-by saw in good working order.
spilled on to the exposed surfaces of An ample supply of saw blades shall
the concrete. Any excess material on be maintained at the site of the work
the surface of the concrete pavement at all times during sawing operations.
shall be removed immediately and The Contractor shall provide
the pavement surface cleaned. The adequate artificial lighting facilities
use of sand or similar material as a for night sawing. All of this
cover for the seal will not be equipment shall be on the job before
permitted. and continuously during concrete
placement.
Preformed compression seals for
sealing joints shall be of the cross- 5.6 SURFACE TEXTURE
sectional dimensions shown on the
Drawings. Seals shall be installed 5.6.1 Texture of Running Surfaces
using suitable tools, without
elongation, and secured in place with After the final regulation and before
an approved adhesive which shall the application of the curing
cover both sides of the concrete membrane, the surfaces of concrete
joints. The seals shall be installed in slabs to be used as running surfaces
a compressed condition and shall at shall be brush-textured in a direction
time of placement be below the level at right angles to the centre line of
of the pavement surface by the carriageway.
approximately 5 mm. The seals
shall be in one piece for the full The type of brush and method of
width of each transverse joint. application for surface texturing shall
be approved by the S.O. based on
Notwithstanding the above, all trial brushing to be conducted by the
sealants shall be applied or installed Contractor.
in accordance with the
manufacturer's instructions or The texture depth shall be
recommendations. determined by the sand patch test as
described herein.
5.5.6 Concrete Saw
The average texture depth for each
When sawing of joints is specified, set of 10 tests shall not be less than
the Contractor shall provide sawing 0.75 mm and not more than one test
equipment adequate in number of of each set shall show a texture depth
of less than 0.65 mm. In no case
Cawangan Jalan, Ibu Pejabat JKR, K.L shall the maximum texture depth
exceed 2 mm.
Page 136
FOR INTERNAL USE ONLY Sand Patch Method
5.6.2 Measurement of Texture Depth : 5.6.2.1 Apparatus

i) A cylindrical container - 25 Standard Specification For Road Works
ml capacity.
31000 where D is the diameter of the of the
ii) A flat wooden disc 64 mm in D x D patch in mm.
diameter with a hard rubber
disc, 1.5 mm thick, stuck to 5.7 ROUNDING OF EDGES
one face, the reverse face
being provided with a handle. Where shown on the Drawings or
directed by the S.O., edges of concrete
iii) Dry natural sand passing a slabs shall be rounded as follows.
300 um B.S. sieve and
retained on a 150 um B.S. After brush texturing but before the
sieve. concrete has attained its initial set, top
edges of concrete slabs shall be worked
5.6.2.2 Method with an approved tool and rounded to
a radius of 5 mm. A well defined and
The surface to be measured shall continuous rounded edge shall be
be dried, any extraneous mortar produced and a smooth, dense mortar
and/or loose material removed, finish obtained.
and the surface swept clean using
a wire brush both at right angles At all transverse joints, any tool marks a
and parallel to the centre line of ppearing on the slab adjacent to the
the carriageway. The cylinder joints shall be eliminated by brooming
shall be filled with the sand, the surface. In doing this, the rounding
tapping the base three times on a of the edge of the slab shall not be
hard surface to ensure disturbed. All concrete on top of joints
compaction, and striking off the shall be removed completely.
sand, level with the top of the
cylinder. The sand shall be 5.8 CURING
poured into a heap on the surface
to be tested. The sand shall be The exposed surfaces of concrete
spread over the surface, working pavement shall be cured immediately
the disc with its face kept flat, in after surface texturing and rounding of
a circular motion so that the sand edges by treating with a curing
is spread into a circular patch compound fulfilling the requirements of
with the surface depressions Sub-Section 5.2.6. It shall be
filled with sand to the level of the mechanically sprayed on to the surface
peaks. at a rate of 0.22 to 0.27 litre per square
metre using a fine spray. The
The diameter of the patch shall mechanical sprayer shall incorporate an
be measured to the nearest 5 mm. efficient mechanical device for
The texture depth in mm of continuous agitation and mixing of the
concrete surfaces shall be compound in its container during
calculated as:- spraying. For the sides of slip formed
slabs or when the side forms are
removed within the curing period, and
Cawangan Jalan, Ibu Pejabat JKR, K.L for small areas where a mechanical
distributor cannot be used, the
compound shall be sprayed by hand
lance at a rate of 0.27 to 0.36 litre per
square metre.
Page 137
FOR INTERNAL USE ONLY continuous, coherent film that shall not
crack or peel and shall be free from pin
The compound shall form a uniform, holes or other imperfections. If
discontinuities, pin holes or abrasions
exist, an additional coat shall be applied Standard Specification For Road Works
within 30 minutes to the affected areas.
Necessary precautions shall be taken to In addition, the entire surface shall be
ensure proper curing at the joints and protected from the effects of solar
that none of the curing compound enters radiation by the use of frames
joints which are to be sealed with joint covered with material with heat and
sealing compounds. Rope of moistened rain deflecting properties for not less
paper, fibre or other suitable material than 4 hours after application of the
shall be used to seal the top of the joint curing compound.
opening, and the concrete in the region
of the joint shall be sprayed with curing Notwithstanding the foregoing, concrete
compound immediately after the rope surfaces which are subjected to heavy
seal has been installed. rainfall within 3 hours after the curing
compound has been applied shall be
Approved stand-by facilities or resprayed, all as specified above at no
approved alternative methods for curing additional cost.
concrete pavement shall be provided at a
readily accessible location at the site of Concrete liable to be affected by running
the work for use in the event of water shall be adequately protected from
mechanical failure of the spraying damage during the setting period.
equipment or any other conditions
which may prevent correct application
of the membrane curing compound at 5.9 REMOVING FORMS
the proper time. In the event of a failure
of the regular spraying equipment, the Forms shall not be removed until the
paving operation shall be stopped, and freshly placed concrete has set for at
the stand-by or alternative curing least 6 hours. The forms shall be
method shall be used on the remaining removed carefully so as to avoid
portion of the paving already placed. damage to the pavement.
Concrete surfaces to which membrane As soon as forms are removed, the ends
curing compounds have been applied of all expansion joints shall be cleaned
shall be adequately protected for the of concrete and the full width of the
duration of the entire curing period from filler exposed for the full depth of the
pedestrian and vehicular traffic, except slab. Any areas showing a minor degree
as required for joint sawing operations of honeycombing shall be repaired with
and surface tests, and from any other 1:3 cement mortar. Where the S.O.
cause which will disrupt the continuity considers that a major degree of
of the membrane. The curing honeycombing is present, the work shall
membrane so formed shall be be considered defective and shall be
maintained intact for a period of not removed and replaced at the expense of
less than fourteen (14) days. the Contractor. In such cases, the
section of concrete removed shall be to
the full width and depth of the slab and
at least 3 metres long.
Page 138
No pavement shall be opened to any
5.10 OPENING TO TRAFFIC traffic earlier than twenty-eight (28)
days from the completion of concreting.
The Contractor shall erect and maintain
suitable barricades and shall employ fixed to the slab edges so exposed. This
watchmen to exclude public traffic and shall be to the full depth of the slab
that of his employees and agents from allowing for the depth of the groove
the newly constructed pavement. required for sealing. Alternatively, the
recesses may be sawn out after the con
These barriers shall be arranged so as crete has hardened.
not to interfere with public traffic on any
lane intended to be kept open and Reinforcement shall be placed as shown
necessary signs and lights shall be on the Drawings and concrete placed by
maintained by the Contractor clearly hand in the space between the main slab
indicating any lanes open to traffic. and the manhole or gully frame. This
concrete shall be of the same grade as
Where, as shown on the Drawings, it is that of the main slab, and the mix shall
necessary to provide for traffic across be modified as necessary to permit full
the pavement, the Contractor shall, at his compaction by the methods adopted.
own expense, construct suitable and
substantial crossings to bridge the newly 5.12 HORIZONTAL ALIGNMENTS,
constructed concrete pavement for as SURFACE LEVELS AND
long as the S.O. shall direct. SURFACE REGULARITY
Any part of the pavement damaged by The alignment, levels and regularity of
traffic or other cause prior to its final the finished surface shall be in
acceptance shall be repaired or replaced compliance with Sub-Section 4.4 of this
all at the expense of the Contractor in a Specification.
manner suitably satisfactory to the S.O.
5.11 TREATMENT OF MANHOLES

AND GULLIES
Manhole covers, gullies and their frames

shall be isolated from the main
pavement slab as shown on the
Drawings and their surrounds cast in
separate operations.
Manholes and gully recesses shall be

formed by casting the main slab against
formwork boxes with vertical sides,
placed and fixed accurately. The
formwork boxes shall be removed
before the concrete around the manhole
or gully cover is to be placed and
preformed joint filler, 20 mm thick,
Page 139
SECTION 6
ROADSIDE FURNITURE

SECTION 6 - ROAD FURNITURE
Page
6.1 CORRUGATED SHEET STEEL BEAM HIGHWAY GUARDRAIL S6-143


6.1.2.1 Beam Element S6-143
6.1.2.2 Posts S6-143
6.1.3 Installation of Guardrails S6-144

6.1.3.1 Setting Posts (Timber or Steel) S6-144
6.1.3.2 Placing Beams S6-144
6.1.3.3 Anchorages S6-144
6.1.4 Marking and Storage S6-144

6.1.4.1 Marking S6-144
6.1.4.2 Storage S6-144
6.1.5 Basis of Acceptance S6-144

6.1.5.1 Beam Elements S6-144
6.1.5.2 Posts and Block-Outs S6-145
6.2 TRAFFIC SIGNS S6-145
6.2.2 Sign Definitions S6-145
6.2.3 Sign Classification S6-145
6.2.4 Standards S6-146
6.2.5 Permanent Traffic Signs S6-146

6.2.5.1 General Requirements S6-146
6.2.5.2 Foundations S6-146
6.2.5.3 Posts S6-147
6.2.5.4 Sign Plate S6-147
6.2.5.5 Sign Faces S6-148
6.2.5.6 Backing Frames S6-149
6.2.5.7 Construction and Assembly S6-149
6.2.5.8 Location and Erection S6-151
6.2.5.9 Covering of Permanent Traffic Signs S6-151

Page
6.2.6 Temporary Traffic Signs S6-152
6.2.7 Traffic Signs On Gantries S6-152
6.2.8 Preparation and Finish of Metal and Other Surfaces S6-152

6.3 ROAD MARKINGS S6-153
6.3.2 Road Marking Materials S6-153
6.3.3 Preparation of Site S6-153
6.3.4 Preparation of Material on Site S6-154
6.3.5 Laying S6-154
6.3.6 Protection of Markings S6-154
6.3.7 Reflectorisation S6-154
6.3.8 Thickness S6-154
6.3.9 Tolerance on Width S6-156
6.3.10 Defective Materials or Workmanship S6-156
6.3.11 Clearing Up S6-156
6.4 CONCRETE KERB S6-157
6.4.3 Installation of Kerbs S6-157

6.4.3.2 Cast In Situ Kerb S6-157
6.4.3.3 Precast Concrete Kerb S6-157
6.4.3.4 Slipforming for Concrete Kerb S6-158

FOR INTERNAL USE ONLY other ancillary works, all in
accordance with this Specification,
and the Drawings, and as directed by
SECTION 6 - ROAD FURNITURE the S.O.
6.1.2 Materials
6.1 CORRUGATED SHEET STEEL
BEAM HIGHWAY GUARDRAIL
6.1.2.1 Beam Element
6.1.1 Description
Unless otherwise specified on the
This work shall comprise the supply Drawings, corrugated sheet steel
and installation of corrugated sheet beam highway guardrails shall
steel beam highway guardrails conform to the requirements of
inclusive of bolts, nuts, posts and AASHTO Specification M180
for Class À' Type II (galvanised)
guardrail with effective length of Standard Specification For Road Works
beam 3810 mm (12 feet 6
inches). Guardrails shall be if used, shall be channel sections
fabricated and furnished complete of dimensions as shown on the
with terminal or buffer sections, Drawings and shall be of the
connecting and splicing bolts, same material as that used for the
nuts and washers, etc., all posts. Both the posts and block-
conforming to the requirements out pieces shall be hot-dip
of AASHTO Specification M180 galvanised in accordance with
and as necessary for erecting the Sub-Section 6.1.2.1.
guardrails as shown on the
Drawings or as required by the (b) Timber Posts
S.O.
Timber posts and block-out
6.1.2.2 Posts pieces shall be of medium
hardwood (except the species
(a) Steel Posts Merpauh and Rengas) as
classified by the Malaysian
Steel posts shall be channel Timber Industry Board in its
sections of dimensions as shown publication `Malaysian
on the Drawings and the material Hardwood', and shall be treated
shall conform to B.S. 449 Part 1 according to M.S. 733. The
Grade 43. The block-out pieces, preservative retention in the
outermost 25 mm shall not be
Cawangan Jalan, Ibu Pejabat JKR, K.L less than 16 kg per cubic metre.
Heavy hardwood can also be
used as an alternative with the
Guardrail timber posts and block-

out pieces shall be of the
dimensions as shown on the
Drawings. The fibres of the block
should run in the same direction
as those of the post. The post
shall be sound and free from
loose knots or decay with no
cracks at the top. All cut faces
shall be smooth and square as
All timber components shall be

cut and drilled before treatment
with preservative.
Page 143
6.1.3.1 Setting Posts (Timber or Steel)
6.1.3 Installation of Guardrails
Before posts are erected, the
alignment and finished levels of Standard Specification For Road Works
the guardrails shall be set
accurately on site for approval by 6.1.4 Marking and Storage
the S.O.
6.1.4.1 Marking
Post holes at the correct positions
shall be dug either manually or In addition to the marking
mechanically to the required specified in AASHTO
level. The posts shall then be set Specification M180, the JKR
plumb in the holes with the front logo shall also be marked on each
face forming a smooth line to the beam element.
approval of the S.O. After the
posts are in place, the holes shall 6.1.4.2 Storage
be backfilled with grade 20/20
concrete compacted in such a All galvanised beam elements,
manner as not to displace the terminal sections, bolts, nuts and
posts from correct alignment as washers and posts shall be stored
shown on the Drawings. Posts under a cover that will protect
may be installed by means of them from rain until they are
driving with suitable equipment if erected or used. While in
the S.O. is satisfied that the storage, the material shall not be
Contractor is capable of installing in direct contact with the soil and
the post to the designed depth, there shall be a minimum space
line and level, accurately. of 300 mm between the lowest
most elements and the ground
Posts shall be spaced as indicated surface.
on the Drawings.
6.1.5 Basis of Acceptance
6.1.3.2 Placing Beams
6.1.5.1 Beam Elements
The guardrail beams shall be
fixed and firmly bolted together All material shall be subjected to
with the block-out pieces on to inspection and sampling in
the post to the lines and grades as accordance with AASHTO
shown on the Drawings, and as Specification M180 at a sampling
directed by the S.O. rate of 1 in every 200 or as
6.1.3.3 Anchorages
Anchorages shall be constructed arrange the testing facilities and
as shown on the Drawings and as the test pieces as and when
directed by the S.O. requested by the S.O. The cost of
all sampling and testing shall be
borne by the Contractor. If, in
the subsequent installation, there
is detection of non-compliance
Cawangan Jalan, Ibu Pejabat JKR, K.L with the requirements of this
Specification through random
sampling carried out by the S.O.,
then the material of the lot will be
rejected and the Contractor shall
remove the same from the Site at
his own cost.
Page 144
(a) Steel
6.1.5.2 Posts and Block-Outs
For each lot of 200 pieces or less
of either steel posts or steel Standard Specification For Road Works
block-outs supplied to the Site,
the Contractor shall submit It shall include all excavation and
certificates from an approved backfilling, all necessary
testing laboratory certifying foundations, anchorages, fixtures
compliance with the properties and fastenings, brackets, lighting
required and the mill certificate. units and electrical installations
However, the S.O. reserves the where required, application of paints
right to conduct further tests on and finishes, etc., to complete the
the materials supplied. work all to the satisfaction of the
S.O.
arrange the testing facilities and 6.2.2 Sign Definitions
test samples at his own expense
as and when instructed by the For the purpose of this Specification,
S.O. The steel which has been traffic signs are defined as follows :-
rejected by the S.O. shall be
removed from the Site. i) Non-illuminated signs are those
signs which are not lit either
internally or externally and shall
(b) Timber be retro-reflective;
For each lot of 200 pieces or ii) Externally illuminated signs are
less of either timber posts or those which comprise either
timber block-outs supplied to the retro-reflective or non-retro-
Site, the Contractor shall submit reflective facing with external
a test report from an approved lighting luminaire.
testing laboratory certifying
compliance with specified timber 6.2.3 Sign Classification
species and other qualities.
However, the S.O. reserves the For the purpose of this Specification,
right to conduct further tests on the following clasifications shall
the materials supplied. apply :-
6.2 TRAFFIC SIGNS (a) Permanent Traffic Signs
Any of the traffic signs defined in

6.2.1 Description Sub-Section 6.2.2 above or any part
thereof as designated on the
This work shall consist of the supply, Drawings or as directed by the S.O.
assembly, erection and installation to remain in position upon
of sign faces, sign plates, posts and completion of the Works.
backing frames, all in accordance
with the details shown on the (b) Temporary Traffic Signs
Drawings and as specified herein.
Any of the traffic signs defined in
Cawangan Jalan, Ibu Pejabat JKR, K.L Sub-Section 6.2.2 above or any part
thereof designed by the Contractor
with the approval of the S.O. which
will not remain in position at the
completion of the Works.
Page 145
All traffic signs shall, except where
6.2.4 Standards specified otherwise, comply with the
requirements of ARAHAN TEKNIK
(JALAN) Series 2, published by Standard Specification For Road Works
Cawangan Jalan, Ibu Pejabat JKR,
Kuala Lumpur. transported and stored in
accordance with the
6.2.5 Permanent Traffic Signs manufacturer's instructions.
6.2.5.1 General Requirements 6.2.5.2 Foundations
Permanent traffic signs shall be The type and size of foundations

constructed, assembled, located for permanent traffic signs shall
and erected as shown on the be as shown on the Drawings
Drawings or as directed by the and, unless otherwise stated
S.O. therein, shall comply with this
Specification.
Each complete traffic sign or part
thereof shall be capable of All excavations, erection of
passing the tests specified in B.S. formworks, placing of
873. reinforcement, etc., for
foundations shall be carried out in
All externally illuminated traffic compliance with this
signs shall comply with Category Specification and shall be
1 luminance of B.S. 873 unless approved by the S.O. before
otherwise shown on the placing of concrete and
Drawings. backfilling.
Before the commencement of Unless otherwise shown on the

fabrication of any traffic sign, Drawings, signs supported by a
unless otherwise shown on the single post placed in the ground
Drawings, the Contractor shall shall have the post installed
submit for the S.O.'s approval centrally in 300 mm diameter
the details of fabrication drawings holes filled with grade 20/20
for all signs. concrete complying with Section
9 of this Specification to within
All traffic sign housings shall be 450 mm of the ground surface.
provided with vandal and The hole shall be excavated
weather resistant locks. Keys, in either mechanically or manually.
the quantities determined by the
S.O., shall be provided to the Posts shall be supported for a
S.O. Types of lock shall be kept minimum of three (3) days after
to a minimum. placing the concrete. Backfilling
shall not take place until at least
Traffic signs shall be carefully 48 hours after placing the
handled to prevent damage concrete, or other period agreed
(methods shall include the use of by the S.O.
proper slings), and shall be
Where signs are illuminated,
Cawangan Jalan, Ibu Pejabat JKR, K.L provision shall be made for cable
entry through the foundation by
means of ducting as shown on
the Drawings.
Page 146
FOR INTERNAL USE ONLY concrete foundations their plan
dimensions shall be 100 mm
Where pockets are formed in larger than those of the post.
All backfilling of foundation pits Standard Specification For Road Works
and reinstatement of existing
surfaces above the foundations 6.2.5.4 Sign Plates
shall comply with the relevant
requirements of this All permanent sign plates shall be
Specification. as shown on the Drawings and
shall comply with B.S. 873.
6.2.5.3 Posts Sign plates shall be made of 10
S.W.G. sheets of aluminium alloy
Posts for permanent traffic signs HS 30-WP conforming to B.S.
shall be as shown on the 1470 with a minimum thickness
Drawings and shall comply with of 3 mm.
B.S. 873.
A sign plate not exceeding 1.2 m
Posts shall be of tubular hollow in height and 2.4 m in width
section steel of not less than 50 shall be made from a single sheet.
mm outside diameter complying
with B.S. 1387. Where more than one sheet is
used to make up a sign plate, the
Unless otherwise shown on the sheets shall be rectangular, of
Drawings, posts shall not approximately the same size and
protrude above the top of the sign shape, and the position of the
unless supporting an external joints shall be to the approval of
luminaire where the protrusion the S.O.
shall be kept to a minimum.
Sign plates shall be drilled at all
Signs erected on a single post locations where rivets or bolts are
shall be positioned so that the required for attaching the plate to
post is in the centre of the sign, the backing frame or fixings
unless otherwise shown on the before application of the sign
Drawings. face. However, riveting shall be
carried out only after the
Compartments for electrical application of the sign face.
equipment shall be as shown on
the Drawings. In the case of signs Subject to the S.O.'s approval,
supported by more than one post, double sided "Very High Bond"
such compartments shall be on (V.H.B.) tapes may be used as an
the post furthest from the alternative to rivets. Nevertheless,
carriageway unless otherwise the tape shall comply with the
directed by the S.O. following requirements :-
Flange plates shall have holes or i) Peel Adhesion - 440 N per

slots as shown on the Drawings 100 mm;
to accommodate any holding
down bolts. ii) Tensile Adhesion - 910 kPa;
Cawangan Jalan, Ibu Pejabat JKR, K.L iii) Dynamic Shear -550 kPa.
Page 147
FOR INTERNAL USE ONLY screens are required as shown on
the Drawings, these shall extend
Where top and bottom light spill for the whole width of the sign,
be fabricated out of the same
material as the sign plate and Standard Specification For Road Works
shall have corners cut to the same
radius as the other corners of the Only vertical and horizontal
sign plate. joints shall be permitted and all
joints in plastic sheeting shall be
Top and bottom light spill screens overlapped by not less than 6
shall be considered part of the mm. The overlap in the
sign plate and any stiffeners and horizontal joints shall be from the
mounting fittings shall be top and the vertical joints shall be
designed to accommodate the from the left; butt joints in plastic
combined size. sheeting will not be accepted.
Plastic sheeting shall be applied
6.2.5.5 Sign Faces evenly over the whole surface of
the sign plate and shall adhere
Sign faces for permanent traffic fully. It shall be free from twists,
signs shall be as shown on the cracks, folds or cuts, air bubbles
Drawings and shall comply with and other blemishes.
the `Draft Malaysian Standard
Specification for Reflective Sign All plastic sheetings used on the
Face Materials' (SIRIM same sign shall be carefully
Reference D111 [ISCF]), and on matched for colour to produce a
replacement of this draft, the uniform appearance both by day
respective Malaysian Standard and by night. Non-uniform
Specification. shades of colour on any one sign
will not be accepted.
All retro-reflective plastic
sheeting shall be fixed in The edges of all plastic sheeting
accordance with the shall be sealed. Edge sealing shall
manufacturer's instructions. be continuous and uniform and
shall also be applied to all bolt
Unless otherwise agreed by the and rivet holes.
S.O., sign faces shall be formed
from a single piece of plastic A coat of clear lacquer shall be
sheeting. applied to the whole of the face
and edges of each finished sign
Where, with the agreement of the plate at the time of fabrication.
S.O., more than one plastic sheet The lacquer shall be continuous
is used, the number of sheets and uniform and shall be of the
shall be kept to a minimum. All type specified or supplied by the
faces up to 1 m in size shall be manufacturer of the sheeting
produced with a single sheet and material.
no joint will be accepted.
Where sheeting is applied to
extruded sections by pressure
roller, it shall extend over the top
and bottom edges of these
Cawangan Jalan, Ibu Pejabat JKR, K.L sections by not less than 3 mm.
Page 148
FOR INTERNAL USE ONLY symbols and borders shall be of
material compatible with the
Any cut-out letters, numerals, sheeting to which they are
applied. They shall be applied in
accordance with the sheeting Standard Specification For Road Works
manufacturer's instructions.
fabricated from 40 mm x 40 mm
Screen processed letters, x 3 mm angles. The angles used
numerals, symbols and borders for the backing frames shall be
shall be screen printed with made from aluminium alloy
materials in accordance with the HE9-TE conforming to B.S.
sheeting manufacturer's 1474.
instructions. Any inks, pastes and
finishing coats used shall be The angles shall be welded,
compatible with the sheeting bolted or riveted together to form
material. the backing frames as shown on
the Drawings.
The finish of all sign faces shall
be capable of passing the tests Backing frames shall not project
described in B.S. 873, and the beyond the face of the sign.
standards of fabrication and
workmanship shall be such that Where large signs are built in
under normal conditions of sections, the backing frames of
service and proper maintenance, these sections shall be bolted
the sign faces shall last not less together with 8 m diameter bolts
than 5 years without any serious at not more than 200 mm
blemishes or defects for centres.
Engineering Grade retro-
reflective sheeting and 8 years The details of joints between
for High Intensity retro-reflective angles of the backing frame and
sheeting. The Contractor shall of joints between sections of
furnish to the S.O. a letter of large signs shall be to the
warranty for the specified period approval of the S.O.
for all sign faces from the
supplier of the sheeting or the The sign plate shall be riveted or
sign fabricator. bonded with double sided V.H.B.
tape to the backing frame after
6.2.5.6 Backing Frames the application of the sign face.
Backing frames for permanent 6.2.5.7 Construction and Assembly

traffic signs shall be as shown on
the Drawings and shall comply Traffic signs shall be constructed
with this Specification. and assembled as shown on the
Drawings and shall comply with
Signs exceeding 600 mm in B.S. 873.
height or width shall be stiffened
by means of angles while signs All sign plates, backing frames,
exceeding 1 m in height or width purlins, posts and other
shall have a backing frame components shall be de-burred
prior to assembly.
Where framing and stiffening are
not an integral part of the sign
plate, their joints shall be welded
or joined with suitable brackets
utilising nuts, bolts and washers.
Page 149
FOR INTERNAL USE ONLY shall be attached to each vertical
member of the backing frame and
Where purlins are adopted, they the sign stiffening and framing
shall be continuous in the vertical
direction. Unless otherwise Standard Specification For Road Works
permitted by the S.O., purlins
shall be spaced equally apart. before final installation and they
Connections shall be made at and their anchorages shall be
every point where a purlin installed so as to achieve the
crosses a post. loadings, torque settings and
requirements shown on the
Where purlins are not adopted, Drawings.
the sign stiffening and framing
shall be continuous in the Sign plates shall be connected to
horizontal direction. posts by a method approved by
the S.O.
All rivets and other devices used
in the fixing of sign plates to their Banding systems shall be of
stiffeners or backing frames, or stainless steel.
those used in the construction of
housings, shall be of a material Where ferrous components are
compatible with the materials permitted, any drilling of such
being joined. components shall be completed
before the application of any
Spacing of rivets or other devices finish.
used in the fixing of sign plates to
their stiffeners or backing frames Any hole drilled to accommodate
shall be uniform and shall not rivets or bolts in plates with
exceed 150 mm around the plastic sheeting shall,
outside edge of any sheet or immediately prior to the
section of a sheet, and shall not insertion of the rivet or bolt,
exceed 300 mm on cross braces. have a clear lacquer, as
Hollow rivets shall be filled with recommended by the
a plastic plug flush with the head manufacturer of the plastic
of the rivet. sheeting, applied to its edge to
prevent the ingress of moisture.
An additional washer of The surfaces of rivets or bolts
neoprene, nylon or other material exposed on the sign face shall be
approved by the S.O. shall be coloured by a material approved
used against the sign face to by the S.O. to match that part of
protect it from the effects of any the face.
metal nuts, bolts, washers and/or
screws. Traffic signs to be erected on
road lighting columns shall have
Where traffic signs, including fixings compatible with the
external lighting luminaires or column cross-section and finish.
their supports, are required to Unless otherwise permitted by
have holding down bolt fixings, the S.O., columns shall not be
the bolts shall be lightly greased drilled and wiring shall be
contained in approved external
Cawangan Jalan, Ibu Pejabat JKR, K.L conduits.
In addition to the requirements of

this Specification, variable
message traffic signs shall be of a
type approved by the relevant
authorities.
Page 150
The approximate location of each
6.2.5.8 Location and Erection permanent traffic sign shall be as
shown on the Drawings. All
traffic signs shall have their exact Standard Specification For Road Works
location determined by the S.O.
and recorded on the as-built 6.2.5.9 Covering of Permanent Traffic
Drawings. Signs
All posts shall be erected plumb Where it is required in the

and where two or more posts are Contract that permanent traffic
provided for any one sign, the signs are to be blanked-out or are
face of the posts shall be lined up. to have an alternative message,
the covering to be adopted shall
Signs erected on two posts shall comply with the following
have each post positioned so that requirements.
the distance from the centre of
the post to the edge of the sign The covering shall be 1.5 mm
plate is 300 mm unless (16 S.W.G.) thick made from a
otherwise directed by the S.O. material compatible with that of
the sign plate, or a material
Any pockets formed in concrete approved by the S.O.
foundations to receive the posts
shall immediately prior to Cover plates shall be fixed by
erection be cleaned out. The posts means of 5 mm diameter stain
shall be placed centrally in the less steel bolts, washers and nuts
pockets and be bedded on and or non-ferrous rivets not more
filled up to finished foundation than 600 mm apart, the bolts
level with grade 20/20 concrete. passing through 12 mm
diameter, 5 mm thick plastic
Traffic signs mounted on posts, distance pieces between the sign
except those on gantries, shall be face and cover plate. Any holes
erected to have their faces plumb remaining in the finished sign
and orientated in relation to the face shall be filled with blocked
carriageway in accordance with rivets coloured on the face by
ARAHAN TEKNIK (JALAN) methods approved by the S.O.
2B/85.
Where self-adhesive plastic film
Traffic signs mounted on gantries is used, it shall be compatible
shall be erected as shown on the with the sign face materials and
Drawings. be applied and removed in
compliance with the
No traffic sign shall be manufacturer's instructions.
dismantled, resited or removed
without prior approval from the Any loose covering used must be
S.O. sufficiently opaque to prevent
reflection from the covered sign
and be securely fastened to the
back of the sign. Under no
circumstances shall tape or other
Cawangan Jalan, Ibu Pejabat JKR, K.L adhesive material be applied to
the face of the sign. A minimum
space of 50 mm shall be left
between the covering and the
face to permit airflow over the
sign.
Page 151
FOR INTERNAL USE ONLY covered shall not be erected on
trafficked highways without the
Traffic signs which are to be covering in place.
Removal of any covering shall be Standard Specification For Road Works
carried out with minimum
disturbance to traffic and only 6.2.7 Traffic Signs On Gantries
after the S.O. has given his
approval. Where traffic signs are erected on
gantries, the signs shall comply with
Irrespective of any requirement in the relevant requirements of this
the Contract to cover signs, any Specification.
traffic sign erected at such a time
that its legend does not relate Fabrication and construction of
either wholly or in part to the gantries shall be as shown on the
traffic movement and route in Drawings and as directed by the S.O.
operation, shall have its sign face
securely covered with one of the
materials described above until 6.2.8 Preparation and Finish
such time as the S.O. authorises of Metal and Other Surfaces
its removal.
Traffic signs shall be prepared,
6.2.6 Temporary Traffic Signs protected against corrosion and
finished in compliance with B.S.
Temporary traffic signs shall be 873.
constructed either as non-illuminated
or externally illuminated signs as Faces of sign plates shall be prepared
directed by the S.O.Location and to receive sign face materials in
erection of temporary traffic signs compliance with B.S. 873 and in
shall be in accordance with accordance with the manufacturer's
ARAHAN TEKNIK (JALAN) recommendations.
2C/85. Erection of temporary traffic
signs mounted on posts shall comply Steel backing frames, fittings and
with Sub-Section 6.2.5.8. purlins shall be prepared and
protected in compliance with B.S.
Any temporary covering of 873.
temporary traffic signs shall comply
with Sub-Section 6.2.5.9. Steel posts and post housings shall
be prepared and protected in
Removal of temporary traffic signs compliance with B.S. 873.
shall be carried out as soon as they
become superfluous or a hazard to Backs of aluminium or aluminium
traffic. Methods of removal and alloy sheets forming plate signs and
making good shall be submitted to external parts of luminaire housings
the S.O. for approval beforehand. and other permanently exposed
Making good shall be carried out components shall, to prevent retro-
immediately after removal of the reflection, be dulled with paint using
traffic sign to the satisfaction of the a method approved by the S.O.
S.O.
Ferrous steel shall be finished both
Cawangan Jalan, Ibu Pejabat JKR, K.L inside and out by galvanising,
electro-plating or application of zinc
or aluminium spray or other e
quivalent finish approved by the S.O.
Aluminium and other metals shall be
left untreated unless otherwise
Page 152
FOR INTERNAL USE ONLY Drawings, stainless steel shall be
left untreated except where the
Unless otherwise shown on the component is visible against the
sign face when it shall be
coloured on the face by methods Standard Specification For Road Works
(a) Thermoplastic Material
External surfaces shall be
prepared and protected as Thermoplastic material shall
described in the Contract. comply with the requirements of
Cabinets and feeder pillars shall B.S. 3262 Part 1. Yellow
have final coats of paint applied thermoplastic material shall be of
on Site after final installation, standard colour B.S. 381C No.
including the fitting of any 356 (Golden Yellow).
internal apparatus required as part
of the permanent Works. Internal (b) Road Marking Paint
surfaces shall, unless otherwise
shown on the Drawings, receive Road marking paint shall comply
the same treatment as for external with the requirements of M.S.
surfaces except that final paint 164. Yellow paint shall be of
coats shall be applied before standard colour B.S. 381C No.
internal components are installed. 356 (Golden Yellow).
6.3 ROAD MARKINGS 6.3.3 Preparation of Site
Thermoplastic material and road

6.3.1 Description marking paint shall be applied only
on a surface which is clean and dry.
This work shall consist of the supply It shall not be laid over loose
of road marking material and its detritus, mud or extraneous matter or
application to form continuous or over old material or paint marking
intermittent lines, letters, arrows, incompatible with the paint being
symbols or figures. The markings applied.
shall be white or yellow laid to the
dimensions and at the locations A tack coat compatible with the
shown on the Drawings and as marking material shall be applied in
specified herein or as directed by the accordance with manufacturer's
S.O. The work includes the supply instructions prior to the application
of all labour, tools, equipment, of thermoplastic material.
materials, and warning and traffic
guidance signs as necessary for the If a primer or undercoat is necessary
safe and efficient completion of the to ensure proper adhesion of the
entire work. marking paint to the road surface
without bleeding or other
6.3.2 Road Marking Materials discoloration, the primer or
undercoat shall be fully compatible
The marking material shall be one of with the marking paint and the road
the types detailed below as indicated surface. The rate of application of
on the Drawings or as directed by tack coat, primer or undercoat shall
the S.O. be in accordance with the
Cawangan Jalan, Ibu Pejabat JKR, K.L manufacturer's instructions and to the
Page 153
(a) Thermoplastic Material
6.3.4 Preparation of Material on Site
Thermoplastic material shall be
HStandard Specification For Road Work is used, the succeeding coat shall not
s be applied until the previous coat has
fully set.
specified. When more than one coat
supplied in block or powder form. If
the material is supplied in block
form it shall be broken into pieces,
each weighing not more than 4 kg,
which shall be melted in a heater
fitted with a mechanical stirrer to
prevent local overheating.
A thermometer of sufficient accuracy

shall be used during laying to ensure
that overheating of the material does
not occur. Once molten hydrocarbon
resins shall be used within 6 hours
and wood and gum resins shall be
used within 4 hours. The material
shall not be heated beyond the
manufacturer's specified temperature
during application. Excess material
shall be discarded on completion of
application.
(b) Road Marking Paint
All paint shall be thoroughly stirred

before application to keep the
pigments in uniform suspension. The
use of thinners or other additives
shall not be permitted unless
otherwise approved by the S.O.
6.3.5 Laying
Centre lines, lane lines and edge

lines shall be marked by approved
mechanical means or as directed by
the S.O. Other markings shall be
applied by brush, spray, screed,
hand-propelled or self-propelled
machine according to the marking
configuration and the type of
marking material approved for use.
The rate of application of the
marking material for each coat shall
be that recommended by the
manufacturer unless otherwise

Road markings of a repetitive nature in marking materials prior to
other than centre lines, lane lines, application to road surfaces shall be
etc., shall, unless otherwise decided Class À' glass beads complying
by the S.O., be set out with stencils with the requirements of Table 1 of
which comply with the size and B.S. 6088 (see Table 6.1).
spacing requirements as shown on
B.S. Percentage Min. % Spherical Max. % Defective
Sieve Retained Beads by mass Beads as tested in
as tested in accordance with
accordance with Appendix D
Appendix C
1.18 mm 0 to 3
850 um 0 to 10 70 30
425 um 90 to 100
the Drawings.
Solid glass beads for additional
6.3.6 Protection of Markings surface reflectorisation shall be
Class `B' glass beads complying with
All markings shall be protected from the requirements of Table 2 of B.S.
traffic until they have dried 6088 (see Table 6.2).
sufficiently so that no pick-up by
vehicle tyre will occur. 6.3.8 Thickness
6.3.7 Reflectorisation The determination of thickness shall

be in accordance with B.S. 3262
Solid glass beads to be incorporated Part 3, Appendices B and C.
B.S. Percentage Min. % Spherical Beads Max. % Defective Beads

Sieve Retained by mass as tested in as tested in accordance
(um) accordance with with Appendix D
Appendix C
850 0 to 5
800 5 to 20
300 30 to 75 80 20
180 10 to 30
Below 0 to 15
180
Page 154
TABLE 6.1 - CLASS À' GLASS BEADS : PARTICLE SIZE DISTRIBUTION, ROUNDNESS
AND DEFECTS
TABLE 6.2 - CLASS `B' GLASS BEADS : PARTICLE SIZE DISTRIBUTION,
ROUNDNESS AND DEFECTS

FOR INTERNAL USE ONLY -sprayed yellow edge lines (for
`no parking', `no waiting', etc.) : not
(a) Thermoplastic Material less than 2 mm nor more than 3 mm.
Thermoplastic material shall be (b) Road Marking Paint

laid to the following
thicknessess :- Road marking paint shall be laid to
give a wet film thickness of not less
i) for synthetic hydrocarbon than 315 microns and not more than
resin binder - 400 microns.
-screed lines : not less than 2 6.3.9 Tolerance on Width

mm nor more than 5 mm;
The tolerance on the specified width
-sprayed lines other than yellow of the marking shall be within the
lines : not less than 1.5 mm; range of + 10% and minus 0%.
-sprayed yellow edge lines (for

`no parking', `no waiting', etc.) :
not less than 0.8 mm.
ii) for gum or wood resin binders -
-screed lines : not less than 3 mm

not more than 5mm;
-sprayed lines other than yellow lines

: not less than 2 mm;
Standard Specification For Road Works markings reapplied all at the
Contractor's own expense and to
6.3.10 Defective Materials or the approval of the S.O.
Workmanship
Where directed by the S.O.,
Materials which are defective or existing markings shall be
which have been applied in an removed in the same manner as
unsatisfactory manner or to above.
incorrect dimensions or in a
wrong location, shall be removed 6.3.11 Clearing Up
by approved chemical or
mechanical means. To the extent The Contractor shall clean up all
necessary, the road pavement spatters, splashes and smirches of
shall be made good and the marking material completely to
the satisfaction of the S.O.

FOR INTERNAL USE ONLY required depth and the base shall
be trimmed and compacted to a
6.4 CONCRETE KERB firm and even surface. All soft
and unsuitable material shall be
removed and replaced with
6.4.1 Description suitable material as defined in
This work shall consist of the supply The bedding material shall then
and installation of cast in situ or be placed and compacted to form
precast concrete kerbs constructed at a bed of required thickness as
the locations and in accordance with shown on the Drawings.
the lines, levels, grades, dimensions
and types as shown on the Drawings,
all in accordance with this
Specification.
6.4.2 Materials
Concrete for kerb sections shall be

grade 25/20 concrete unless
otherwise indicated on the
Drawings and shall conform to the
requirements of Section 9 of this
Specification.
Unless otherwise shown on the

Drawings, bedding shall be grade
10/25 concrete.
6.4.3 Installation of Kerbs
6.4.3.1 Excavation
Excavation shall be made to the

Standard Specification For Road Works defects shall be repaired with
mortar containing 1 part Portland
6.4.3.2 Cast In Situ Kerb cement to 2 parts sand.
When a cast in situ kerb is placed After placing and compaction,

next to a concrete pavement, the concrete shall be covered
expansion joints in the kerb shall with suitable material and kept
be located in line with expansion moist for a period of 7 days.
joints in the pavement. Expansion
joints shall be formed at the 6.4.3.3 Precast Concrete Kerb
intervals shown on the Drawings
using preformed filler 10 mm in Precast concrete kerbs shall be
thickness in accordance with the cast using steel moulds and shall
specification for the pavement be of the types as shown on the
joint filler. Drawings.
Concreting shall generally be in Each kerb shall be set so that its

accordance with the front top arris conforms to the
requirements of Section 9 of this line and grade required. All
Specification. Forms shall not be spaces under the kerb shall be
removed within 24 hours of the filled with bedding material
concrete being placed. Minor which shall be thoroughly
tamped.

FOR INTERNAL USE ONLY practicable in the case of concrete
pavements, by the concrete
Kerbs shall be laid with joints as paver itself. The kerbs shall be
narrow as possible and filled with dense with regular sides, edges,
mortar containing 1 part Portland arrises and chamfers, finished to
cement to 2 parts sand. Where a a fine surface free from blow
Portland cement concrete holes and dragging, and shall be
pavement is to be constructed impervious.
contiguous to a kerb, expansion
joints shall be constructed in the
kerb directly in line with
pavement expansion joints. The
expansion joint in the kerb shall
be 20 mm in width and shall be
filled with an expansion joint
filler of the same nominal
thickness as the pavement joint.
Any voids between filler and the
concrete kerb shall be filled with
mortar.
6.4.3.4 Slipforming for Concrete Kerb
In situ concrete kerbs shall be

laid by an approved automatic
kerbing machine or, if
Standard Specification For Road Works layers of not more than 150 mm
until properly compacted.
6.4.3.5 Backfilling
The finished work shall be true to
The spaces in the front and back line, grade and level to within
of each kerb shall be refilled to ±10 mm and shall present a
the required elevation with smooth appearance free from
suitable material approved by the kinks and distortion visible to the
S.O. which shall be tamped in eye.

SECTION 7
STREET LIGHTING

SECTION 7 - STREET LIGHTING

Page
7.1 GENERAL
7.1.1 Scope of Work S7 - 162
7.1.2 On Site Commissioning Tests S7 - 162
7.1.3 As-Built Drawings S7 - 162
7.1.4 Maintenance S7 - 163
7.1.5 Traffic Safety and Control S7 - 163
7.2 LOW VOLTAGE UNDERGROUND CABLES
7.2.1 General S7 -164
7.2.2 Types of Cables S7 - 164

7.2.2.1 Power Cables S7 - 4
7.2.2.2 Earthing Conductors S7 - 4
7.2.3 Lengths of Cables S7 - 164
7.2.4 Cable Routes S7 - 164
7.2.5 Cable Trenches S7 - 165
7.2.6 Cable Ducts S7 - 165

7.2.7 Cable Termination S7 - 166
7.2.7.1 Termination of PVC Insulated Armoured Cable S7 - 166
7.2.7.2 Termination of Paper Insulated Cables S7 - 166
7.2.8 Cable Jointing S7 - 167
7.2.9 Cable Markers S7 - 167
7.2.10 Cable Laying and Installation S7 - 168
7.3 STREET LIGHTING LUMINAIRES
7.3.1 Light Distribution Requirements S7 - 170
7.3.2 Constructional Requirements S7 - 170

7.3.2.1 Luminaires S7 - 170
7.3.2.2 Lamps S7 - 171
7.3.2.3 Ballast S7 - 172
7.3.2.4 Capacitors S7 - 172
7.3.2.5 Ignitors S7 - 172

page
7.4 FEEDER-PILLARS S7 - 14
7.4.1 General S7 - 172
7.4.2 Fabrication of Feeder-Pillars S7 - 172
7.4.3 Factory Inspection S7 - 173
7.4.4 Foundation S7 - 173
7.4.5 Earthing S7 - 173
7.4.6 Time Switches S7 - 173
7.4.7 Contactors S7 - 173
7.4.8 By-Pass Switches and Selector Switches S7 - 173
7.5 COLUMNS AND BRACKETS S7 - 16
7.5.1 General S7 - 174
7.5.2 Design Loading S7 - 174
7.5.3 Fabrication of Column Sections S7 - 174

7.5.3.1 Doors and Door Openings S7 - 174
7.5.3.2 Service Slots S7 - 174
7.5.4 Bracket Arms S7 - 174

7.5.5 Base-Plates S7 - 175
7.5.6 Baseboards S7 - 175
7.5.7 Street Lighting Cut-Outs S7 - 175
7.5.8 Earthing Terminals S7 - 175
7.5.9 Cable Entry S7 - 175
7.5.10 Erection of Columns S7 - 175
7.5.11 Protection Against Corrosion S7 - 176

FOR INTERNAL USE ONLY The tests to be carried out shall be as
prescribed in the latest edition of the
SECTION 7 - STREET LIGHTING IEE Wiring Regulations and the
Electricity (Board Supplies) Rules
1949, and shall include other tests
deemed necessary by the S.O. In the
7.1 GENERAL event that the installation fails to pass
any of these tests, the Electrical
7.1.1 Scope of Work Contractor shall take such measures
as are necessary to remedy the
This work shall comprise the design defects and the installation shall not
of cabling works and the supply and be considered to have been
installation of all luminaires, lamps, completed until all such tests have
ballasts, capacitors, ignitors, feeder been passed.
pillars, columns, ducting and cabling, Cawangan Jalan, Ibu Pejabat JKR, K.L
and all necessary ancillary
equipment, together with the
transportation, storage, erection,
connection, testing and
commissioning of the same for a
complete street lighting system, all in
accordance with the Drawings and
this Specification. The work shall
also include cabling from the nearest
specified power source of the local
supply authority to the street lighting
system, if required.
7.1.2 On Site Commissioning Tests
On completion of the installation

work on site, the Electrical
Contractor shall, at his own expense,
arrange for all necessary tests to be
carried out on the installation by
competent personnel as part of the
tests required of him for the whole of
the installation under this Contract.
Standard Specification For Road Works Within three (3) calender months
from the practical completion of the
Tests on cables shall include installation, one set of true-to-scale
continuity, phasing out and insulation negatives (110/115 g/sq.m A0 or A1
resistance between conductors and sizes) and four sets of prints of each
between conductors and sheaths by of the following as-built drawings
employing a 500 V insulation shall be submitted to the S.O. by the
tester.The date of commissioning Electrical Contractor :-
shall be agreed to by the S.O. and the
Electrical Contractor shall ensure i) Site plans;
that the installation is safe before the
cable is energised. ii) Schematic wiring diagrams;
The S.O. reserves the right to be iii) Layout plans showing cable
present at all tests and the Electrical routes with reference to easily
Contractor shall give at least one (1) recognisable buildings and
week's notice in writing to the S.O. structures, sizes and types of
for this purpose. In any case, no test cables, locations and types of
shall be carried out without prior joints, cable ducts, street lighting
approval from the S.O. Copies of all poles and luminaires, feeder
test certificates shall be submitted to pillars and earthing points.
the S.O. within one (1) week of the
completion of the testing.
7.1.3 As-Built Drawings

Page 162
FOR INTERNAL USE ONLY During the Defects Liability Period,
the Electrical Contractor shall per
These as-built drawings shall be form maintenance work for the
properly stencilled and shall complete cabling and associated
have, at the lower right hand works. All labour, materials, tools
corner, the Electrical Contractor's and parts necessary to rectify the
name and address, the date of defects due to manufacturing or
commissioning, the scale, installation faults shall be supplied
drawing number (this shall be and/or executed at no extra cost to
obtained from the S.O.) and title, the Government. Maintenance work
and the following particulars:- shall be carried out as soon as the
Electrical Contractor has been
JABATAN KERJA RAYA informed by the S.O. to do so.
CAWANGAN ELEKTRIK
CONTRACT NO. The work to be performed shall
TENDER NO. include but shall not be limited to the
following :-
In addition, one (1) set of the as-
built drawings shall be properly i) replacing or making good any
framed and kept in the defective cables, cable joints and
switchroom. cable terminations;
If the as-built drawings submitted Cawangan Jalan, Ibu Pejabat JKR, K.L
are not acceptable by the S.O.,
the Electrical Contractor shall
amend and resubmit the drawings
within two (2) weeks from the
date of return of the drawings.
7.1.4 Maintenance
Standard Specification For Road Works Lumpur, and shall be submitted by
the Electrical Contractor and
ii) replacing any broken or defective approved by the S.O. before work
cable markers; commences.
iii) making good any damage to Where it is necessary for any pit or
buildings, concrete areas, slopes, trench to be left open overnight,
drains, culverts, existing cables, flashing warning lamps shall be
pipes, etc., which have not been placed at each end of the pit or
properly made good as a result of trench and at intervals not greater
the Electrical Contractor's work; than 10 m apart. In built-up areas,
and barricades shall be erected along the
length of the pit or trench in addition
iv) carrying out any other work to the warning lamps.
deemed necessary by the S.O.
Where necessary, flag-men shall be
7.1.5 Traffic Safety and Control stationed to control traffic.
When work is being carried out

beside any public road or other
existing road, warning signs shall be
erected. The general arrangement
and location of temporary warning
signs shall be strictly in accordance
with ARAHAN TEKNIK (JALAN)
2C/85, published by Cawangan
Jalan, Ibu Pejabat JKR, Kuala Page 163
FOR INTERNAL USE ONLY galvanised steel wires and
sheathed with PVC; or
7.2 LOW VOLTAGE
UNDERGROUND CABLES ii) B.S. 6480 Part 1 and shall
have high conductivity plain
7.2.1 General copper stranded conductors,
insulated with strong long-
The Electrical Contractor shall fibred paper, uniform in
submit, for the approval of the S.O., texture, free from metallic
a program of work for the excavation particles, mass impregnated
of cable trenches, laying of cables, with non-draining insulating
reinstatement of trenches, etc., one oil compound suitable for a
(1) week before the work is to be voltage of between 600 and
executed. 1000 V, lead alloy sheathed
and served; or
7.2.2 Types of Cables
7.2.2.1 Power Cables
Power cables shall be

manufactured and tested in
accordance with :-
i) M.S. 274 or B.S. 6346 and
shall have high conductivity
plain copper stranded
conductors, insulated with
PVC suitable for a voltage of
between 600 and 1000 V, laid
together and bedded with
PVC, armoured with
The lengths of each type of cable
iii) B.S. 6480 Part 1 and shall indicated on the Drawings and/or in
have high conductivity plain the B.Q. are for tendering purposes
copper stranded conductors, only. The Electrical Contractor shall
insulated with strong long- as certain the length of each cable
fibred paper, uniform in required before placing orders for
texture, free from metallic cables. The actual length of each
particles, mass impregnated cable installed shall be measured on
with non-draining insulating site and the Electrical Contractor
oil compound suitable for a shall be paid according to the rate
voltage of between 600 and specified in the Contract. The rates
1000 V, lead alloy sheathed, quoted shall include any wastage due
double steel tape armoured to cutting to lengths, terminations,
and served. etc.
7.2.2.2 Earthing Conductors 7.2.4 Cable Routes
Cables from street-lighting cut- Cable routes shown on the Drawings

outs and earthing cables to are for tendering purposes only. The
luminaires shall be 2.5 sq.mm Electrical Contractor shall, after
PVC/PVC cables bundled consulting the S.O., peg out cable
together with cable ties and routes for the S.O.'s approval prior to
terminated with lugs where excavation of the cable trenches.
necessary.
7.2.3 Lengths of Cables Page 164

FOR INTERNAL USE ONLY restoration has been completed for
reasonable access of persons and
7.2.5 Cable Trenches vehicles to the areas of buildings
adjacent to the trenches.
Unless otherwise specified, cable
trenches shall be 750 mm deep. They Where a trench passes from a foot
shall be of sufficient width as to way to a roadway or at other
enable provision of adequate spacing positions where a change in level is
between cables but in any case shall necessary, the bottom of the trench
not be less than 450 mm wide. shall rise and/or fall gradually.
Trenches shall be as straight as 7.2.6 Cable Ducts

possible and shall have vertical sides
which shall be timbered where At road crossings, sewerage pipe
necessary so as to avoid subsidence crossings, water pipe crossings,
damage. The bottoms of trenches paved areas, concrete areas and
shall be firm and of smooth contour where specified by the S.O., cables
and any objects likely to damage the shall be protected by galvanised steel
cable sheathing shall be removed. pipes buried to a depth of 900 mm
Material excavated from trenches below finished ground level. The
shall be placed or removed so as to pipes shall be heavy duty pipes
prevent nuisance or damage to
adjacent areas or buildings. Cawangan Jalan, Ibu Pejabat JKR, K.L
Trench excavation and backfilling

shall be so executed that all roads,
walls, sewers, drains, pipes, cables,
structures, etc., shall be reasonably
secured against risk of subsidence
damage. Provision shall be made
during excavation and until interim
Standard Specification For Road Works project through the blocks into
the ground to a depth of at least
complying with B.S. 1387, 750 mm.
complete with screwed and
socketed joints. Unless otherwise All ducts shall be extended at
specified, the pipes shall be 150 least 600 mm beyond paved
mm in diameter. areas, concrete areas, drains, road
crossings, pipe crossings, etc.
The Electrical Contractor shall
provide pumps and other Cables entering buildings shall be
appliances for the necessary protected by pitch fibre ducts of
pumping required for the disposal 150 mm diameter, complying
of water so as to prevent any risk with B.S. 4108, complete with
of the cables and other materials bend pieces, buried to a depth of
to be laid in the trench from 900 mm and encased in 75 mm
being detrimentally affected. of concrete all round. The ducts
Where necessary, bailing shall be shall be installed with a gradient
provided. so as to drain away any water in
the ducts. All ducts passing
Where it is necessary to cross through walls shall be effectively
drains, culverts or similar sealed and made water-tight.
obstructions which are too deep
for the cables to be buried below,
galvanised steel pipes as specified
above shall be provided. The
pipes shall be supported at each
end in a concrete block and shall Page 165
FOR INTERNAL USE ONLY Armoured Cables
Unless otherwise approved by the PVC/SWA/PVC cables shall be

S.O., the number of cables provided with compression cable
installed in each duct shall be gland termination. The cable
such that the space factor shall be gland shall be of gunmetal or
not less than 60%. A drawn wire brass and shall grip both the inner
shall be provided for each duct. and outer PVC sheath of the
cable. It shall be so designed that
Unless specified to be provided any strain on the cable is taken by
by others, the above galvanised the steel wire armouring which
steel pipes and /or pitch fibre shall be effectively sealed
ducts shall be provided by the between the gland itself and the
Electrical Contractor whether or outer cable sheath.
not they are shown on the
Drawings.
7.2.7 Cable Termination
Unless otherwise permitted, all cable

termination and jointing works shall
be carried out in the presence of the
S.O. A plastic laminated plate Cawangan Jalan, Ibu Pejabat JKR, K.L
engraved with details such as size of
cable, number of cores, date of com
missioning, date of jointing, length
of cable, distance of cable joint, etc.,
shall be securely fixed near the
termination.
7.2.7.1 Termination of PVC Insulated

Standard Specification For Road Works Phasing and insulation resistance
tests shall be taken on each length
7.2.7.2 Termination of Paper Insulated of cable laid before termination is
Cables commenced.
PILCDS and PILCDSTAS paper The heat shrinkable termination

insulated cables, unless otherwise materials used shall be supplied
specified, shall be terminated by in a complete kit to suit various
the heat shrinkable method. sizes of cable and to provide
stress controlled, non-tracking,
The cables shall be tested for environmentally sealed
moisture before termination is termination. They shall consist of
commenced. Samples of paper high permittivity, high resistivity,
both from the layers nearest to heat shrinkable, stress controlled,
and furthest from the conductor UV stable, non-tracking
shall be immersed in transformer polymeric materials and heat-
oil or paraffin wax heated to a activated sealants to prevent
temperature of approximately ingress of moisture and
115ºC. If any residual moisture is contamination.
present, this will be detected
immediately through the presence Terminations shall meet the
of bubbles. Samples of paper performance tests of IEC 112,
shall be tested singly and shall IEC 446 and IEC 507, Section 3.
not be touched by hand, but shall They shall also have the
be gripped with a pair of following performance
tweezers. characteristics :-
Page 166
FOR INTERNAL USE ONLY jointing materials used shall be of an
approved type. Every cable joint
i) A.C. Voltage withstand shall be started and finished on the
for 15 minutes, 50 Hz : same day.
4.0 kV phase to earth;
Wherever cables are to be jointed in
ii) A.C. Voltage withstand the open during wet weather
for 4 hours, 50 Hz : conditions, the Electrical Contractor
3.0 kV phase to earth; shall take all necessary precautions
to prevent moisture from getting into
iii) Impulse Voltage withstand 10 the cables. Where cable sheaths are
positive and 10 negative, to be used as earth continuity
1.2/50 microseconds : conductors, the glands shall have the
8.0 kV peak phase to earth; necessary contact surface to provide
a low resistance path under fault
iv) Continuous A.C. Voltage : conditions.
1.5 kV phase to earth;
Phasing and insulation resistance
v) Insulation Resistance tests shall be taken before jointing is
between phase conductor commenced.
and ground : > 1000
Megaohms.
7.2.8 Cable Jointing Cawangan Jalan, Ibu Pejabat JKR, K.L
Jointing of cables shall be

undertaken only by competent and
fully experienced jointers.
Cable boxes, compounds and

Standard Specification For Road Works heavy duty reinforced concrete
construction and shall be approved
Core numbers printed on papers by the S.O.
shall be observed when jointing
and, whenever possible, such The cable marker shall form a
numbers shall be maintained trapezoidal block with a 100 mm
throughout the system. Core square top face and 150 mm square
numbers `0', `1', `2' and `3' shall bottom face, and shall be 400 mm in
denote neutral, red, yellow and height as shown on the Drawings.
blue phases respectively. In the The top face shall be indented in
case of 2-core cables, core number bold lettering with the initials "L.V."
`1' shall denote the phase conductor and a directional sign or signs
and `0' the neutral. Crossing of cores indicating the direction/directions of
in the cable boxes shall be avoided the cable route. The cable marker
wherever possible and connections shall be buried to a depth of 300 mm
shall be consistent with the foregoing or any other depth as directed by the
requirements. S.O. Cable joint markers of similar
construction but with the symbol "X"
7.2.9 Cable Markers shall be provided and installed at
every cable joint in a similar manner.
Cable markers with lettering and
signs as shown on the Drawings
shall be provided by the Electrical
Contractor at every change of
direction of underground cable
routes and every 15 m on straight
runs. Cable markers shall be of Page 167
The minimum bending radius of
7.2.10 Cable Laying and Installation the cables shall be in accordance
with Table 52 C of the latest
All cables shall be handled, laid edition of the IEE Wiring
and installed according to this Regulations. Wherever cables are
Specification, the latest edition of cut, the ends shall be immediately
the IEE Wiring Regulations, the sealed in an approved manner
cable manufacturer's unless it is intended to proceed
recommendations and ERA with cable jointing or termination
Reports, using proper installation immediately.
equipment, all to the satisfaction
of the S.O. Unless otherwise permitted by
the S.O., no cable shall be laid
All cables shall be supplied in and/or covered up in the absence
complete lengths to suit the of the S.O.
circuits they serve and no straight
through joints shall be used.
Straight through joints in the
cable shall only be permitted in
very exceptional circumstances
such as those arising from
unavoidable limitations in Cawangan Jalan, Ibu Pejabat JKR, K.L
manufactured length. Where
straight through joints or other
approved joints are permitted by
the S.O., the cost of such joints
shall be borne by the Electrical
Contractor. No joints in the cable
will be allowed unless approved
in writing by the S.O.
Standard Specification For Road Works size is not more than 120 sq.mm.
For cable sizes in excess of 120
(a) Cable Laid Direct In Ground sq.mm, more than one row of
bricks shall be laid. Each cable
Before any cable is laid, the shall be seperately protected by
trench shall be thoroughly these bricks and the cover shall
inspected and any debris and have at least 25 mm overhang on
other sharp objects shall be each side of the cable.
removed. The bottom of the
trench shall be covered with a The trench shall then be
layer of clean sand 75 mm thick. backfilled with earth and shall be
The cables shall then be laid on compacted in layers of 150 mm
this bedding in an orderly manner using a mechanical rammer. An
without overlapping and crossing orange coloured multi-strand
each other. 75 mm of clean sand nylon rope of minimum 6 mm
shall cover the laid cables and diameter shall be laid at a depth
shall be spread over the trench of 300 mm along the trench to
before placing the cable identify the cable route. At every
protective covers. 10 m interval, an extra 2 m of
nylon rope shall be coiled and
Cable protective covers shall be laid. The finished surface shall be
of clay bricks. The bricks shall be left proud by 50 mm to allow for
new, well burnt and in complete subsidence and the Electrical
pieces. They shall be laid
lengthwise from end to end along
the entire route of the
underground cable if the cable Page 168
FOR INTERNAL USE ONLY Cables laid in the bottoms of
trenches shall be in accordance
Contractor shall be responsible with Method Type L of Table 9A
for the removal of any surplus of the latest edition of the IEE
material to a position indicated by Wiring Regulations.
the S.O.
Cables installed on trench walls
The surface of the refilled trench shall be in accordance with
shall be temporarily reinstated Method Type M or Type N of the
and maintained in a thoroughly latest edition of the IEE Wiring
safe condition until complete Regulations and shall be secured
consolidation of the soil has been on a cable tray by means of
achieved. As soon as the soil has saddles at suitable intervals. In
consolidated, the trench shall be the case of single core cables,
made good to its original whether secured individually or
condition, all to the satisfaction of in a group to the cable tray, non-
the S.O. ferrous saddles shall be used.
Cable trays shall be fabricated
(b) Cable Installed In Precast from perforated hot-dipped
Concrete Trenches galvanised sheets finished in an
orange enamel.
Methods of installation of cables
in precast concrete trenches shall Cawangan Jalan, Ibu Pejabat JKR, K.L
be in accordance with Type L,
Type M, or Type N of Table 9A
of the latest edition of the IEE
Wiring Regulations. However, if
the method is not specified, the
cables shall be installed as
Standard Specification For Road Works otherwise approved by the S.O.
Trenches inside buildings shall be
The minimum thickness of the filled with clean sand up to a
sheet steel used shall be 1.5 mm level above the cable ducts.
for cable trays with widths of up
to 300 mm, and 2.0 mm for (c) Cable Run On Walls and
widths exceeding 300 mm. Cable Under Floor Slabs
trays shall be supported at least
25 mm from the trench wall by Cable run on walls and under
mild steel brackets at 600 mm floor slabs shall be mounted on
intervals. Brackets shall be perforated hot-dipped galvanised
anti-rust treated and painted with sheet steel cable trays. The
one coat of primer. Samples of construction and finish of the
cable trays and brackets shall be cable trays and the method of
submitted to the S.O. for installation of cables on cable
approval prior to installation. trays shall be as described in Sub-
Section 7.2.10 (b) above.
To provide electrical continuity,
all cable joints shall be bridged Cable trays shall be suspended
by means of tinned copper tape from floor slabs by hangers or
of dimensions not less than 25 mounted on walls by brackets at
mm x 3 mm. All saddles for 600 mm intervals. The materials
cables on cable trays shall be and finishes used for the hangers,
installed by bolts, washers and brackets and other suspending
nuts. All tees, intersection units, and supporting structures shall be
adaptor units, etc., shall be
factory manufactured unless Page 169
FOR INTERNAL USE ONLY of the downward vertical and the
maximum permissible value of the
the same as those described for intensity emitted at 90º and 80º shall
brackets in Sub-Section 7.2.10 not exceed 10 cd/1000 lumens and
(b) above. 30 cd/1000 lumens respectively.
Where cable trays pass through Each luminaire shall normally direct
floors or fire resistant walls, the two beams along the length of the
surrounding holes shall be sealed road. The polar light distribution
to the full thickness of the floor curves for the luminaire shall
or wall with non- hygroscopic generally be smooth and free from
fire-resisting material of any abrupt variations so that the
minimum 2-hour fire rating as luminous intensity diminishes
approved by the Jabatan Bomba smoothly and progressively from its
Malaysia. maximum.
7.3 STREET LIGHTING

LUMINAIRES
7.3.1 Light Distribution Requirements

Unless otherwise specified, the
performance and light distribution of
street lighting luminaires shall be of
the Low Threshold Increment (LTI)
type.
The direction of maximum intensity

of flux shall lie between 0º and 65º
Standard Specification For Road Works material that will more than
effectively withstand the current,
7.3.2 Constructional Requirements voltage and temperatures
expected within the luminaire
7.3.2.1 Luminaires during both the starting and
operating modes in the ambient
All luminaires shall be new, temperature of the Site.
totally enclosed, dust proof,insect
proof and watertight and shall be The lamp compartment of the
tested in accordance with B.S. luminaire shall be accessible via a
4533. All exposed parts shall be hinged bowl made of ultraviolet
of non-corrosive materials. The stabilised plastic material such as
luminaires shall provide the acrylic which shall, in the closed
requisite light distribution with position, bed firmly upon a soft
the size and type of lamp resilient neoprene or non-ageing
specified. Each luminaire shall felt gasket. The gasket shall be
consist of a lamp compartment positively secured in the
made up of an upper canopy or luminaire housing and shall be
housing and a lower bowl weather-resistant. The bowl shall
assembly, a lampholder, cable be secured firmly to the luminaire
clamps, mains connectors and body by means of stainless steel
earth terminations, as well as all clips and hinged pins.In the
necessary control gear. The lowered position of the bowl, it
control gear shall be pre-wired shall be restrained from
and integral with the luminaire. becoming detached or being
The luminaire wiring shall be of
a size and insulated with a Page 170
FOR INTERNAL USE ONLY luminous efficiency of
approximately 115 lumens per
blown towards the other portion watt for a 400 watt lamp and 100
of the luminaire or the column lumens per watt for a 250 watt
arm. If independent reflectors are lamp. The lumens output after
incorporated in the luminaire, 100 operating hours shall be
such reflectors shall be of high 45,000 lumens for a 400 watt
purity aluminium mirrors, lamp and 25,000 lumens for a
chemically anodised to yield 250 watt lamp.
optimum reflection of light
distribution. Full details of the The lamps shall be of tubular or
luminaire and accessories shall be of any other approved shape and
furnished as required in the shall have plated brass caps
Appendices to this Specification. securely fitted to the glass
envelopes. The cap shall be of
7.3.2.2 Lamps GESE40 material to fit the
luminaire supplied.
(a) High Pressure Sodium Vapour
(HPSV) Lamps
High presssure sodium vapour

(HPSV) lamps shall conform to
IEC Publication 662 and shall Cawangan Jalan, Ibu Pejabat JKR, K.L
have a colour temperature of
approximately 21,000 K. The
majority of the light output shall
fall within the 560-610
nanometre waveband, i.e. in the
yellow/orange, range.
The lamps shall have an initial

Standard Specification For Road Works nanometre waveband range.
The lamps shall have an
The lamps supplied shall have a initial luminous efficacy of
mortality rate not greater than approximately 160 lumens per
10% at 5,000 switched operating watt for a 135 watt lamp. The
hours and shall not take longer lumens output after 100
than 4 minutes after the initial operating hours shall be not
"switch on" to attain 80% of their less than 50 lumens per watt.
guaranteed output at the rated
voltage of 200/250 V and The lamps shall be of tubular
frequency 50 Hz. The reignition shape with a bayonet cap
period after an interruption of the (B.C.), shall take no longer
supply shall not be longer than 1 than 11 minutes after initial
minute to attain 80% of the "switch on" to attain 90% of
lumens output. of their quoted lumens output.
All LPSV lamps shall be

guaranteed for a minimum
(b) Low Pressure Sodium Vapour operating life of 4,000
(LPSV) Lamps operating hours. All lamps
shall be suitable for use, in
Low pressure sodium vapour conjunction with their control
(LPSV) lamps shall conform gears, on 220/240 V supply
to the requirements as laid and shall be capable of being
down in B.S. 3767. The started and operated at 10%
majority of the lumens output reduction in rated voltage.
shall be within the 580-590 Page 171
Ignitors for the discharge lamps
7.3.2.3 Ballast shall be of the electronic /
superimposed pulse type rated for
The ballast shall be manufactured the appropriate wattage. The unit
to B.S. 4782. It shall be correctly shall be capable of operating on a
rated for its duty and shall be voltage ranging from 200 to 250
designed to operate on a dual volts. The unit shall be totally
mains voltage of 220/240 V by enclosed with an external
means of suitable tappings. The terminal block for the supply
tappings shall be brought out to connection and a length of high
marked terminals. The ballast tension cable shall be included
shall have laminated cores and for the lamp connection. It shall
high conductivity windings with be compatible with the normal
power loss and noise kept to a control gear.
minimum.
The case of the unit shall carry a
7.3.2.4 Capacitors label showing the connections
and listing the appropriate
Capacitors shall be manufactured voltage.
to B.S. 4017 and housed in
extruded aluminium canisters
with shrouded screw terminals. Cawangan Jalan, Ibu Pejabat JKR, K.L
They shall not be fused but shall
have an an external safety dis
charge resistor. The capacitor
shall be capable of raising the
power factor of each circuit to at
least 0.85 lagging.
7.3.2.5 Ignitors
Standard Specification For Road Works The feeder-pillar housing shall
consist of a drip canopy, rigidly
7.4 FEEDER-PILLARS welded channeled steel framework
manufactured from 2.64 mm (12
s.w.g.) sheet steel. It shall be hot-dip
7.4.1 General galvanised and the process of
galvanising, treatment before
Feeder-pillars shall be supplied galvanising and treatment after
completely assembled with control galvanising shall be as described in
gear and all internal electrical and Sub-Section 7.5.10 of this
mechanical inter-connections and Specification. On the front and rear
structural parts for voltages up to and sides of the feeder-pillar, the
including 1,000 volts A.C. They following sign shall be stencilled in
shall comply with and be tested to red paint using a lettering height of
the requirements of B.S. 5486. 90 mm :-
7.4.2 Fabrication of Feeder-Pillars BAHAYA

415 V
The Electrical Contractor shall LAMPU JALAN
submit a design drawing of the
shape, size, electrical and mechanical The door of the feeder-pillar shall be
connections, materials, etc., of the rigidly reinforced and hinged internally
feeder-pillar for the approval of the to prevent unauthorised access. The
S.O. prior to manufacture. The feeder-pillar shall be lockable with either
plinth, foundation work, etc., shall be wedge-type locks protected by screw
included in the design drawing.
Page 172
FOR INTERNAL USE ONLY required, compacted and levelled
before the reinforced concrete base
plugs or some other secret locks of minimum 250 mm height above
approved by the S.O. The feeder- the finished earth level is
pillar shall be self-ventilated and constructed. Cable entry ducts shall
weather proof and such ventilation also be provided.
openings shall be protected by wire
mesh to prevent the entry of vermin, 7.4.5 Earthing
rodents and birds.
The earthing system for the feeder-
A baseboard made of tufnol or pillar shall comply with the Rules
other approved treated hardwood and Regulations of the Supply
of at least 16 mm thickness shall Authority, The British Code of
be included to mount equipment Practice C.P. 1013, the relevant
such as time switches, contactors, sections of the latest edition of the
etc. IEE Wiring Regulations and the
Contract Drawings.
7.4.3 Factory Inspection
Each feeder-pillar shall be effectively
The Electrical Contractor shall make earthed using 4.8 mm x 16 mm
arrangements to witness the diameter steel core copper-jacketted
electrical tests and for joint earth electrodes, 25 mm x 3 mm
inspection to be carried out at the
factory prior to transportation to the Cawangan Jalan, Ibu Pejabat JKR, K.L
Site.
7.4.4 Foundation
The Site of the foundation of the

feeder-pillar shall be filled where
Standard Specification For Road Works V, 50 Hz supply. The contacts of the
contactor shall be rated for the
copper tape, precast concrete earth breaking capacity of the connected
chambers with covers, etc. load.
7.4.6 Time Switches 7.4.8 By-Pass Switches and Selector

Switches
Time switches supplied for the
control of luminaires, etc., shall be of Single or three-phase by-pass
the synchronous/step-by-step motor- switches as applicable shall be
wound handset dial plug-in type. connected in parallel with the
They shall incorporate a 24-hour contactors for use in the event of the
spring reserve or a battery back-up failure of the contactors. These shall
system. Time switches shall be rated be manufactured to B.S. 5419 and
as specified in the Drawings and shall be capable of breaking the load
shall be operational on a 220/240 V, connected to the contactors without
50 Hz supply. undue ageing or damage.
7.4.7 Contactors A four-position selector switch shall

be provided to select the mode of
Contactors shall comply with B.S. operation and shall be appropriately
5424 with uninterrupted ratings, labelled.
mechanical duty Class 2 and a
utilisation category of at least AC3.
The contactor coils shall be fully
tropicalised and wound for
continuous operation for a 220/240 Page 173
iii) other applied loads if applicable.
7.5 COLUMNS AND BRACKETS
7.5.3 Fabrication of Column Sections
7.5.1 General Each column section shall be

mechanically formed and
All columns and brackets shall be of longitudinally welded by the
tapered, octagonal, hot-dip continuous automatic gas shielded
galvanised interchangeable sections electric arc process (M.I.G. process)
complying in all respects with the to B.S. 5135. The sections shall be
Drawings. They shall be constructed so as to overlap each
manufactured to comply with B.S. other by a minimum of 1.5 times the
1840 and B.S. 5649 with Grade 43C diameter of the immediate lower
or 50C steel conforming to B.S. section (external across-faced
4360. The base-plates and bracket dimension) and to be easily
arms shall be manufactured as assembled on site by using simple
seperate units suitable for mounting tools without employing welding
or fixing on to the columns. techniques. The manufacturer shall
provide a mark on the finished
7.5.2 Design Loading column section indicating the
The columns shall be designed to Cawangan Jalan, Ibu Pejabat JKR, K.L
withstand loadings comprising :-
i) loads due to wind speeds of up to

27 m/sec.;
ii) loads due to the weight of the

columns, lighting luminaires and
bracket arms;
Standard Specification For Road Works shown on the Drawings. A
suitable duct for cable entry shall
minimum overlapping position of 1.5 also be provided at the concrete
times the external across-faced base.
dimension.
For planted root types of
7.5.3.1 Doors and Door Openings columns, service slots shall be on
the same side and vertically
Weather proof doors shall be below the service doors.
provided with an anti-vandal
locking device over the door 7.5.4 Bracket Arms
opening of each column as
shown on the Drawings. The Bracket arms shall be of suitable
complete locking device shall be outreach as indicated on the
made from stainless steel. Door Drawings and in the B.Q. The
openings shall have internal bracket arms shall be octagonal in
reinforcement to compensate for shape for up to 2.0 m in length. For
the loss of stiffness in the bracket arms longer than 2.0 m in
columns caused by forming the length, the extra length shall be
door openings. formed from Grade 43C tubular steel
conforming to B.S. 4360. The
7.5.3.2 Service Slots bracket arms shall be arranged so as
to give a 50 uplift as shown on the
For flange mounted types of Drawings. A tubular steel spigot of
columns, cable entries shall be appropriate dimensions for the
through the flange plates via a
hole of suitable diameter as Page 174
FOR INTERNAL USE ONLY thickness. Alternative baseboards
made from galvanised perforated
luminaire shall be welded at the end metal may also be used with the
of each bracket arm. After welding, approval of the S.O. Baseboards
etc., bracket arms shall be treated as shall be made to the dimensions as
described in Sub-Section 7.5.10 indicated on the Drawings and shall
before being hot-dip galvanised. be fixed securely in position inside
the columns.
7.5.5 Base-Plates
7.5.7 Street Lighting Cut-Outs
For flange mounted types of
columns, flange-plates of substantial Street lighting cut-outs shall be of a
thicknesses as shown on the type manufactured for use in street
Drawings shall be welded on to the lighting installations. They shall
columns. have facilities for double fusing
loop-in loop-out terminals. The cut-
For planted root types of columns, out bases shall have a supply cable
detachable anti-sink plates shall be contact block rating of at least 50 A
supplied. and shall be capable of accepting
circular cable cores of up to 25
Base-plates, nuts and bolts, etc., shall sq.mm copper 2-core or 4-core
be hot-dip galvanised after
manufacture. Cawangan Jalan, Ibu Pejabat JKR, K.L
7.5.6 Baseboards
A piece of baseboard shall be

included in each base compartment
for cable termination or control gears
assembly. Baseboards shall be made
from fibre board of 10 mm
Standard Specification For Road Works diameter and shall be provided with
two suitable washers and nuts.
cables as appropriate. Cut-outs shall
be provided with adequate shrouding 7.5.9 Cable Entry
to prevent cross-phasing or
accidental contact with live metal. Armoured cables brought into the
columns shall be provided with
The fuse carriers shall be self- compression cable gland
aligning and shall accept any of the terminations.
standard rated fuses for the purpose.
Each unit shall possess high An appropriate type of earthing
mechanical and di-electric strength clamp shall be provided to bond the
and shall be suitable for use in the armouring of the cables which shall
tropics. Samples of complete cut-out be effectively earthed.
units shall be submitted for the
approval of the S.O. 7.5.10 Erection of Columns
7.5.8 Earthing Terminals Columns shall be installed in

accordance with the manufacturer's
Columns shall be provided with a recommendations and as shown on
corrosion resistant terminal having the Drawings. The Electrical
substantial contact surfaces for the Contractor shall peg out the positions
attachment of an earthing lead. This of the columns for the approval of
terminal shall be provided close to the S.O. before planting the columns.
the door opening inside each
column. Where bolts are used, they
shall be not less than 6 mm in Page 175
Columns shall be erected such that Treatment prior to galvanising shall

the service doors shall face away include degreasing, rinsing, pickling,
from on-coming traffic except at further rinsing and fluxing.
parapets of bridges and retaining
walls. At such locations, the The minimum average weight of the
orientation of the service doors shall zinc coating shall be 460 g/sq.m for
be determined by the S.O. After any individual test area.
erecting each column, backfill shall
be compacted by means of suitable The galvanised columns and bracket
ramming equipment. arms shall be of prime finish and of
good uniformity, i.e. they shall be
7.5.11 Protection Against Corrosion free from injurious defects such as
blisters, flux and uncoated spots.
Individual sections of the columns,
base-plates, doors and bracket arms The planted sections of columns and
shall be protected against corrosion the base-plates shall be factory-
by hot-dip galvanising the sections coated with bitumen using the hot-
both internally and externally, all in dipping process conforming to
accordance with B.S. 729. All AASHTO M 190.
welding works shall be completed
before galvanising.
SECTION 8
TRAFFIC SIGNALS
SECTION 8 - TRAFFIC SIGNALS
Page
8.1 GENERAL
8.1.1 Scope of Work S8-182
8.1.2 Design and Construction

8.1.2.1 Contractor's Responsibility S8-182
8.1.2.2 Cleanlines S8-182
8.1.2.3 Metric Range of preferred Dimensions S8-182
8.1.2.4 Self-Tapping Screw S8-182
8.1.2.5 Corrosion S8-182
8.1.3 Compliance With Manufacturer's Instruction S8-183
8.1.4 Component and materials

8.1.4.1 Conditions of Operation S8-183
8.1.4.2 Maintenance To Be Kept To A Minimum S8-183
8.1.4.3 Components S8-183
8.1.4.4 Metering S8-183
8.1.5 Identification of Equipment S8-184
8.1.6 Protective Requirements

8.1.6.1 General S8-184
8.1.6.2 Insulating Bushes S8-184
8.1.6.3 Isolation From Main Supply S8-184
8.1.6.4 Earthing of Transformer Secondary Circuits S8-184
8.1.6.5 Current Loading of Wires S8-184
8.1.6.6 Danger Notices S8-185
8.1.6.7 Cable Connecting Units S8-185
8.1.6.8 Insulation S8-185
8.1.6.9 Whiskering of Tin S8-185
8.1.7 Electricity Supply S8-185
8.1.8 On-Site Commisioning Test Procedures S8-185
8.1.9 Documentation
8.1.9.1 General S8-186
8.1.9.2 Hardware, Software and maintenance Manual S8-186
8.1.10 Guarantee of Supply S8-187
8.1.11 Warranty Period S8-187

Page
8.2 LOW VOLTAGE UNDERGROUND CABLES
8.2.1 Type of Cables S8-187

8.2.1.1 Power Cables S8-187
8.2.1.2 Feeder Cables for Vehicle Detectors S8-188
8.2.1.3 Loop Cables for Vehicle Detectors S8-188
8.2.1.4 Earthing Conductors S8-188
8.2.2 Cable Termination S8-188
8.2.3 Cable Jointing S8-188
8.2.4 Cable Markers S8-188
8.3 SIGNAL LANTERNS
8.3.1 Standard Requirements S8-189
8.3.2 Optical Requirements S8-189

8.3.2.1 Optical Arrangement for Drivers S8-189
8.3.2.2 Optical Arrangement for Pedestrians S8-189
8.3.2.3 Height of Signal S8-189
8.3.3. Constructional Requirements S8-190

8.3.3.1 Lamps S8-190
8.3.3.2 Target Boards S8-190
8.4 SIGNAL POSTS AND MAST ARMS
8.4.2 Cable Entry S8-191
8.4.3 Connecting Facilities for Cables S8-191
8.4.4 Location and Erection S8-191

8.4.5 Finish S8-191
8.5 PEDESTRIAN PUSH-BUTTONS
8.5.2 Location S8-192
8.5.3 Pedestrian Demand Indicator S8-192
8.5.4 Audible Signal S8-192

Page
8.6 TRAFFIC CONTROLLER
8.6.1 General Requirements S8-1192
8.6.2 Housing S8-193
8.6.3 Controller Mains Switch Board S8-193
8.6.4 Facility Switch S8-194
8.6.5 Pedestrian Facilities S8-194
8.6.6 Logic Module S8-194

8.6.6.1 Microcomputer System S8-194
8.6.6.2 Input/Output Interfaces S8-195
8.6.6.3 Real 'Time-Of-Day' Clock S8-195
8.6.6.4 Operator Interface and Controller Display S8-195
8.6.6.5 Supply Monitor S8-195
8.6.6.6 Watchdog Timer S8-196
8.6.7 Mains Supply Interruptions S8-196
8.6.8 Circuit Breakers S8-196
8.6.9 Inputs S8-196
8.6.10 Interchangeability S8-196
8.6.11 Vibration and Noise S8-196
8.6.12 Radio Interference S8-196
8.6.13 Safety S8-196
8.6.14 Timing S8-197
8.7 VEHICLE DETECTORS

8.7.2 Number of Traffic Lanes S8-197
8.7.3 Supply Voltage S8-197
8.7.4 Equipment Construction S8-197
8.7.5 Performance Requirements S8-197

Page
8.8 ROADWORKS
8.8.1 General S8-197
8.8.2 Permission to Excavate Road S8-198
8.8.3 Excavation, Backfilling, Reinstatement and maintenance of

Excavations S8-198
8.8.3.1 General S8-198
8.8.3.3 Bedding of Excavation S8-199
8.8.3.4 Cable Ducts S8-199
8.8.3.5 Cable Laying and Installation S8-199
8.8.3.6 Cable Laid Direct On The Ground S8-200
8.8.3.7 Cables Installed in Precast Concrete Trenches S8-200
8.8.3.8 Backfilling of Excavations And Reinstatements S8-201
8.8.3.9 Sensing Loop Slots S8-201
8.8.3.10 Maintenance of drains and Services During Excavations S8-201
8.8.3.11 Reinstatement of Drains and Precast Units S8-202
8.8.3.12 Completion of Works S8-202
8.8.3.13 Maintenance of Excavation S8-202
8.8.4 Traffic Arrangements S8-203
8.8.4.1 General S8-203

8.8.4.2 Arrangement and Location of Signs Barriers and Barricades S8-203
8.8.4.3 Temporary Warning lamps S8-204
8.8.4.4 Use of Traffic Guidance Cones S8-204
8.8.4.5 Temporary Traffic Diversions S8-204
8.8.4.6 Temporary Traffic Control S8-204
8.8.4.7 Plant and Equipment S8-205
8.8.4.8 Vehicles S8-205
8.8.4.9 Maintenance of Signs, Lights, Barriers,Temporary Traffic
Diversions, etc. S8-205
be responsibile for the design,

SECTION 8 - TRAFFIC SIGNALS material quality and
workmanship of the system and
8.1 GENERAL every part of the system offered,
whether manufactured by him or
8.1.1 Scope of Work supplied to him by other
manufacturers. Approval by the
This work shall comprise the design S.O. does not relieve the
of cabling works and the supply and Contractor of these
installation of all signal lanterns, responsibilities.
traffic controllers, detectors, posts,
ducting and cabling, and switchgears Materials shall as far as possible
with all necessary ancillary be of Malaysian origin except
equipment, together with the where such materials can be
transportation, storage, erection, shown to be unavailable in
connection, testing and Malaysia.
commissioning of the same for a
complete traffic signal installation, 8.1.2.2 Cleanliness
all in accordance with the Drawings
and this Specification. The work Particular attention shall be given
shall also include cabling from the in the design of the equipment for
nearest specified power source of the the exclusion of dust, dirt, etc.,
local supply authority to the traffic especially in the case where
control system, if required. forced ventilation is employed.
The type of signal operation, number 8.1.2.3 Metric Range of Preferred

of plans, number and sequence of Dimensions
phases, cycle times, timings of each
phase, offset times, locations of Except as may be agreed for
controllers and power source tapping practical reasons, design shall
points, and other specific make use of the metric range of
requirements shall be as shown on preferred dimensions and
the Drawings. tolerances.
8.1.2 Design and Construction 8.1.2.4 Self-Tapping Screws
8.1.2.1 Contractor's Responsibility Self-tapping screws shall be used

only for retaining duties. They
The Contractor shall design the shall not be used for fixing
interconnecting signal cabling for removable covers, nor for the
the proposed signal system as support of direct loads.
shown on the Drawings. The
cabling design drawings are to be 8.1.2.5 Corrosion
approved by the S.O. before
construction commences. All equipment shall be designed
Equipment offered shall be in all to resist corrosion in the
respects suitable for the Malaysian environment for a
requirements and for the period of 20 years from the date
environmental conditions of installation.
specified. The Contractor shall

Page 182
FOR INTERNAL USE ONLY 8.1.3 Compliance With Manufacturer's
Instructions
The Contractor shall ensure that the Standard Specification For Road Works
equipment and parts used shall be
entirely suitable for the work to be replaceable may be accepted with
performed and that they shall be the aproval of the S.O.
manufactured to proper tolerances
and fit. He shall further ensure that 8.1.4.3 Components
the loading of equipment shall under
all normal circumstances not exceed All active and passive
the maximum laid down or agreed to components, their mounting and
in writing by the manufacturer. the plugs, sockets and
connections, shall be designed
The Contractor shall be responsible for a life expectancy of 20 years
for the inspection of all equipment as specified in Sub-Section
and parts before their incorporation 8.1.4.2. All shall operate well
in the Works to ensure that they within their ratings with due
comply with the requirements of this consideration for the
Specification and that they are not environmental conditions and
defective in any way as regards temperature rises within cabinets
materials or workmanship. Should or enclosures.
any such non-compliance or defects
be found during the inspection, the Thermionic valves other than
Contractor shall correct or cause to cathode-ray tubes shall not be
be corrected such non-compliance used.
and defects, all at the Contractor's
expense and to the satisfaction of the Metal oxide or grade II carbon
S.O. resistors shall be used. Grade I
carbon film resistors shall not be
8.1.4 Components and Materials used.
8.1.4.1 Conditions of Operation Where high dissipation power

resistors are used, metal oxide
The system shall be designed to resistors shall be used whenever
operate continuously. Account they are available, in preference
shall be taken of equipment being to wire wound types.
sited in all exposed locations.
Metal can transistors shall be
8.1.4.2 Maintenance To Be Kept To A used wherever possible.
Minimum Germanium transistors shall not
be used unless approved by the
The materials and components, S.O.
excluding expendable items such
as lamps, shall be such as to 8.1.4.4 Metering
provide a life expectancy of up to
20 years unless specifically stated The equipment shall be provided
otherwise in this Specification. with waveforms and voltage test
Components which have a points as necessary for indicating
shorter life span but are easily circuit conditions.
Page 183
The Contractor shall mark or label
8.1.5 Identification of Equipment clearly all modules, units and main
parts of the system with a functional
code or title, type number, trade Standard Specification For Road Works
name and serial number. The
marking or labelling of main items 8.1.6.3 Isolation From Main Supply
shall be clearly visible on the
outside. The labels and markings of Unless otherwise agreed by the
encased units or modules shall be S.O., systems shall be
visible when the case or cover is completely isolated from the
removed. Components shall not be mains supply by means of a
marked with circuit references. The suitable double-wound
marking shall be adjacent to the transformer which shall include
component. Markings required for an earthed screen. The primary
controls, maintenance or warning and secondary output
shall be adjacent to the part terminations shall be separated in
concerned. Markings shall maintain an approved manner.
legibility throughout the life of the
equipment in the specified The main transformers at the
environmental conditions. controller shall be provided with
primary tappings so that the
Techniques used shall be approved equipment operates with mains
by the S.O. supply in the range of 200 to 260
volts.
8.1.6 Protective Requirements
8.1.6.4 Earthing of Transformer
8.1.6.1 General Secondary Circuits
All metal work not normally When a dangerous voltage is

required to carry current shall be connected to the primary winding
connected to an earth point of a transformer, the secondary
except where otherwise dictated circuit shall be connected where
by transmission or other practicable to an earthed point.
requirements (such metal work
shall include cases, screens, 8.1.6.5 Current Loading of Wires
cores, cable glands, cable
conduits and cable sheaths, etc.). All wirings shall be suitably rated
to carry in excess of the current
8.1.6.2 Insulating Bushes permitted by their fuses, circuit
breakers or other current linking
Insulating bushes shall be devices. Similar precautions shall
provided wherever conductors be taken to reduce the possibility
carrying dangerous voltages pass of overheating components.
through holes in metal parts and
where the conductors would be Provisions shall be made in the
likely to touch the edge of the equipment :-
holes.
i) to prevent damage to circuits
due to failure of any pulses,
Cawangan Jalan, Ibu Pejabat JKR, K.L power supplies or mains
supply;
ii) to prevent damage to power

supplies by inadvertent
removal of the load.
Page 184
All equipment or units working
8.1.6.6 Danger Notices at a voltage at or above 150
volts D.C. or 100 volts A.C.
(RMS) shall be protected by an Standard Specification For Road Works
approved cover, which shall be
removable. The cover shall have 8.1.6.9 Whiskering of Tin
a sign with a danger symbol
indication of the voltage. The Where non-insulated electronic
highest voltage to which access circuits are positioned within 4
can be had by removal of the mm of a non-insulated tinned
cover shall be shown, where surface, a loose barrier of
dangerous voltages exist. insulated materials shall be
provided between the surface and
8.1.6.7 Cable Connecting Units the connection to prevent the
possibility of unwanted contact.
Terminal strips and terminals Approved soldered-in-lead
shall be clearly and indelibly through connectors are exempted
coded. Terminals carrying mains from this requirement.
electrical power shall be
segregated from other terminals. 8.1.7 Electricity Supply
Unless approved by the S.O., not
more than three cable cores shall The Contractor shall comply with all
be retained by any terminal. All LLN or the power source authority
wiring and cabling shall be neat, requirements in getting an electricity
adequately supported to prevent supply to the installation, and any
vibration, and so arranged as to costs associated with obtaining this
prevent strain on individual supply shall be included in the
wires, particularly on hinged Tendered rates. The Contractor shall
panels. ensure that the equipment supplied
will function correctly at the supply
8.1.6.8 Insulation voltage, and shall allow for normal
variation and surges.
If no value is specified, the
insulation resistance between any 8.1.8 On-Site Commissioning Test
two parts not intended to be in Procedures
electrical contact shall not be less
than 100 megaohms when Testing and commissioning of all
measured at a voltage appropriate equipment shall be successfully
to the equipment. Where `n' such completed within one (1) month
paths are effectively connected in from the date of completion of the
parallel, the resistance of the installations.
combination shall be not less than
100/n megaohms. The Contractor shall notify the S.O.
when the on-site commissioning
tests are to be undertaken. The
Contractor and the Supervisor shall
forward to the S.O. duly certified
copies of the test results when the
tests have been successfully
Cawangan Jalan, Ibu Pejabat JKR, K.L completed. When the S.O. has
received these test results and is
satisfied that the system has passed
the test, the S.O. shall notify the
Contractor in writing that the system
has passed the on-site
Page 185
FOR INTERNAL USE ONLY notify the Contractor in writing of all
faults detected during these tests. If
commissioning tests. The S.O. shall the S.O. decides the system is not in
accordance with the Contract, he
may reject the system, and he shall Standard Specification For Road Works
inform the Contractor of the reasons
in writing within a reasonable time. 8.1.9.2 Hardware, Software and
Maintenance Manual
8.1.9 Documentation
The manual shall contain
8.1.9.1 General descriptions of the complete
hardware system followed by
System manuals for each maintenance procedures. A
equipment associated with the description of the complete
Contract shall be delivered to the software system shall also be
S.O. Reissues shall be provided included.
if site commissioning and testing
make this necessary. The hardware description shall
start with the overall
All documentation shall be configuration of the system, with
indexed and shall carry an issue layouts showing the location of
number and date. every unit, with block diagrams
and an explanation of the
Two copies each of the operation of the system.
documentation shall be supplied
to the S.O. Detailed descriptions of
component units shall explain
All documentation shall be their operation. Block diagrams
produced in uniform style in A4 showing the flow and interaction
size. All diagrams relating to the of data, logic diagrams, circuit
final documentation shall be diagrams with component
reduced to page height, bound valves, and layout diagrams
and correctly referenced to the shall be provided. Parts lists and
text. They shall fold clear of the wiring schedules shall be
text for ease of use. provided, but care shall be taken
to avoid these obscuring the
Great care shall be taken to operational description.
ensure that in the writing of all Maintenance procedures shall
documentation, expert familiarity cover the diagnosis of faults,
with apparently simple features is testing and setting up
not advertently assumed. adjustments, replacement of units
Difficulties should be anticipated. and routine mechanical servicing.
All documentation shall be in The software description should

English or Bahasa Malaysia. aim at enabling new programs for
an intersection to be written, and
to provide the basic standard
techniques used in writing the
system programs. Where
programming technique is
Cawangan Jalan, Ibu Pejabat JKR, K.L dependent on particular features
of the system, it is important that
program material is specially
written. This shall be in the form
of guidance, referring to
operational features in the
software manual.
Page 186
FOR INTERNAL USE ONLY final wiring diagrams, pole
locations, controller locations,
An as-built plan showing the detector placement, conduit runs
and timing plan shall be
included in each controller Standard Specification For Road Works
cabinet.
The Contractor shall carry out any
8.1.10 Guarantee of Supply repair within 24 hours of being
informed of the damages. Upon
The Contractor shall be required to failure to do so, the S.O. has the
ensure that for a period of not less option to appoint another party for
than 10 years from the date of repair and the cost thus incurred will
commissioning the system, a supply be borne by the Contractor.
of replacement components and
materials or their agreed equivalent All maintenance conducted shall be
is available, as the S.O. may require. entered into the Local Controller
A Contractor who is not a Logbook, dated and signed by the
manufacturer is required to submit a maintenance staff of the Contractor.
letter from the manufacturer
certifying that the manufacturer will Repainting of the signal aspects,
support the equipments and posts, and local controllers shall be
components. performed just before the end of the
Warranty Period.
8.1.11 Warranty Period
8.2 LOW VOLTAGE UNDER
After acceptance of the installation, GROUND CABLES
the Contractor shall still be subject to
obligation of free servicing, change 8.2.1 Types of Cables
in phasing, maintenance and free
replacement of all defective parts and 8.2.1.1 Power Cables
fused bulbs for a period of twelve
(12) months from the date of issue of Power cables shall be
the Certificate of Completion. A manufactured and tested in
qualified Service Engineer provided accordance with M.S. 274 and
by the Contractor must be available shall have high conductivity plain
on 24 hours service a day to attend to copper stranded conductors,
any breakdown at anytime including insulated with PVC suitable for a
public holidays. voltage of between 600 and 1000
V, laid together and bedded with
All repairs and replacements PVC, armoured with galvanised
required during the Warranty Period steel wires and sheathed with
shall be carried out with despatch PVC. The copper conductors for
and an adequate supply of spares Mains Power cables running
shall be available for this purpose. from the power source to the
The Contractor shall be liable for controller shall have a nominal
damages if he does not undertake cross-sectional area not less than
remedial works within 24 hours. 16 sq.mm. Other interconnecting
signal cables shall be multicore
cables having copper conductors
of nominal cross-sectional area
Cawangan Jalan, Ibu Pejabat JKR, K.L not less than 1.5 sq.mm with a
minimum of 5 cores.
Page 187
FOR INTERNAL USE ONLY comply with the appropriate
Tables of the latest IEE Wiring
The current rating of cables shall Regulations for the class of
conductor used.
8.2.1.2 Feeder Cables for Vehicle
Detectors 8.2.1.4 Earthing Conductors
The material for feeder cables to Earthing conductors shall have a

vehicle detectors shall be nominal cross-sectional area of
screened, twisted balanced-twin 2.5 sq.mm and earthing rods shall
cables which shall be have a minimum cross-sectional
manufactured and tested in area of 10 sq.mm.
accordance with M.S. 274. The
core conductors shall be of 8.2.2 Cable Termination
annealed copper having a
nominal cross-sectional area of Unless otherwise permitted, all cable
1.5 sq.mm unless otherwise termination and jointing works shall
specified. The cable shall have a be carried out in the presence of the
nominal characteristic impedance S.O. A plastic laminated plate
(Zc) of 90 ohms at 50 kHz. engraved with details such as size of
cable, number of cores, date of
The conductors shall be insulated. commissioning, date of jointing,
The insulation shall be length of cable, distance of cable
waterproof and, when installed, joint, etc., shall be securely fixed
shall withstand a temperature of near the termination.
70ºC without suffering damage or
deformation. PVC/SWA/PVC cables shall be
provided with compression cable
8.2.1.3 Loop Cables for Vehicle gland termination. The cable gland
Detectors shall be of gunmetal or brass and
shall grip both the inner and outer
The material for inductive type PVC sheath of the cable. It shall be
vehicle-detector loop cables shall so designed that any strain on the
be in accordance with Australian cable is taken by the steel wire
Standard 2276.3 unless armouring which shall be effectively
otherwise specified herein. Any sealed between the gland itself and
deviation from A.S. 2276.3 shall the outer cable sheath.
be at the request of or subject to
the approval of the S.O. The 8.2.3 Cable Jointing
detector sensing shall be of a type
which can be easily assembled No cable jointing shall be allowed
from bulk cable on Site, and for interconnecting signal cables.
shall be approved by the S.O. Jointing of mains power cables shall
be allowed only when approved by
the S.O.
8.2.4 Cable Markers
Cable markers with lettering and

Cawangan Jalan, Ibu Pejabat JKR, K.L signs as shown on the Drawings
shall be provided by the Contractor
at every change of direction of
underground mains power cable
routes and at every 15 metres on
straight runs. Cable markers shall be
Page 188
FOR INTERNAL USE ONLY construction and shall be approved
by the S.O.
of heavy duty reinforced concrete
The cable marker shall form a
trapezoidal block with a 100 mm Standard Specification For Road Works
square top face and 150 mm square
bottom face, and shall be 400 mm in For horizontal overhead signals,
height as shown on the Drawings. the coloured lens of the left-most
The top face shall be indented in optical system shall be green,
bold lettering with the initials `L.V.' the middle one amber, and the
and a directional sign or signs right-most one red, as seen by the
indicating the direction/directions of driver.
the cable route. The cable marker
shall be buried to a depth of 300 mm Primary signals shall be fitted
or any other depth as directed by the with a type A visor and secondary
S.O. Cable joint markers of similar signals shall be fitted with a type
construction but with the symbol `X' B visor as described in A.S.
shall be provided and installed at 2144.
every cable joint in a similar manner.
8.3.2.2 Optical Arrangement for
8.3 SIGNAL LANTERNS Pedestrians
Each signal face shall contain

8.3.1 Standard Requirements two optical systems arranged
vertically, each having a diameter
All components, their installation of not less than 295 mm nor
and performance, shall be in more than 305 mm, which shall
accordance with A.S. 2144 unless incorporate pedestrian symbols as
otherwise specified herein. Any shown on the Drawings. The
deviation from A.S. 2144 shall be at upper optical system shall
the request of or subject to the illuminate a red `DON'T WALK'
approval of the S.O. symbol and the lower one a green
`WALK' symbol. The optical
8.3.2 Optical Requirements system spacings shall be as
8.3.2.1 Optical Arrangement for Drivers
8.3.2.3 Height of Signal
Each signal face shall, unless
otherwise shown on the (a) Post-Mounted Signals
Drawings, contain three optical Intended For Drivers
systems arranged vertically, each
having a diameter of not less The height of signals shall be
than 295 mm nor more than 305 such that when erected the centre
mm. For post-mounted signals, of the amber optical system shall
the coloured lens of the upper be not less than 2.4 metres nor
optical system shall be red, the more than 4 metres above the
middle one amber, and the lower carriageway level. Where no
one green. amber signal is installed these
dimensions apply to the centre of
the green signal.
Page 189
FOR INTERNAL USE ONLY Pedestrians
(b) Light Signals Intended For The height of signal shall be

such that when erected the
height of the lower edge of Standard Specification For Road Works
the housing enclosing the green
signal shall be not less than 2.1 iv) overall length : 44 mm
metres nor more than 2.6 metres maximum;
above the carriageway level.
v) overal diameter : 12 mm
(c) Overhead Mounted Traffic maximum;
Control Light Signals
vi) nominal operating voltage :
The height of overhead mounted 11.7 V.
signals shall be such that when
erected, the lowest point of the
signal head assembly shall be not Each tungsten halogen lamp shall
less than 5.5 metres nor more be provided with an appropriate
than 8.5 metres above the transformer complying with the
carriageway level. requirements of B.S. 9720,
mounted within the signal head
8.3.3 Constructional Requirements and connected to a terminal block
which may be mounted remotely.
8.3.3.1 Lamps Wiring between the lamp holder
and the transformer and the
The lamp used in the optical terminal block shall be in
system, to meet the requirements compliance with the requirements
of A.S. 2144 Section 3, shall be of M.S. 136 and B.S. 6007.
a 12 V, 50 W, long life tungsten
halogen lamp. 8.3.3.2 Target Boards
The bulb shall be clear, Unless otherwise specified, a

uncoloured and the filament shall target board shall be provided
only be used in the horizontal with each signal face intended for
position. The lamp shall meet the vehicle drivers, extending not less
following requirements as tested than 275 mm above the centre
in A.S. 2144 :- of the upper optical system nor
less than 275 mm below the
i) nominal lumens : 820 centre of the lower optical
lm at 12 V; system. It shall extend not less
than 280 mm horizontally either
ii) nominal life : 2000 hours side of the vertical centre line of
continuous the optical system. Other types
burning at of target boards shall be as shown
12 V input; on the Drawings. The target
boards shall be manufactured
iii) nominal colour temperature : from a durable resilient material
2850 K at 12 V input; and shall be stiffened where
necessary to resist distortion due
to wind and extreme ambient
Cawangan Jalan, Ibu Pejabat JKR, K.L temperature. All target boards
shall have an orange border not
less than 45 mm nor more than
55 mm wide.
Page 190
FOR INTERNAL USE ONLY ARMS
8.4 SIGNAL POSTS AND MAST 8.4.1 Standard Requirements

All signal posts, signal mast arms Standard Specification For Road Works
and mountings of signal lanterns
shall be as shown on the Drawings. 8.4.3 Connecting Facilities for Cables
The posts and mast arms shall be so
designed and constructed as to Provision shall be made for the
provide adequate support and connection of terminating and inter
stability for the signal head assembly. connecting cables coming from
within the post or mast arm and of
All signal posts shall be of tubular cables from the traffic signal
hollow section of steel with a lanterns.
nominal diameter of 100 mm and
fitted with a weather-proof cap to 8.4.4 Location and Erection
prevent ingress of water.
The posts and mast arms shall be
Mast arms shall be tubular hollow erected at the approximate locations
sections of steel of a generally as shown on the Drawings. On
tapered form mounted on a baseplate roadways whose edges are defined
as shown on the Drawings. by a raised kerb, the posts shall be
erected so that no part of the signal
Every post shall be provided with head other than overhead signals
one nickel-plated brass earthing projects over the roadway.
screw located within the post, 25
mm below the top. Where possible, the signal should
have a clearance of 300 mm to 450
The posts and mast arms shall be mm behind the kerb line. The post
capable of having holes drilled in the shall be at a distance not less than 1
vertical section, 1 metre above the metre before the edge line.
ground, for the mounting of one
pedestrian push-button assembly in In areas where there is no kerb, the
accordance with Sub-Section 8.5. steel posts should be erected so that
the signal head is clear of the
8.4.2 Cable Entry shoulder (or usable area) and
should not be less than 2 m nor
Buried posts shall incorporate a more than 3 m from the edge of the
cable-entry aperture as shown on the nearest traffic lane.
Drawings. Baseplate-mounted posts
shall provide for entry of the cable All posts and mast-arms shall have
into the interior of the post through a their exact location determined by
hole in the baseplate having a the S.O. and recorded on the as-built
diameter not less than the inside Drawings.
diameter of the post.
8.4.5 Finish
Unless otherwise specified, the

interior and exterior of steel posts
shall be protected by a finish
complying with the requirements of
M.S. 740.

FOR INTERNAL USE ONLY painted with alternate black and orange bands
of 300 mm width in weather resisting plastics
The exterior surface of steel posts shall be material as specified in Clause 6 of B.S. 873,
Part 1, and as shown on the Drawings.
Any surface cut after galvanizing, painting, or
the application of the plastics finish, shall be 8.5.4 Audible Signal
wire brushed and given two coats of good qual-
ity zinc-rich paint in accordance with B.S. An audible signal shall, unless
4652. otherwise specified, be provided
with all pedestrian push-buttons in
8.5 PEDESTRIAN PUSH-BUTTONS accordance with A.S. 2353.
8.5.1 Standard Requirements 8.6 TRAFFIC CONTROLLER
All pedestrian push-buttons, their 8.6.1 General Requirements

mechanism and operation, shall be
in accordance with A.S. 2353 A controller is the complete timing
unless otherwise specified herein. mechanism which controls the
Any deviation from A.S. 2353 shall signal phases at an intersection. The
be at the request of or subject to controller shall be microprocessor-
the approval of the S.O. based consisting of :-
8.5.2 Location i) a microprocessing unit;
Pedestrian push-button detectors ii) interfacing for inputs and outputs;

shall be provided facing the footpath
at each end of each crosswalk where iii) ancillary equipment.
pedestrian actuated signals are
required as shown on the Drawings. The control equipment and
components shall be housed in a
8.5.3 Pedestrian Demand Indicator weatherproof cabinet as specified in
Sub-Section 8.6.2.
When the button is pressed, an
internally illuminated panel shall The controller shall be able to
light up bearing the legend `NANTI', provide four phases and shall be
which shall be white on a black or capable of expansion to at least eight
blue background. It shall continue to phases by the addition of modules on
be displayed until the cross signal site, which shall be in addition to any
(green man) commences. The special phase required in connection
pedestrian demand indicator shall be with start up sequences, all reds,
provided with all pedestrian push- etc. It shall also provide a variety of
buttons unless otherwise shown on timing functions and differing
the Drawings. operational modes. The controller
unit shall be capable of operating a
minimum of eight plans in a 24 hour
period. All active and passive
components, their mountings and
plugs, sockets and connections
shall be suitable for their application.

FOR INTERNAL USE ONLY The housing shall have a
weatherproof enclosure for the
8.6.2 Housing protection of :-
i) the logic module; Standard Specification For Road Works
ii) interfacing and/or lamp switching All means of access shall be

modules; protected by locks of different
patterns and the corresponding locks
iii) power supplies; and keys shall be identical for
controller housings of the same
iv) a `call-recorded' tranformer; make, type and series. Not less
than two keys of each type shall be
v) mains switch board; supplied with each controller and
they shall be handed over to the S.O.
vi) facility switch; after the completion of testing and
commissioning.
vii)shelf space for mounting of
vehicle detectors. A log book shall be provided in each
housing for the purpose of
The housing cabinet shall be in maintenance and inspection records.
accordance with A.S. 2578, Part 1, The log book shall be attached to the
unless otherwise specified herein. housing by a cord or similar method
Any deviation from A.S. 2578, Part to prevent removal from the housing
1, shall be at the request of or cabinet. A pocket or shelf shall be
subject to the approval of the S.O. provided within the housing for its
storage.
Housing shall be manufactured from
such material approved by the S.O. 8.6.3 Controller Mains Switch Board
Appropriate means of entry and The controller mains switch board

support for cables shall be provided. shall consist of :-
Sufficient ventilation shall be i) one mains switch and one mains

provided to prevent condensation fuse (rated 30 A);
inside the cabinet under all weather
conditions. Charcoal or some other ii) one isolation switch together with
dehydration agent shall be placed in a fuse to control mains supply,
the housing as directed by the S.O. active to all lamps;
All non-current carrying metal parts iii) one flashing yellow feature
shall be bonded together and switch and fuse;
effectively earthed in accordance
with CP 1013. iv) one equipment switch and fuse
(rated 15 A) to supply four
sub-circuits labelled as :-
. controller
. detectors
. auxiliary
Cawangan Jalan, Ibu Pejabat JKR, K.L . general purpose outlet;
v) neutral link;
vi) earth link.
Page 193
FOR INTERNAL USE ONLY operation at 240 V + 6%, 50 Hz +
1%, single phase A.C. supply.
The controller shall be suitable for
8.6.4 Facility Switch
A facility switch shall be provided to
switch the signal lanterns to ON, When the pedestrian indications are
OFF or FLASH or other facilities allowed an exclusive phase, the
such as manual operation. The pedestrian steady green shall be
switch shall only control the signal controlled by the appropriate control
lamps and flashing yellow circuits command and followed by the
while leaving the control equipment flashing green pedestrian signal. The
fully operative. intergreen periods shall be inserted
before the pedestrian steady green
Access to this facility shall be via a and between the end of the flashing
separate locked door or some other green and the start of the next
means which does not give access to vehicle phase green. It shall be
the controller. The facility shall be possible to operate the pedestrian
located not less than 1 metre from phase with or without pedestrian
the ground level. detection. This shall be selected by a
switch or other methods within the
8.6.5 Pedestrian Facilities controller, subject to the approval of
the S.O.
Pedestrian indications shall be
allocated as exclusive phases or be 8.6.6 Logic Module
connected in parallel to a green
phase(s). Arrangement of the microprocessor
based logic module shall be subject
When the pedestrian indications are to the approval of the S.O.
connected in parallel to a green
vehicle phase, the steady pedestrian 8.6.6.1 Microcomputer System
green shall commence at a preset
period adjustable to 0, 1, 2, 3, 4 The microcomputer system shall
or 5 seconds before or after the start contain a stored program in read-
of the green vehicle phase. The only-memory (ROM). Part or all
steady pedestrian green shall persist of the ROM shall be
until the end of a preset period. reprogrammable. The stored
program shall permit the traffic
It shall be followed by the flashing controller to be operated in
pedestrian green. The flashing different traffic modes as
pedestrian green shall flash at 76 to follows :-
84 flashes per minute, and the lamp
shall be on for between 50% to i) isolated traffic-actuated
70% of the time. The amber signal operation;
terminating the vehicle green phase
shall not commence until a preset ii) cableless/Synchronous
period adjustable to 0, 1, 2, 3, 4 or operation;
5 seconds has elapsed after the
termination of the flashing pedestrian iii) fixed time operation.
green.
Cawangan Jalan, Ibu Pejabat JKR, K.L All information relating to a
particular signal installation,
such as number of plans, signal
groups, detector logic, time
setting and description of logical
Page 194
FOR INTERNAL USE ONLY contained in the reprogrammable
ROM.
and conditional features, shall be
Time settings may be stored by
means of :- Standard Specification For Road Works
i) reprogrammable ROM; and The clock shall derive its timing

from two sources, either from the
ii) battery back-up RAM. 50 Hz mains supply or a crystal
oscillator. When the mains
The RAM settings shall be such supply is normal, the 50 Hz
that they may be changed by mains frequency shall provide the
means of a detachable keyboard time. The crystal reference signal
while the controller is shall be phase locked to the
functioning. The reprogrammable mains frequency by a digital
ROM shall be separate from the phase locked loop. The real time
CPU and its associated circuitry clock shall provide time in
to facilitate field servicing. seconds, minutes, hours and
days to the microprocessor via a
8.6.6.2 Input/Output Interfaces data bus.
The Contractor shall provide for 8.6.6.4 Operator Interface and Controller
the approval of the S.O., detailed Display
technical information on the
input and output interfaces. A keyboard display unit shall be
Inputs include those from vehicle provided as an operator interface
detectors, pedestrian push with the controller logic module.
buttons and signal links. The Visual indicators shall be
output shall be to the vehicle provided to indicate the status of
signal lamps, pedestrian lamps, various traffic parameters such as
wait indicators and signal the phase currently running, base
linking. phase step for each phase,
demand for each phase, pedestri
8.6.6.3 Real `Time-of-Day' Clock an demands recorded, etc.
For cableless/synchronous When operated in link mode, the

linking operations, a hardware display shall be able to provide
clock shall be provided. The all traffic parameters associated
circuit generating the hardware with the appropriate link mode.
clock shall be backed up by a
standby battery for up to 48 8.6.6.5 Supply Monitor
hours or more (when fully
charged). All D.C. power supplies to
various cards in the logic module
shall be constantly monitored to
ensure correct operation of the
controller.
The monitor shall be arranged so

that if one or more of the supply
Cawangan Jalan, Ibu Pejabat JKR, K.L output voltages falls below
certain preset levels, the power
failure detection circuit will
activate to cause the controller to
black out the intersection.
Page 195
FOR INTERNAL USE ONLY also be monitored. Any voltage
drop below certain levels shall
The mains supply voltage shall cause a black out situation.
8.6.6.6 Watchdog Timer Standard Specification For Road Works
A watchdog timer shall be used 8.6.10 Interchangeability

to detect failure of the
microprocessor system to execute All parts shall be interchangeable
its traffic control program. Any with like parts for equipment of the
failure to execute traffic same make, type and series.
instruction shall black out the
intersection. 8.6.11 Vibration and Noise
8.6.7 Mains Supply Interruptions The apparatus shall be reasonably

quiet and the mechanism shall not
In the event of a mains supply cause undue vibration. The
interruption equal to or less than apparatus shall be constructed so as
50 milliseconds, the controller shall to reduce to a minimum any damage
continue to function correctly. When to lamps and equipment due to
a controller commences to fail (after vibration caused by traffic.
a mains supply interruption in
excess of 50 milliseconds) it shall 8.6.12 Radio Interference
shut down for the duration of the
mains interruption plus a nominal The design of equipment shall be
period of about 5 - 10 seconds. At such as to prevent interference to
the expiration of this nominal period telegraphic, telephonic or
the controller shall commence radiotransmissions. The
operation at an all red state. This apparatus will be considered to
state shall persist for at least 5 meet this requirement, as far as
seconds and shall be followed by radio interference is concerned,
the pre-selected phase. if the interference produced by it
does not exceed the limits laid
8.6.8 Circuit Breakers down in M.S. 71 and B.S. 800.
Appropriate fuses or circuit breakers 8.6.13 Safety

shall be provided by the Contractor
for the connection of the controller to Where right of way signals are
the mains supply. A mains isolation shown for any controlled traffic
switch shall also be provided. in one phase, it shall not be
possible through failure of any
8.6.9 Inputs operating component of the
controller to give a right of way
All inputs shall be suitably protected signal to a conflicting traffic
against high voltage peaks and short signal.
circuits.
The Contractor shall satisfy the
S.O. as to how the conflicting
green state can be detected and
what action is to be taken on its
Cawangan Jalan, Ibu Pejabat JKR, K.L detection. The use of two
independent safeguard systems is
favoured. A method of testing
the operation of the safeguards
shall be provided.
Page 196
The Contractor shall satisfy the S.O. as to how the conflicting

green state can be detected and 8.7.3 Supply Voltage
what action is to be taken on its
detection. The use of two The detectors shall operate on 240
independent safeguard systems is V + 6%, 50 Hz + 1% single phase
favoured. A method of testing A.C. power supply. Power shall be
the operation of the safeguards supplied from the traffic controller.
shall be provided.
8.7.4 Equipment Construction
8.6.14 Timing
The Contractor shall be responsible
The duration of all periods timed for the manufacture, installation and
by the controller shall be within commissioning of the detector
+ 10% of the nominal time when system.
the applied main voltage is within
the range between + 10% of the 8.7.5 Performance Requirements
nominal value and + 4% of its
nominal frequency. This shall The detector shall respond to any
apply to those timing vehicle, except bicycles and
arrangements which measure trishaws, normally encountered on
selected fixed periods. The public roads travelling at any speed.
flashing rate of any flashing The Contractor shall satisfy the S.O.
signals shall be between 76 and with respect to the accuracy of the
84 flashes per minute within the detector unit in terms of false or nil
same voltage and frequency presence actuation at normal
limits. operating sensitivity for all types of
vehicles including high-bodied
8.7 VEHICLE DETECTORS vehicles and multi-axle vehicles.
8.7.1 Standard Requirements 8.8 ROADWORKS
All equipment, its construction and 8.8.1 General

performance, shall be in accordance
with A.S. 2703 unless otherwise The Contractor shall carry out all
specified herein. Any deviation from necessary roadworks in connection
A.S. 2703 shall be at the request of with the installation of the system.
or subject to the approval of the These shall include any roadworks
S.O. associated with :-
8.7.2 Number of Traffic Lanes i) installation of Local Controller

and Detector Recording
The loop detector shall sense traffic housings;
flow on one to four traffic lanes
depending on where it is installed. It ii) installation of signal poles and
shall sense traffic moving in one heads;
direction only and detection on a two
way road shall be achieved by using iii) installation of cable ducting;
two sets of detectors so that the
information obtained for each
direction is separate.
Page 197
8.8.2 Permission to Excavate Road
If an existing conduit has been
installed across the road carriageway, The Contractor shall apply to the
all cross-carriageway cabling shall S.O. for approval to excavate the
be carried by this conduit. roadway. This approval shall not be
unreasonably withheld. Standard Specification For Road Works
The application shall be made not 8.8.3 Excavation, Backfilling

less than seven (7) days before the Reinstatement and Maintenance of
commencement of the work. Excavations
The Contractor shall comply with the 8.8.3.1 General

following conditions and other
additional instructions from the The Contractor shall cause as
S.O. :- little obstruction as possible to
the general public during the
i) trenching in sidetables, footpaths execution of all works under this
and carriageways shall be Contract, and shall pay due
excavated, backfilled, reinstated regard to the interests and
and maintained as specified in convenience of the public and of
this Sub-Section; all private persons who have
property in or are resident in the
ii) cables to be laid in carriageway neighbourhood of the works.
shall be at least 750 mm below
the carriageway level; The Contractor shall ensure that
no delay occurs between opening
iii) cables running longitudinally in excavations, laying cables,
footpaths and side-tables shall be backfilling and reinstatement and
at least 600 mm clear of the that these actions form a
edge of the kerb line or continuous process.
carriageway and at least 750 mm
below the adjacent carriageway 8.8.3.2 Excavation
channel level;
Each trench shall be excavated to
iv) no work shall be done during the required level and materials
traffic peak hours unless taken out shall not be re-used
approved by the S.O. unless otherwise specified or
For excavation in side-tables,

turfs shall be carefully removed,
stacked and periodically watered
for later re-use. The remaining
excavated materials may be
stockpiled on the Site for later
backfilling but excavated topsoil
Cawangan Jalan, Ibu Pejabat JKR, K.L shall be kept separate.
For excavation in carriageways

and footpaths, selected granular
materials, excavated premix and
subbase may be stockpiled on
Site for later backfilling. All
other unsuitable excavated
material must be removed to
spoil on the day it is excavated.
Page 198
FOR INTERNAL USE ONLY kept clear of the carriageways at
all times.
All excavated materials shall be
All sides of excavations shall be
vertical. In soft or unstable Standard Specification For Road Works
ground the sides shall be
adequately supported. necessary to cross drains, culverts
or similar obstructions which are
All excavations shall be kept free too deep for the cables to be
of standing water. buried below, galvanised steel
pipes shall be provided. The
If, for unavoidable reasons, a pipes shall be supported at each
trench running laterally across a end in a concrete block and
road cannot be backfilled and shall project through the blocks
must be left open overnight or for into the ground to a depth of a
a longer period, then steel plates, least 750 mm. All ducts shall be
securely bolted and adequate to extended at least 600 mm beyond
take traffic loading, shall be paved areas, concrete areas,
placed across the trench and the drains, road crossings, pipe
section of road opened to traffic. crossings, etc.
8.8.3.3 Bedding of Excavation Unless otherwise approved by the

S.O., the number of cables
Before ducts are laid, the trench installed in each duct shall be
beds shall be levelled and sand such that the space factor shall
placed on the bed and hand not be less than 60 %. A drawn
tamped to a thickness of not less wire shall be provided in each
than 75 mm. All ducts shall be duct.
covered by a layer of sand hand
tamped to a thickness of at least Unless specified to be provided
75 mm above the crown of the by others, the above galvanised
duct. steel pipes shall be provided by
the Contractor whether they are
8.8.3.4 Cable Ducts shown on the Drawings or not.
At road crossings, sewerage pipe 8.8.3.5 Cable Laying and Installation

crossings, water pipe crossings,
paved areas, concrete areas and All cables shall be handled, laid
areas specified by the S.O., and installed according to this
cables shall be protected by Specification, the IEE Wiring
galvanised steel pipes buried to a Regulations, cable manufacturer's
depth of 900 mm below recommendations and ERA
finished ground level. The pipes Reports by using proper
shall be heavy duty pipes, installation equipment.
complying with B.S. 1387,
complete with screwed and All cables shall be supplied in
socketed joints. Unless otherwise complete length to suit the
specified, the pipes shall be 150 circuits they serve and no straight
mm in diameter. Where it is through joints shall be used.
Straight through joints in the
Cawangan Jalan, Ibu Pejabat JKR, K.L cable will only be permitted in
very exceptional circumstances
such as those arising from
unavoidable limitations in
manufacturing length. If straight
through joints or other approved
Page 199
FOR INTERNAL USE ONLY the cost of such joints shall be
borne by the Contractor. No
joints are permitted by the S.O., joints in the cable will be allowed
unless approved in writing by the
S.O. Standard Specification For Road Works
The minimum bending radius the underground cable if the

of the cable shall be in cable size is not more than 120
accordance with Table 52C of sq.mm. For cable sizes
the IEE Wiring Regulations (15th exceeding 120 sq.mm, more
Edition). Wherever cables are than one row of bricks shall be
cut, the ends shall be laid. Each cable shall be
immediately sealed in an separately protected by these
approved manner unless it is bricks and the cover shall have at
intended to proceed with cable least 25 mm overhang on each
jointing or termination straight side of the cable.
away.
An orange coloured, multi-strand
Unless otherwise permitted by nylon rope of minimum 6 mm
the S.O., no cable shall be laid diameter shall be laid at a depth
and covered up in the absence of of 300 mm along the trench to
the S.O. identify the cable route. At every
10 metres interval, an extra 2
metres length of nylon rope shall
8.8.3.6 Cable Laid Direct On The be coiled and laid.
Ground
8.8.3.7 Cables Installed in Precast
Where trench beds have been Concrete Trenches
covered with sand, the cables
shall then be laid on this bedding Methods of installation of cables
in an orderly manner without in precast concrete trenches shall
overlapping and crossing each be in accordance with Table 9A
other. After laying the cables, a of the IEE Wiring Regulations
layer of 75 mm clean sand shall (15th Edition) for Type L, Type
cover the cables and shall be M or Type N cables. However,
carefully spread over the trench if the method is not specified, the
before placing the cable cables shall be installed as
protective covers. directed by the S.O.
The cable protective covers shall Cables laid at the bottom of

be clay bricks. The bricks shall trenches shall be Type L cables
be new, well burnt and in in accordance with Table 9A of
complete pieces. They shall be the IEE Wiring Regulations (15th
laid lengthwise from end to end Edition). Cables installed on the
along the entire route of the trench walls shall be Type M or
underground cable if the cable Type N cables in accordance
size is not more than 120 sq.mm. with Table 9A of the IEE Wiring
For cable sizes exceeding 120 Regulations (15th Edition) and
sq.mm, more than one row of the cables shall be secured on a
cable tray by means of saddles at
Cawangan Jalan, Ibu Pejabat JKR, K.L suitable intervals. In the case of
single core cables, whether
secured individually or in groups
to the cable tray, non ferrous
saddles shall be used.
Page 200
FOR INTERNAL USE ONLY from perforated hot-dipped
galvanised sheets finished in an
The cable tray shall be fabricated orange enamel. The minimum
thickness of the sheet steel used
shall be 1.5 mm for cable trays Standard Specification For Road Works
with widths of up to 300 mm
and shall be 2.0 mm for widths For excavations in carriageways
exceeding 300 mm. The cable and footpaths the backfilling shall
tray shall be supported at least be done in 150 mm layers to
25 mm from the trench wall by within 300 mm of the surface
mild steel brackets at 600 mm level using clean sand and
intervals. The brackets shall be suitable excavated granular
treated with anti-rust and painted material or other approved
with one coat of primer. Samples granular material. Each layer
of the cable tray and brackets shall be compacted using a power
shall be submitted to the S.O. for driven rammer. The next 230
approval prior to installation. mm of backfill shall consist of
crushed aggregate roadbase con
To provide electrical continuity, forming to Sub-Section 4.1.4 of
all cable joints shall be bridged this Specification, laid and
by means of tinned copper tape compacted by a power driven
of dimensions not less than 25 rammer. A tack coat of cationic
mm x 3 mm. All saddles for bituminous emulsion shall be
cables on cable trays shall be applied on the crushed aggregate
installed using bolts, washers surface and a 75 mm thick layer
and nuts. All tees, intersection of compacted asphaltic premix
units, adaptor units, etc., shall shall be placed as the final layer,
be factory manufactured unless all in accordance with the
otherwise approved by the S.O. relevant requirements of Section
4 of this Specification.
8.8.3.8 Backfilling of Excavations and
Reinstatements 8.8.3.9 Sensing Loop Slots
For excavations in sidetables, The Contractor shall be

berms and slopes, the excavated responsible for providing the slot
material shall be replaced in 150 in the roadway for the loop
mm layers in the reverse order to sensor; the installation and
which the material was jointing of the loop feeder cable;
excavated. Each layer shall be the backfilling of the slot in the
compacted with a power driven roadway; and the slot or trenches
rammer. The top 150 mm of for the feeder cables, all as
the excavation and adjacent shown on the Drawings.
disturbed ground shall be filled
with good loamy topsoil and 8.8.3.10 Maintenance of Drains and
hand tamped. Approved quality Service During Excavations
grass turfs shall be closely and
continuously fitted over the The Contractor shall ensure that
topsoiled area where necessary he has full knowledge of the
and directly pegged down to location of all drains and services
prevent displacement. in the area of any excavation
Cawangan Jalan, Ibu Pejabat JKR, K.L prior to the excavation
commencing. The Contractor
shall ensure that all precautions
are taken not to disturb such
drains and services and shall be
Page 201
FOR INTERNAL USE ONLY during the reinstatement of such
excavations.
responsible for their maintenance
The Contractor should note if the
Site of the Works is subject to Standard Specification For Road Works
frequent and heavy rainfall and
all precautions shall be taken to 8.8.3.13 Maintenance of Excavation
maintain existing drainageways
to prevent flooding. The Contractor shall be entirely
responsible for the proper
8.8.3.11 Reinstatement of Drains and maintenance and good condition
Precast Units of each excavation and each
reinstatement up to a period of
The Contractor shall carry out the three (3) calendar months after
reinstatement of all existing the date of the S.O.'s written
precast channel drains, gulleys, approval of such reinstatement
pavement slabs, dividers, kerbs, works.
etc., which have been affected by
any trench opening. Only All excavation sites prior to,
excavated units in a sound and during, and after reinstatement
undamaged condition may be shall be maintained in a sound
replaced, otherwise the and firm condition, free from
Contractor shall supply and lay depressions, humps, loose stones
similar new units. The units shall and any other similar defects
be replaced to the original lines such as not to constitute danger
and levels and shall be bedded, or unreasonable nuisance to
backed and jointed to the traffic or members of the public.
satisfaction of the S.O. Loose materials or stones shall
not be allowed to accumulate
8.8.3.12 Completion of Works over or around any excavation,
but shall be promptly swept clear.
On completion of reinstatement
works at any one site, the Any part of reinstatement in a
Contractor shall clear away all footpath or carriageway that
debris, surplus materials and settles more than 15 mm below
plant and leave the site in a clean the adjacent undisturbed surface
and tidy condition. The level shall promptly be re-
Contractor shall carry out any surfaced to a level not more than
further remedial works as 15 mm above the adjacent
directed by the S.O. and shall undisturbed surface level. The
obtain the S.O's written approval resurfacing shall be carried out by
for the reinstatement works. applying a prime/tack coat and
asphaltic premix as specified in
The Contractor shall be required

to maintain a small mobile gang
of workmen for the above
purpose, and a regular system of
daily inspection shall be instituted
Cawangan Jalan, Ibu Pejabat JKR, K.L for all trenches awaiting
temporary and permanent rein
statement. Should the Contractor
default in the maintenance of
excavations and reinstatement
where, in the S.O.'s judgement,
Page 202
FOR INTERNAL USE ONLY any way a traffic hazard, then
the S.O. shall have the power to
such default would constitute in attend forthwith to such defects
and the entire cost of the work
plus 25% shall be borne by the Standard Specification For Road Works
Contractor.
On multilane roads, not more
Before the expiration of the than one traffic lane in either
maintenance period of each item direction shall be closed except as
of work, the Contractor shall may be otherwise directed by the
write to the S.O. for final S.O. On roads of not more than
inspection of the work to one traffic lane in each direction,
determine any outstanding the Contractor shall ensure that
defects which have to be both lanes are kept open during
rectified. The Contractor will peak periods as previously
only be absolved of all the defined. This may be
responsibilities of the accomplished by the use of steel
maintenance after such defects plates as specified in Sub-Section
are rectified to the satisfaction of 8.8.3.2.
the S.O.
When the work is such that the
In the event that the Contractor simultaneous closing of several
fails to notify the S.O. of the date lanes cannot be avoided and
of expiration of the maintenance would cause undue interference
period and has not arranged for with traffic, the work should
the inspection of the work, the either be carried out at night or
maintenance period of each item during weekends. However, the
of work shall be deemed to have S.O. may give permission for the
been extended by the Contractor simultaneous closing of lanes for
due to his fault to such time until emergency works or other works
the final inspection is carried out. as deemed necessary.
8.8.4 Traffic Arrangements 8.8.4.2 Arrangement and Location of

Signs, Barriers and Barricades
8.8.4.1 General
The general arrangement and
Obstructions and excavations location of temporary signs at
shall be adequately fenced and works in progress shall be strictly
guarded at all times for the in accordance with ARAHAN
protection of all persons who use TEKNIK (JALAN) 2C/85,
the roadway. Particular attention published by Cawangan Jalan,
shall be paid to the positioning of Ibu Pejabat JKR, Kuala Lumpur,
the barriers. The whole and shall be submitted by the
obstruction or excavation shall be Contractor and approved by the
completely fenced off, but S.O. before work commences.
unnecessary blocking of traffic
lanes shall not be permitted. Work on a road involving less
Roads shall not be used for the than one-third of a traffic lane
unnecessary storage of materials. and work on a footpath in the
immediate vicinity of the
Cawangan Jalan, Ibu Pejabat JKR, K.L carriageway of a high speed road
shall be deemed to be minor
obstructions. In these cases, as it
will not be necessary to close up
one full lane, shorter barriers
shall be used.
Page 203
FOR INTERNAL USE ONLY temporary signing must be
reflectorised. When practicable,
All traffic signs used in signs shall be sited where they
will receive maximum benefits
from street lighting. Standard Specification For Road Works
8.8.4.3 Temporary Warning Lamps Cones shall be of rubber or

equivalent flexible material and
Temporary warning lamps shall shall be bright orange in colour.
be used during the hours of
darkness in conjunction with all 8.8.4.5 Temporary Traffic Diversions
temporary signs, barriers and
other traffic control devices For the duration of the work, a
which are to remain in position at satisfactory roadway shall be
night. Lamps shall be kept alight provided for the traffic. Where a
at all times during the hours of sufficient width of carriageway is
darkness. not available, a temporary traffic
diversion shall be constructed if
Warning lamps shall consist of possible. The extra carriageway
standard battery operated flashing shall be properly maintained in a
lights and shall be placed at smooth and hard condition at all
salient points of the site every times for the duration of the
night. work.
8.8.4.4 Use of Traffic Guidance Cones The maintenance of pedestrian

movement shall be provided by
When a portion of a roadway is construction of temporary walks,
closed to traffic by the use of barricades and handrails. Certain
barriers, barricades or signs, areas along the construction site
traffic guidance cones shall be may be restricted to pedestrian
placed on the road so as to guide use where such restrictions are in
traffic smoothly from the wide the interest of pedestrian safety.
section to the narrow section in
which a portion of the roadway 8.8.4.6 Temporary Traffic Control
has been closed to traffic.
It is essential that traffic control at
Cones shall be used only when the site be exercised diligently
the work is in progress or where and by competent personnel, if
there is a watchman who can the need arises.
reposition any of the cones which
may have been dislodged by the The methods of temporary traffic
traffic. Otherwise they shall be control are :-
removed from the roadway when
work ceases at night. At night, i) Police supervision : this
continuously operating flashing applies where the works are
lights shall be used to guide the of a very short duration with
traffic. some special feature, such as
a busy road junction;
ii) Manually operated 'Stop' and

Cawangan Jalan, Ibu Pejabat JKR, K.L 'Go' signs : this applies at
works of short duration,
provided that traffic is not
dense. Red and green flags
should, under no
Page 204
FOR INTERNAL USE ONLY traffic control, but could be
used to supplement the disc
circumstances, be used for signs.
8.8.4.7 Plant and Equipment Standard Specification For Road Works
In all cases where traffic is flashing lights on the top of the

permitted to use the whole or a vehicles. They should also have a
portion of the existing road, all plate on the rear side with the
plant items and similar words `SLOW MOVING' or
obstructions shall be removed `KENDERAAN PERLAHAN'.
from the road at night, if at all
practicable. During the day, a red 8.8.4.9 Maintenance of Signs, Lights,
flag shall project beyond the Barriers,Temporary Traffic
extremity of all plant items (other Diversions, etc.
than vehicles) adjacent to the
traffic lane. Signs, lights, barriers and other
traffic control devices shall be
Plant and equipment shall be lit at maintained in good order and in
night if within 5 metres of the the correct position day and
edge of the carriageway by two night. Signs shall be neat, clear
red lights suspended vertically and legible at all times.
from the point of obstruction Temporary traffic diversions shall
nearest to the carriageway. The be maintained in good order at all
lights may be omitted in cases times.
where there are permanent
obstructions, such as trees less
than 5 metres from the edge of
carriageway and the plant or
equipment are not closer to the
road than the permanent
obstructions.
8.8.4.8 Vehicles
Vehicles which carry out

operations on the road and which
are required to travel slowly or to
stop at frequent intervals should
be made as conspicuous as
possible. This shall be achieved
by painting such vehicles a
distinctive colour, and/or
painting their rear portions with
diagonal stripes of a contrasting
colour, and/or providing
Page 205
SECTION 9
CONCRETE

SECTION 9 - CONCRETE
Page

9.2 MATERIALS S9-211
9.2.1 Cement S9-211

9.2.1.1 Transportation and Storage S9-211
9.2.2 Aggregates S9-211

9.2.2.1 Coarse Aggregates S9-211
9.2.2.2 Fine Aggregates S9-211
9.2.2.3 Grading S9-211
9.2.2.4 Sampling and Testing of Aggregates S9-212
9.2.2.5 Storage of Aggregates S9-213
9.2.3 Water S9-213
9.2.4 Admixtures S9-214
9.3 CLASSIFICATION OF CONCRETE MIXES S9-214
9.3.1 Requirements for Prescribed Mixes S9-214
9.3.2 Requirements for Designed Mixes S9-215

9.3.2.1 Target Mean Strength S9-215
9.3.2.2 Suitability of Proposed Mix Proportions S9-216
9.3.2.3 Mixes S9-217
9.3.2.4 Control of Strength of Designed Mixes S9-217
9.3.3 Requirements for Concrete

9.3.3.1 Workability S9-218
9.3.3.2 Concrete Grade S9-218
9.3.3.3 Minimum Cement Content S9-218
9.3.3.4 Maximum Cement Content S9-218
9.3.3.5 Total Chloride Content S9-219
9.3.3.6 Maximum Sulphate Content S9-220
9.4 COMPLIANCE WITH SPECIFIED REQUIREMENTS
9.4.1 Prescribed Mix S9-220
9.4.2 Designed mix S9-221

9.4.2.1 Characteristic Strength S9-221
9.4.2.2 Sampling and Testing S9-221
9.4.2.3 Testing plan S9-222
9.4.3 Additional Cubes S9-223

Page
9.5 PRODUCTION OF CONCRETE
9.5.1 Supervision S9-223
9.5.2 Batching and Mixing S9-223
9.5.3 Transporting S9-224

9.5.4 Placing S9-224
9.5.5 Temperature Requirements S9-226
9.5.6 Compaction S9-226
9.5.7 Curing and protection S9-227

9.5.7.1 Normal Curing S9-227
9.5.7.2 Accelerated Curing S9-228
9.5.8 Ready-Mixed Concrete S9-228
9.6 CONSTRUCTION WITH CONCRETE
9.6.1 Construction Joints S9-228
9.6.2 Fixing Blocks, Brackets, built-In-Bolts, Holes, Chases, etc. S9-229
9.6.3 Precast Concrete Construction

9.6.3.1 Manufacturer Off the Site S9-230
9.6.3.2 Storage S9-230
9.6.3.3 Handling and Transport S9-230
9.6.3.4 Assembly and Erection S9-230
9.6.3.5 Forming Structural Connections S9-230
9.6.3.6 Protection S9-231
9.7 STEEL REINFORCEMENT
9.7.3 Construction Method S9-232

9.7.3.1 Cutting and Bending of Reinforcement S9-232
9.7.3.2 Fixing of Reinforcement S9-232
9.7.3.3 Splicing S9-233
9.7.3.4 Supporting and Spacer Blocks S9-233
9.7.3.5 Welding of Reinforcement S9-233

Page
9.8 FORMWORK AND SURFACE FINISH FOR STRUCTURE
9.8.1 Design and Construction

9.8.1.2 Voids In Concrete S9-234
9.8.1.3 Form Lining S9-235
9.8.1.4 Projecting Reinforcement, Fixing Devices S9-235
9.8.2 Finishes
9.8.2.1 Formed Surfaces S9-235
9.8.2.2 Unformed Surfaces S9-236
9.8.2.3 Remedial Treatment of Surfaces S9-236
9.8.3 Preparation of Formwork Before Concreting S9-237
9.8.4 Removal of Formwork S9-237

FOR INTERNAL USE ONLY with this Specification and the lines,
levels, grades, dimensions and cross-
SECTION 9 - CONCRETE sections shown on the Drawings and as
required by the S.O.
9.1 DESCRIPTION
9.2 MATERIALS
This work shall consist of the
9.2.1 Cement
construction of all structures or parts of
structures to be composed of Portland
The cement to be used throughout
cement concrete with or without steel
reinforcement, except for reinforced the work shall be Portland cement
concrete pipe culverts, which shall be obtained from an approved
constructed in accordance with the manufacturer. The cement shall be
provisions of Section 3.9, and Portland described under one of the following
cement concrete pavement, which shall headings :-
be constructed in accordance with the
i) Ordinary Portland Cement
provisions of Section 5. The work
shall be carried out all in accordance - the cement shall comply with
M.S. 522;
ii) Rapid Hardening Portland
Cement Manufacturer's certificates of test will, in
- the cement shall comply with general, be accepted as proof of
M.S. 522; soundness. Additional tests shall be
carried out on any cement which
iii) Moderate Sulphate Resisting appears to have deteriorated through
Portland Cement age, damage to containers, improper
- the cement shall comply with storage or any other reason. In any
B.S. 12; event, the batch of cement which has
been sampled and tested and found not
iv) Sulphate Resisting Portland to have complied with the requirements
Cement shall be rejected and removed from the
- the cement shall comply with Site.
B.S. 4027.
9.2.1.1 Transportation and Storage
The cement shall be transported
to the Site in covered vehicles
adequately protected against
water. It shall be stored in a
weather-proof cement store to the
approval of the S.O. and shall be
taken for use in the Works in the
order of its delivery into the store.
Cement delivered in bulk shall be
stored in silos of an approved
design.
9.2.2 Aggregates
Aggregates shall be naturally

occurring sand, gravel or stone,
crushed or uncrushed except as
otherwise specified, and shall
comply with M.S. 29. They shall be
obtained from a source approved by
the S.O. and shall be hard, strong,
durable and clean. They shall be free
from adhering coatings and shall not
contain any harmful material in
sufficient quantity so as to affect
adversely the strength, durability and
impermeability of the concrete.
Marine aggregates shall not be used

unless otherwise specified.
Page 210
9.2.2.1 Coarse Aggregate
Coarse aggregate shall comply

with M.S. 29.
9.2.2.2 Fine Aggregate
Fine aggregate shall comply with

9.2.2.3 Grading
(a) Coarse Aggregate
B.S. % Passing By Weight

410
Test
Sieve
Nominal Size of Nominal Size of
graded aggregate single-sized aggregate
(mm) 37.5mm 20.0mm 14.0 mm

to to to 63.0 37.5 20.0 14.0 10.0
5.0 mm 5.0 mm 5.0 mm mm mm mm mm mm
75.0 100 - - 100 - - - -
63.0 - - - 85 - 100 100 - - -
37.5 95 - 100 100 - 0 - 30 85 - 100 100 - -
20.0 30 - 70 95 - 100 100 0-5 0 - 20 85 - 100 100 -
14.0 - - 90 - - - - 85 - 100 -
100
10.0 10- 35 25 - 55 - 0-5 0 - 20 0 - 45 85 - 100
40 - 85
5.0 0- 5 0 - 10 0 - - 0-5 0 - 10 0 - 20
0 – 10
2.36 - - - - - - -
-
The grading of coarse aggregate

shall be analysed as described in
M.S. 30 and shall be within the
limits given in Table 9.1.
M.S. 29. If it is found necessary,
the fine aggregate shall be
washed and screened to the
TABLE 9.1 - COARSE AGGREGATE

(b) B.S. 410 % Passing By Weight Fine Aggregate

Test
Sieve Grading Grading Grading Grading The grading of
fin Zone 1 Zone 2 Zone 3 Zone 4 e aggregate shal
lb e analysed as d
escr ibed in M.S. 3
10.0 mm 100 100 100 100
0a nd shall be with
in t he limits of on
5.0 mm 90 - 100 90 - 100 90 – 100 95 – 100
eo f the grading zo
nes 2.36 mm 60 – 95 75 – 100 85 – 100 95 – 100 given in Table 9
.2.
1.18 mm 30 - 70 55 – 90 75 – 100 90 – 100
600 um 15 - 34 35 – 59 60 – 70 80 – 100 TABLE 9.2 - FI

N E AGGREGAT
E 300 um 5 - 20 8 – 30 12 – 40 15 – 50
150 um 0 - 10 0 – 10 0 - 10 0 - 15
9.2.2.4 Sampling and Testing of course of the work.

Aggregates
Samples of the fine and coarse

aggregates approved by the S.O.
shall be kept on Site, and shall
give a fair indication of the
general quality of the aggregates
for comparison with the
aggregates delivered during the
Tests shall be carried out on testing shall be in accordance
samples of the latter taken at with M.S. 30 and other standards
intervals as required by the S.O. as specified in Table 9.3. Any
The method of sampling and batch of aggregate rejected by the
S.O. sha
Properties Test Methods Limits ll be re
moved f
rom the
Grading M.S. 30 Table 9.1 & Table 9.2 Site.
Elongation Index M.S. 30 not exceeding 30%
Flakiness Index M.S. 30 not exceeding 25%
Water Absorption M.S. 30 not exceeding 1.5%
Clay, Silt and Dust M.S. 30 not exceeding 2%
Organic Impurities M.S. 30 not exceeding 0.4%
Aggregate Crushing M.S. 30 not exceeding 20%

Value Page 2
AASHTO Test loss not exceeding 12% 12
Soundness Test Method T104
(Sodium Sulphate)
B.S 812 not exceeding 0.06% by
Chloride Content Part 4 weight
of chloride ions
B.S 1377
Sulphate Content Test 9 not exceeding 0.4% be
weight of SO3

TABLE 9.3 - TESTING OF AGGREGATE
9.2.2.5 Storage of Aggregates 9.2.3 Water
Separate storage facilities with Water shall comply with the

adequate provision for drainage requirements of M.S. 28. It shall be
shall be provided for each clean and free from harmful matter
different size of aggregate used. and shall be from a source approved
by the S.O. The Contractor shall
Aggregate shall be handled and make adequate arrangements to
stored so as to minimise supply and store sufficient water at
segregation and contamination. the work site for use in mixing and
curing concrete. All costs for
installing and maintaining the supply
shall be borne by the Contractor.
9.2.4 Admixtures Admixtures which contain calcium

chloride or calcium formate as the
Suitable admixtures may be used in active constituents shall not be used
concrete mixes with the prior for structural concrete containing
approval of or as directed by the reinforcement, prestressing tendons
S.O. or other embedded metal.
All requirements for sampling, 9.3 CLASSIFICATION OF

acceptance tests, uniformity tests, CONCRETE MIXES
independant tests, chloride content,
information to be provided by
manufacturer, compliance and The concrete mixes shall be
storage certificates and marking shall classified as :-
be in accordance with M.S. 922.
(a) Prescribed Mix
All admixtures shall be used strictly
in accordance with manufacturer's The Contractor shall provide
instructions. concrete that contains constituents in
the specified proportions.
Before allowing the admixture to be
used in the work, relevant tests based (b) Designed Mix
on trial mixes shall be carried out.
The trial mix shall be made using The Contractor shall select the mix
job-site materials and under job-site proportions and unless otherwise
conditions. A control mix shall be specified, the workability, in order to
made using a conventional trial mix, satisfy the strength and other
that is without using the admixture, requirements of the Contract.
to determine the water/cement ratio
and mix proportions required to give 9.3.1 Requirements for Prescribed Mixes
the specified strength with the
required slump. Using the same mix Unless otherwise specified, the
proportions as in the control mix, a concrete mix shall be as detailed in
test shall be prepared using the Table 9.5 which shows the weights
recommended dosage of the of cement and total dry aggregates,
admixture. The results of relevant in kilograms, to produce
tests obtained from the control mix approximately one cubic metre of
and test mix shall be compared. The fully compacted concrete, together
S.O. may allow the use of the with the percentages by weight of
admixture only when the results are fine aggregates in total dry
found to be satisfactory and aggregates.
comparable to the effects as claimed
by the manufacturer. Table 9.4 of
admixture acceptance test
requirements shall be complied with.

9.3.2 Requirements for Designed Mixes Standard Specification For Road Works
9.3.2.1 Target Mean Strength Where there are insufficient data

to satisfy (i) or (ii) above, the
The concrete mix shall be margin for the initial mix design
designed to have at least the shall be taken as 7.5 N/sq.mm
required minimum cement for concrete of grade 15 and 12
content and to have a target mean N/sq.mm for concrete of grade
strength greater than the required 20 or above. This margin shall
characteristic strength by at least be used as the current margin
the current margin. only until sufficient data are
available to satisfy (i) or (ii)
The current margin for each above. However, subject to the
particular type of concrete shall approval of the S.O., when the
be determined by the Contractor specified characteristic strength
and shall be taken as the lesser approaches the maximum
of :- possible strength of concrete
made with a particular aggregate,
i) 1.64 times the standard a smaller margin not less than 5
deviation of cube tests on at N/sq.mm for concrete of grade 15
least 100 separate batches of or 7.5 N/sq.mm for concrete of
concrete of nominally similar grade 20 or above may be used
proportion of similar materials for the initial mix design.
and produced over a period
not exceeding 12 months by
the same plant under similar
supervision, but not less than
2.5 N/sq.mm for concrete of
grade 15 or 3.75 N/sq.mm
for concrete of grade 20 or
above;
ii) 1.64 times the standard

deviation of cube tests on at
least 40 separate batches of
concrete of nominally similar
proportions of similar
materials and produced over a
period exceeding 5 days but
not exceeding 6 months by
the same plant under similar
supervision, but not less than
5 N/sq.mm for concrete of
grade 15 or 7.5 N/sq.mm for
concrete of grade 20 or above.

TABLE 9.5 - PER

PRESCRIBED MIXESOFFOR
CUBIC METRE GENERAL USE
CONCRETE
Nominal Max.
Grade of 28-day Sizes of 40 20
Concrete Characteristic Aggregate
Strenght of (mm)
Concrete
(N/sq.mm) Workability Medium High Medium High
Slump Limits 50 -100 100 - 150 25 - 75 75 - 125

(mm)
15P 15 Cement (kg) 250 270 280 310
Total aggregate 1850 1800 1800 1750

(kg)
30 - 45 30 - 45 35 - 50 35 – 50
Fine aggregate
(%)
20P 20 Cement (kg) 300 320 320 350
Total aggregate
(kg) 1850 1750 1800 1750
Fine aggregate 25 - 35 25 – 40 25 – 40 20 - 45
(%)
25P 25 Cement (kg) 340 360 360 390
Total aggregate 1800 1750 1750 1700

(kg)
25 - 35 25 - 40 25 - 40 30 - 45
Fine aggregate
(%)
Fine aggregate is expressed as a i) the nature and source of each

percentage by weight to the total material;
dry aggregates. The lower value
shall be used for finer grading. ii) appropriate existing data as evidence
of satisfactory previous performance
9.3.2.2 Suitability of Proposed Mix for target mean strength, current
Proportions margin, workability and
water/cement ratio; OR
The Contractor shall submit for full details of tests on trial mixes
the approval of the S.O., prior to carried out in accordance with Sub-
the supply of any designed mix, Section 9.3.2.3;
the following :-

Page 216
FOR INTERNAL USE ONLY iii) the proposed quantities of
each material per cubic metre
of fully compacted concrete. Standard Specification For Road Works
9.3.2.3 Trial Mixes During production, the S.O. may

require additional trial mixes to
The Contractor shall give notice be made before a substantial
to enable the S.O. to be present at change is made in the materials
the making of trial mixes and or in the proportion of the
preliminary testing of the cubes. materials to be used. Trial mixes
The Contractor shall prepare trial need not be carried out when
mixes, using samples of approved adjustments are made to the mix
material typical of those he proportions in accordance with
proposes to use in the Works, for Sub-Section 9.3.2.4.
all grades to the satisfaction of
the S.O. prior to commencement 9.3.2.4 Control of Strength of Designed
of concreting. Mixes
Sampling and testing procedures (a) Adjustment to Mix

shall be in accordance with M.S. Proportions
26. Three separate batches of
concrete shall be made. The Adjustment to mix proportions
workability of each of the three shall be made subject to the
trial batches determined by approval of the S.O. in order to
means of the slump test, minimise the variability of
compacting factor test or vebe strength and to maintain the
consistometer test in accordance target mean strength. The
with M.S. 26, shall be specified limits of minimum
appropriate to the proposed uses cement content and maximum
and methods of placing and water/cement ratio shall be
compaction of the mix and shall maintained. Changes in cement
be approved by the S.O. Six have to be declared. Such
cubes shall be made from each adjustment shall not be taken to
batch. Three from each set of six imply any change in the current
shall be tested at an age of 7 days margin.
and three at an age of 28 days.
The average strength of the nine (b) Change of Current Margin
cubes tested at 28 days shall
exceed the specified characteristic A change in the current margin
strength by the current margin used for judging compliance with
minus 3.5 N/sq.mm. The specified characteristic strengths
approved trial mix shall then be becomes appropriate when the
designated as the "designed mix" results of a sufficiently large
and its corresponding workability number of tests show that the
as the "designed workability". previously established margin is
significantly too large or too
small.

FOR INTERNAL USE ONLY recalculated margin is almost
certain to differ numerically from
Recalculation of the margin shall the previous value, the adoption
be carried out in accordance with of the recalculated value will not
Sub-Section 9.3.2.1. Although a generally be justified if the two
values differ by less than 18%
when based on tests on 2 separate Standard Specification For Road Works
batches or less than 11% when
based on tests on 100 separate - ±0.04 where the "designed
batches, or less than 5% when workability" is between 0.8
based on tests on 500 separate and 0.9.
batches.
- ±0.05 where the "designed
On the adoption of a recalculated workability" is 0.8 or less.
margin it shall become the
current margin for the judgement iii) Vebe
of compliance with the specified
characteristic strength of concrete - ±3 seconds or ±one-fifth
produced subsequent to the of the "designed
change. workability", whichever is
less.
9.3.3 Requirements for Concrete
9.3.3.2 Concrete Grade
9.3.3.1 Workability
The grade of concrete to be used
The workability of the fresh in the Works shall be as stated on
concrete shall be such that the the Drawings and in the Bill of
concrete is suitable for the Quantities.
conditions of handling and
placing so that after compaction, (Concrete grade shall be
it surrounds all reinforcement, designated as GRADE X/Y
tendons and ducts and completely where `X' is the numerical value
fills the formwork. of the characteristic strength in
N/sq.mm as determined from
Workability of the concrete shall test cubes at 28 days, and `Y' is
be within one of the following the nominal size of aggregate in
limits :- mm. For a prescribed mix, a
suffix `P' shall be added after
i) Slump `X').
- ±25 mm or ± one-third of
the "designed 9.3.3.3 Minimum Cement Content
workability", whichever is
the greater. The minimum cement content
shall be in accordance with Table
ii) Compacting Factor 9.6 unless otherwise shown on
- ±0.03 where the the Drawings.
"designed workability" is
0.9 or more. 9.3.3.4 Maximum Cement Content
The maximum cement content
shall not exceed 550 kg/cu.m
unless otherwise described in the
Contract or agreed by the S.O.
Page 218
TABLE 9.6 - MINIMUM CEMENT CONTENT AND MAXIMUM FREE

Type of Concrete Maximum Total Chloride
Prestressed Reinforced (%)
Plain Max.
Concrete Concrete Concrete Free
Exposure Water/
Nominal max. Nominal max. Nominal max.
Reinforced Concrete size of Cement
size of Size of aggregate
made with cement complying Ratio
aggregate aggregate (in mm)
with M.S. 522. (in mm) (in mm) 40 20
40 20 40 20 0.35 for 95%
of test results
Surfaces sheltered from (kg/cu.m) (kg/cu.m) (kg/cu.m)
with no result
severePlain
rain :-Concrete greater than 0.50.
containing embedded metal
1) surface protected
and made with cement complying
by a water-proof
with M.S. 522.
membrane;
2) internal surfaces, 300 320 270 300 250 280 0.55

whether or notmade
Concrete subjectwith
to condensation;
cement complying with B.S. 4027. 0.2
3) surfaces continuously
buried and/or submerged
under water.
Prestressed Concrete and
Structural Concrete that is steam
1) soffits;
0.1
cured.
2) surfaces exposed to
driving rain, alternate
wetting and drying 320 350 320 350 270 300 0.50
e.g.in contact with
backfill.
1) surfaces exposed to
the action of sea
water with abrasion 350 350 380 320 350 0.45
having a pH of 4.5 380
or less.
WATER/CEMENT RATIO FOR DESIGNED MIX
9.3.3.5 Total Chloride Content Tests shall be carried out in

accordance with B.S. 1881 for
The total chloride content of the each grade of concrete, to
concrete mix arising from the demonstrate that these limits are
aggregate or any other source not exceeded.
shall not in any circumstances
exceed the limits in Table 9.7
expressed as a percentage
relationship between chloride
ions and weight of cement in the
mix.

TABLE 9.7 - MAXIMUM TOTAL CHLORIDE
Notes on Table 9.7 :- 9.4 COMPLIANCE WITH SPECIFIED

REQUIREMENTS
(1) % Chloride ionsx 1.648
= % equivalent sodium 9.4.1 Prescribed Mix
chloride.
A prescribed mix shall be judged on
(2) % Chloride ionsx 1.56 the basis of the specified mix
= % equivalent anhydrous proportions. The workability shall be
calcium chloride. chosen to suit the construction
requirements.
9.3.3.6 Maximum Sulphate Content
Notwithstanding this, strength tests
The total estimated sulphate shall be carried out during the
content of any mix, including that progress of work. The rate of
present in the cement shall not sampling shall be as per Rate 2 for
exceed 4.0% by weight of ordinary structural concrete as in
cement in the mix. Tests shall be Table 9.8. For each sampling, three
carried out in accordance with test cubes shall be made. One test
B.S. 1881 for each grade of cube from each sample-batch shall
concrete to demonstrate that these be tested for the 7-day compressive
limits are not exceeded. strength.

FOR INTERNAL USE ONLY 75% of the 28-day compressive
strength, then the S.O. may direct
If the cube strength falls below the Contractor to take necessary
steps to review the process of the
production of concrete for future Standard Specification For Road Works
use.
9.4.2 Designed Mix
The remaining two test cubes
from the sample-batch shall be 9.4.2.1 Characteristic Strength
tested for the 28-day compressive
strength. The appropriate The characteristic strength of
strength requirement shall be concrete is that 28-day cube
considered to be satisfied if at strength, below which not more
least one of the following is than 5% of the test results may
complied with :- be expected to fall. Compliance
with the specified characteristic
i) none of the two test cubes is strength shall be judged by tests
below the specified made on cubes at an age of 28
compressive strength; days.
ii) the average strength of the 9.4.2.2 Sampling and Testing

two test cubes is not less than
the specified compressive All sampling and testing of
strength and the difference constituent materials shall be
between the two strengths is carried out in accordance with the
not more than 20% of the provisions of the appropriate
average strength. available Malaysian Standards.
In particular, sampling and testing
In the event that the results of the of fresh and of hardened concrete
test do not meet the specified shall be carried out in accordance
requirements, the S.O. shall with the provisions of M.S. 26.
determine the action to be taken
in respect of the concrete member The rate of sampling shall be as
represented by the sample-batch given in Table 9.8, but not less
test cubes. Such action may than one sample shall be taken
include demolition of the from each source of production
member. The Contractor shall, if on each day that concrete of any
required by the S.O., take cored particular grade is used.
samples from the hardened
concrete member and carry out
the compressive strength test.
Rate Volume of concrete from
which a sample shall be taken
Rate 1 Every 10 cu.m

(Prestressed Concrete) or every group of 10 batches *
Page 221
Rate 2 Every 20.0 cu.m

(Ordinary Structural or every group of 20 batches *
Concrete)
Rate 3 Every 50 cu.m

(Mass Concrete) or every group of 50 batches *

TABLE 9.8 - MINIMUM RATE OF SAMPLING
* The sample shall be taken from the mixer or, in the

from one single batch randomly case of
selected from the group of ready-mixed concrete, at
batches. the
point of discharge from t
9.4.2.3 Testing Plan he
delivery vehicle.
Three test cubes shall be made
from a single sample taken from One test cube from each
a randomly selected batch of sample
concrete. The samples shall be shall be tested for the 7-
taken at the point of discharge day
compressive strength. If the cube The remaining two test cubes
strength falls below the 7-day from the same sample shall be
strength as determined from the tested for the 28-day
trial mixes, then the Contractor compressive strength. The
shall take the necessary steps to average strength of the two cubes
review the process of the shall constitute the 28-day
production of concrete and make compressive strength of the
certain adjustments where appli sample.
cable.
For compliance purposes :-
i) the average 28-day strength

Cawangan Jalan, Ibu Pejabat JKR, K.L determined from any group of
four consecutive samples shall
exceed the specified
characteristic strength by at
least 0.5 times the curent
margin.
The current margin shall be taken

as 7.5 N/sq.mm for concrete of
grade 15 or 12 N/sq.mm for
concrete of grade 20 or above
unless, in accordance with Sub-
Section 9.3.2.1 or 9.3.2.4 (b), a
smaller margin has been
established to the satisfaction of
the S.O.
Page 222
FOR INTERNAL USE ONLY requirement (i), or more than one
sample test result in a group fails to
In this respect, consecutive meet the second requirement (ii),
samples are samples taken at then all the concrete in all the
intervals not exceeding 14 days. batches represented by all such
In all cases, at least four samples sample test results shall be deemed
shall be taken of concrete on the not to comply with the strength
first day of concreting for each requirements.
grade of concrete to be used in
the Works, irrespective of the For the purpose of this Sub-Section,
volume of concrete produced or batches of concrete represented by
the sampling rate. groups of four consecutive sample
test results shall include the batches
ii) Each individual sample test result from which samples were taken to
shall be at least 85% of the obtain the first and the last sample
specified characteristic strength. results in the group of four, together
with all the intervening batches.
If any one sample test result fails to
meet the second requirement (ii),
then that result may be considered to
represent only the particular batch of
concrete from which the sample test
cubes were taken.
If the average strength of any group

of four consecutive sample test
results fails to meet the first
Cawangan Jalan, Ibu Pejabat JKR, K.L Standard Specification For Road Works
9.4.3 Additional Cubes
Additional cubes may be reuqired for

various purposes. These shall be
made and tested in accordance with
M.S. 26 but the methods of sampling
and the conditions under which the
cubes are stored shall be varied
according to the purpose for which
they are required.
For determining the cube strength of

prestressed concrete before transer or
of concrete in a member before
striking formwork, sampling shall be
at the point of placing and the cubes
shall be stored as far as possible
under the same conditions as the
concrete in the members.
The extra cubes shall be indentified

at the time of making and shall not
be used for the normal quality
control or compliance procedures.
9.5 PRODUCTION OF CONCRETE
9.5.1 Supervision
The Contractor shall ensure the

required standard of control over
materials and workmanship. The
S.O. shall be afforded all reasonable
opportunity and facility to inspect the
materials and the production of
concrete, to take any samples and to
make any test.
9.5.2 Batching and Mixing
The quantities of cement, fine

aggregate and various sizes of coarse
aggregate shall be measured by
weight unless otherwise approved
by the S.O. A separate weighing
machine shall be provided for
weighing the cement. Alternatively
the cement may be measured by
using a whole number of bags in
each batch. The quantity of water
Page 223
FOR INTERNAL USE ONLY by weight. Any solid admixtures
to be added shall be measured by
shall be measured by volume or weight but liquid or paste ad
mixtures may be measured by
volume or weight. Standard Specification For Road Works
The batch weight of aggregate Mixing plant shall be thoroughly

shall be adjusted to allow for the cleaned before changing from
moisture content of the aggregate one type of cement to another.
being used. The accuracy of the
measuring equipment shall be The water content of each batch
within :- of concrete may be adjusted so as
to produce a concrete of the
± 3% of the quantity of cement workability required.
per batch;
9.5.3 Transporting
±3% of the quantity of water
per batch; Concrete shall be transported from
the mixer to the formwork as rapidly
±3% of the quantity of total as practicable by methods which will
aggregate per batch; prevent segregation or loss of the
ingredients and maintain the required
± 5% of the quantity of workability. It shall be deposited as
admixture per batch. near as practicable in its final
position to avoid rehandling. The
The mixer shall comply with the concrete shall be conveyed by chutes
requirements of B.S. 1305 or or concrete pumps only with
B.S. 4251 where applicable. The permission from the S.O.
mixing time shall be not less than
two minutes or more than five 9.5.4 Placing
minutes after all the ingredients
have been placed in the mixer. For all concrete whether mixed on or
For cements other than ordinary off the site of the Works, each batch
Portland cement, the mixing shall be placed and compacted with
time shall not be less than that in 2 hours of adding the cement to
recommended by the the dry aggregates and within 45
manufacturer and subject to the minutes (or any other period of time
S.O.'s approval of the trial mix. as approved by the S.O. if admixture
is used) of adding water to the
Mixers that have been out of use cement and aggregates. Concrete
for more than 30 minutes shall be shall not be placed in any part of the
thoroughly cleaned before any structure until the S.O.'s approval
fresh concrete is mixed. Unless has been obtained. If concreting is
otherwise agreed by the S.O., the not started within 24 hours of
first batch of concrete through the approval given, approval shall again
mixer shall then contain only be obtained from the S.O.
two-thirds of the normal quantity
of coarse aggregate. All formwork and reinforcement
contained in it shall be clean and free
from standing water immediately
Cawangan Jalan, Ibu Pejabat JKR, K.L before the placing of the concrete.
Concreting shall be carried out
continuously between and up to pre
determined construction joints in one
sequence of operation. In the event
of unavoidable stoppage in positions
Page 224
FOR INTERNAL USE ONLY shall be terminated on a
horizontal plane and against
not predetermined, the concreting vertical surfaces by the use of
stopping-off boards.
Fresh concrete shall not be placed
against in situ concrete which has No concrete shall be placed in
been in position for more than flowing water. Underwater
45 minutes (or any other period concrete if deemed unavoidable
of time as approved by the S.O. if by the S.O. shall be placed in
admixture is used) unless a position by tremies or pipelines
construction joint is formed in from the mixer. Concrete to be
accordance with Sub-Section placed under water shall be an
9.6.1. When in situ concrete has approved mix with the amount of
been in place for 4 hours, no cement increased by 20%.
further concrete shall be placed During and after concreting under
against it for a further 20 hours. water, pumping or dewatering
operations in the immediate
Except where otherwise agreed vicinity shall be suspended until
by the S.O., concrete shall be the S.O. permits them to
deposited in horizontal layers to a continue. Where the concrete is
compacted depth not exceeding placed by a tremie, the following
450 mm where internal vibrators requirements shall be
are used; or 300 mm in all other applicable :-
cases. The surface of the
concrete shall be maintained i) unless otherwise agreed by
reasonably level during placing. the S.O, when concreting of
bored piles is being carried
Concrete shall not be dropped out under water, temporary
into place from a height casing shall be installed to the
exceeding 1500 mm. When full depth of the borehole so
trunking or chutes are used, they that fragments of ground can
shall be kept clean and used in not drop from the sides of the
such a manner as to avoid hole into the concrete as it is
segregation. placed;
The Contractor shall maintain an ii) the hopper and tremie pipe
experienced steel fixer at the site shall be a closed system. The
of reinforced concrete works bottom of the tremie shall be
during the placing of concrete to kept as far as practicable
reposition any reinforcement beneath the surface of the
which may be displaced during placed concrete;
the work.
iii) the tremie pipe shall be large
enough with due regard to the
size of aggregate. For 20 mm
aggregate the tremie pipe
shall be of diameter not less
than 150 mm and for larger
aggregate, larger diameter
tremie pipe shall be required;

FOR INTERNAL USE ONLY the S.O., the first charge of
concrete shall be placed with
iv) unless otherwise agreed by a sliding plug pushed down
the tube ahead of it to prevent
mixing of concrete and water; Standard Specification For Road Works
v) the tremie pipe shall always iv) no concrete shall be placed

penetrate well into the when the air temperature at
concrete with an adequate the point of deposition
margin of safety against exceeds 36ºC.
accidental withdrawal if the
pipe is surged to discharge the 9.5.6 Compaction
concrete;
Unless otherwise agreed by the S.O.,
vi) the concrete shall be concrete shall be thoroughly
deposited wholly by tremie compacted by vibration and
and the method of deposition thoroughly worked around the
shall not be changed part way reinforcement, tendons, or
up to prevent the laitance duct formers, around embedded
from being entrapped within fixtures and into corners of the
the structure; formwork to form a dense
homogenous mass free from voids
vii)all tremie pipes shall be and which will have the required
scrupulously cleaned after surface finish when the formwork is
use. removed. Vibration shall be applied
continuously during the placing of
9.5.5 Temperature Requirements each batch of concrete until the
expulsion of air has practically
During hot weather, additional ceased and in a manner which does
precautions shall be taken to prevent not promote segregation of the
premature setting and loss of water ingredients.
during placing of concrete in the
formwork. These precautions shall The concrete maintained between the
include :- two walls of formwork shall be
compacted by vibrating of the
i) no concrete having an internal internal type and concrete in slabs
temperature exceeding 33ºC with no formwork on its upper
shall be deposited; surface shall be compacted either by
vibrators of the pan type or by a
ii) concrete shall not be placed in vibrating screed.
formwork or around
reinforcement whose temperature The internal vibrators shall be
exceeds 36ºC; inserted and withdrawn slowly and at
a uniform pace of approximately
iii) newly placed concrete shall be 100 mm per second. Compaction
protected from direct sunlight and shall be deemed to be completed
from loss of moisture by when cement mortar appears in an
covering, shading or other means; annulus around the vibrator. Over
vibration leading to segregation of
the mix must be avoided. The
Cawangan Jalan, Ibu Pejabat JKR, K.L internal vibrators shall be inserted at
points judged by the area of mortar
showing after compaction, with a
certain allowance made for
overlapping, and they shall not be
allowed to come into contact with
Page 226
FOR INTERNAL USE ONLY reinforcement and shall be
inserted at a distance of not less
the formwork or the than 75 mm from the former.
The pan vibrator shall be placed Standard Specification For Road Works
on the surface of the concrete
which shall have previously been Concrete shall not be subjected to
tamped and levelled leaving an any disturbance within 24 hours
allowance in height for after compaction. No standing or
compaction until the cement flowing water shall be allowed to
mortar appears under the pan. come into contact with exposed
The vibrator shall then be lifted concrete surfaces during the first
and placed on the adjoining two hours after placing and
surface and this operation shall be compaction of the concrete.
repeated until the whole surface
has been compacted. 9.5.7 Curing and Protection
Alternatively a vibrating screed
spanning the full width of the All work shall be protected from
surface may also be used. damage by shock or overloading or
falling earth or flowing water, etc.
Whenever vibration has to be
applied externally, the design of 9.5.7.1 Normal Curing
formwork and disposition of
vibration shall receive special Exposed surfaces, immediately
consideration to ensure efficient after compaction, shall be
compaction and to avoid surface protected from the sun and rain in
blemishes. The mix shall be such a manner approved by the S.O.
that there will be no excess water All concrete, after it has set, shall
on the top surface on completion be kept continuously damp until
of compaction. thoroughly cured. Provision shall
be made for adequate water
External vibrators shall be firmly distribution to all parts of the
secured to the formwork which Works, so that if required, this
must be sufficiently rigid to treatment can be continued
transmit the vibration and strong efficiently throughout the whole
enough not to be damaged by it. period of construction. In order
to keep the concrete continuously
Internal vibrators shall be capable damped, all exposed surfaces
of operating at not less than shall be covered with
10,000 cycles per minute and continuously damped gunny bags
external vibrators at not less than or shall have water impounded
3,000 cycles per minute. on them for the full period of
Sufficient vibrators in serviceable curing which shall be not less
condition shall be on Site so that than 7 days.
spare equipment is always
available in the event of break Other methods of curing may be
down. used subject to the approval of
the S.O.
Page 227
Elevated temperature curing may
9.5.7.2 Accelerated Curing be used only with ordinary
Portland cement. After the
completion of the placing of the Standard Specification For Road Works
concrete, 4 hours shall elapse
before its temperature is raised. relevant production details in
The rise in temperature within suitable format. In addition the
any period of 30 minutes shall manufacturer shall supply to the S.O.
not exceed 10ºC and the test certificates for testing of
maximum temperature attained materials, indicating the sources of
shall not exceed 70 ºC. The rate supplies and other relevant details.
of subsequent cooling shall not
exceed the rate of heating. The 9.6 CONSTRUCTION WITH
use of accelerated curing methods CONCRETE
for concrete containing other
types of cement or any admixture 9.6.1 Construction Joints
shall be subject to the approval of
the S.O. The position and detail of any
construction joints not described in
9.5.8 Ready-Mixed Concrete the Contract shall be subject to the
approval of the S.O. and shall be so
Ready-mixed concrete shall comply arranged as to minimise the
with the requirements of M.S. 523. possibility of the occurance of
The concrete shall be carried in shrinkage cracks.
purpose-made agitators operating
continuously or truck mixers. The If for any reason the Contractor has
concrete shall be compacted and in to interrupt a planned pour for more
its final position within 2 hours of than 45 minutes (or any other period
the introduction of cement to of time as approved by the S.O. if
aggregate and within 45 minutes (or admixture is used), additional
any other period of time as approved construction joints shall be
by the S.O. if admixture is used) positioned and constructed as
after the addition of water to the directed by the S.O.
cement-aggregate mix unless
otherwise agreed by the S.O. The The number of construction joints
time of such introduction shall be shall be kept as few as possible
recorded on the Delivery Note consistant with reasonable
together with the weight of the precautions against shrinkage.
constituents of each mix. Concreting shall be carried out
continuously up to construction
Ready-mixed concrete delivered to joints. The joints shall be at right
the job site shall be accompanied by angles to the general direction of the
manufacturer's certificates stating member and shall take due account
the details of mix proportions by of shear and other stresses.
weight, grade of concrete, type and
size of aggregate, date and time of Concrete shall not be allowed to run
production, type and dosage of to a feather edge and vertical joints
chemical admixtures and other shall be formed against a stop board.
The top surface of a layer of concrete
Cawangan Jalan, Ibu Pejabat JKR, K.L shall be level and flat unless design
considerations make this undesirable.
Joint lines shall be so arranged that
they coincide with features of the
finished work, wherever possible.
Page 228
FOR INTERNAL USE ONLY gauge strips about 25 sq.mm in
section shall be placed inside the
At horizontal construction joints, forms along all exposed surfaces to
ensure a straight joint on those
surfaces. Standard Specification For Road Works
If a kicker (i.e. starter stub) is used mortar skin and expose the larger
it shall be at least 70 mm high and aggregates without disturbing them.
carefully constructed. It is preferable Where this treatment is
for the kicker to be incorporated with impracticable, sand blasting or a
the previous concrete. Where needle gun shall be used to remove
possible, the formwork shall be the surface skin and laitance.
designed to facilitate the preparation Hardened surfaces shall not be
of the joint surface, as the optimum hacked.
time for treatment is usually two to
four hours after placing.
9.6.2 Fixing Blocks, Brackets, Built-In-
Where vertical construction joints Bolts, Holes, Chases, etc.
are necessary in mass concrete
structures, reinforcing bars shall be All fixing blocks, brackets, built-in-
placed across the joints so as to make bolts, holes, chases, etc., shall be
the structure monolithic, all to the accurately set out and formed and
satisfaction of the S.O. carefully sealed prior to the concrete
being placed. No cutting away of
Prior to recommencement of concrete for any of these items shall
concreting on a joint, the surface of be done without the permission of
the concrete against which new the S.O.
concrete will be cast shall be free
from laitance and shall be roughened Bolts and other inserts to be cast into
to the extent that the largest the concrete shall be securely fixed
aggregate is exposed but not to the formwork in such a way that
disturbed. Care shall be taken to they are not displaced during the
avoid damaging the lines of the joint. concreting operations, and that there
Care shall also be taken that the joint is no loss of materials from the wet
surface is clean and damp but not concrete through holes in the form
wet. Immediately before the fresh work.
concrete is placed against the joint,
fresh cement mortar shall be applied Unless shown otherwise on the
to the exposed surface. Drawings or instructed by the S.O.,
reinforcement shall be locally moved
Where the S.O. considers that so that the minimum specified cover
special preparation is necessary, e.g. is maintained at the locations of
for an in situ structural connection, inserts, holes, chases, etc.
preparation shall be carried out,
preferably when the concrete has set Temporary plugs shall be removed
but not hardened, by spraying with a and the threads of built-in-bolts shall
fine spray of air and water or be proved to be free and shall be
brushing with a stiff brush greased before handing over any part
sufficiently to remove the outer of the Works.
Page 229
9.6.3.1 Manufacture Off the Site
9.6.3 Precast Concrete Construction
After the method of manufacture
has been approved, no changes Standard Specification For Road Works
shall be made without the consent
of the S.O. 9.6.3.3 Handling and Transport
The Contractor shall inform the Items shall be lifted only at points
S.O. in advance of the date of described in the Contract or
commencement of manufacture otherwise agreed by the S.O. and
and casting of each type of item. shall be handled and placed
without impact. The method of
When the S.O. requires tests to lifting, the type of equipment and
be carried out, no items to which transport to be used, and the
the tests relate shall be dispatched minimum age of the items to be
to the Site until the tests have handled shall be subject to the
been satisfactorily completed and approval of the S.O.
the results approved by the S.O.
9.6.3.4 Assembly and Erection
All items shall be indelibly
marked to show the item mark as The method of assembly and
described in the Contract, the erection described in the Contract
production line on which they shall be strictly adhered to on
were manufactured, the date on Site.
which the concrete was cast and,
if they are of symmetrical Immediately a unit is in position,
section, the face that will be and before the lifting equipment
uppermost when the member is is removed, temporary supports
in its correct position in the or connections between items, as
Works. necessary, shall be provided.
The final structural connections
9.6.3.2 Storage shall be completed as soon as is
practicable.
When items are stored, they shall
be firmly supported only at the 9.6.3.5 Forming Structural Connections
points described in the Contract.
The accumulation of trapped No structural connections shall be
water and deleterious matter in made until approval has been
the units shall be prevented. Care given by the S.O.
shall be taken to avoid rust
staining and efflorescence. Unless otherwise agreed by the
S.O., the composition and
Items shall be stacked in such a water/cement ratio of the in situ
manner that their removal in cor concrete or mortar used in any
rect order of age is facilitated. connection and the packing of
joints shall be in accordance with
the assembly instructions.
Levelling devices shall only be

Cawangan Jalan, Ibu Pejabat JKR, K.L released or removed with the
Page 230
9.6.3.6 Protection
At all stages of construction,

precast concrete units and other
concrete associated therewith
shall be properly protected to
prevent damage to permanently
exposed surfaces, especially
arrises and decorative features.
9.7 STEEL REINFORCEMENT
9.7.1 Description
The work shall consist of furnishing

and placing reinforcing steel in
accordance with this Specification
and in conformity with the Drawings
or as directed by the S.O.
9.7.2 Materials Designation Nominal Characteristic

Sizes Strength, fy
( mm ) ( N/sq.mm )
Hot rolled mild steel and high yield
bars shall comply with the
requirements of M.S. 146, as Hot rolled grade All sizes 250
250 ( M.S. 146 )
denoted on the Drawings. Cold
worked steel bars shall comply with Hot rolled grade All sizes 460
the requirements of B.S. 4461. 460 ( M.S. 146 )
Hard drawn mild steel wire shall
comply with the requirements of Cold worked All sizes 460
M.S. 144. ( B.S. 4461 )
Hard drawn steel Up to and 485

Steel fabric reinforcement shall wire( M.S. 144 ) including 12
comply with the requirements of
M.S. 145 and shall be delivered to
the Site in flat sheets.
Bar-mats shall conform to the

requirements of M.S. 146 and shall
consist of bars of the sizes and
spacings as shown on the Drawings.
Dowel bars shall be plain round

bars conforming to the
requirements of M.S. 146. They
shall be free from burring or other
deformations restricting slippage in
the concrete. Dowel bar sleeves

used for debonding shall be of

approved synthetic material. The
closed end of the sleeve shall be
filled with 25 mm thick
compressible foam filler and the
sleeve shall fit tightly over the length
of bar to be debonded.
The Contractor shall furnish

manufacturer's certificates for rein
forcement supplied by him, and
these shall be submitted for
acceptance by the S.O. before any
material is brought onto the Site.
The characteristic strengths of steel
reinforcement are given in Table
9.9.
TABLE 9.9 - CHARACTERISTIC

STRENGTH OFSTEEL REINFORCEMENT
Binding wire shall be 1.6 mm

diameter soft annealed steel wire
complying with the requirements of
B.S. 1052.
The Contractor shall, on request,

furnish the S.O. with samples of
reinforcement brought onto the Site,
not withstanding any previous
acceptance on the manufacturer's test
certificates. The reinforcement
represented by by the sample may
Page 231
FOR INTERNAL USE ONLY 9.7.3.1 Cutting and Bending of
Reinforcement
be rejected by the S.O. and shall, if it
fails to meet the Specification, Bars shall be of their correct
require its removal from the Works lengths and bent to the exact
Site. shapes required before being
fixed in the work.
Steel reinforcement shall be stored in
clean and dry conditions. When Bars shall be cut and bent cold by
placed in the Works it shall be clean the application of slow, steady
and free from loose rust, mill scale, pressure or in an approved bar-
oil, grease, paint, dirt or anything bending machine. Bending at
which may reduce its bond with temperatures in excess of 100 oC
concrete. may only be carried out with the
S.O.'s approval and under his
If directed by the S.O., the steel supervision. Except where
shall be brushed or otherwise otherwise indicated on the
cleaned before use, at the Drawings, bars shall be bent and
Contractor's expense. measured in accordance with
B.S. 4466.
Cold worked and hot rolled bars
shall not be straightened or bent
again once having been bent. Standard Specification For Road Works
Where it is necessary to bend
mild steel reinforcement already Special care shall be taken that
cast in the concrete, the internal the overall length of bars with
radius of bend shall be not less multiple bends is accurate and
than twice the diameter of the that after bending and fixing in
bar. position the bars remain in place
without wrap or twist.
9.7.3.2 Fixing of Reinforcement
The number, size, length, form

and position of all reinforcing
bars, links, stirrups, spacer bars
and other parts of the steel
reinforcement, shall be in
accordance with the Drawings.
Reinforcement shall be secured

against displacement. Unless
specified otherwise, the actual
concrete cover shall be not less
than the required nominal cover
minus 5 mm. In a member
where the nominal cover is
dimensioned to the links, spacers
between the links and formwork
shall be of the same dimension as
the nominal cover.
Unless otherwise permitted by

the S.O., all intersecting bars
shall be tied together with
binding wire and the ends of the
wire shall be turned into the main
body of the concrete.
The Contractor shall take

particular care that the
reinforcement is laid out correctly
in every respect and temporarily
suspended by annealed wire or
supported on concrete blocks or
other approved spacers in the
forms to prevent displacement
before or during the placing and
compacting of concrete.
Page 232
FOR INTERNAL USE ONLY be kept tight to the bars they
embrace or support and all
Stirrups and distance pieces shall reinforcement shall be kept away
from the face of the concrete at
the distances shown on the Standard Specification For Road Works
Drawings.
be as described in Sub-Section
No concrete shall be placed until 9.7.2. Other types of spacers
the reinforcement has been may be used only with the
inspected and approved by the approval of the S.O.
S.O.
9.7.3.5 Welding of Reinforcement
Reinforcement temporarily left
projecting from the concrete at Reinforcement in structures shall
construction or other joints shall not be welded except where
not be bent out of position during detailed on the Drawings or
the periods in which concreting is required by the Specification. If
suspended except with the the reinforcement needs to be
approval of the S.O. welded, the reinforcement shall
comply with the requirements of
9.7.3.3 Splicing B.S. 4360.
Laps and joints including lapping Welding shall be carried out in

bars, sleeving, threading and accordance with B.S. 5135 and
other mechanical connections B.S. 638. Butt welds shall be of
shall be made strictly in the double V type and two butt
accordance with the method weld bond tests shall be carried
specified and at the positions out on a specimen prepared to
shown on the Drawings or as represent each form of butt
otherwise approved by the S.O. welded joint used in welding the
reinforcement and for each
9.7.3.4 Supporting and Spacer Blocks position of welding. The method
of making butt weld tests shall be
Supporting and spacer blocks that laid down in B.S. 709. The
required for ensuring that the specimen shall pass the test to the
reinforcement is correctly satisfaction of the S.O. before
ositioned shall be as small as approval is accorded to use the
possible consistent with their joint which the specimen
purpose, of a shape acceptable to represents.
the S.O., and designed so that
they will not overturn when the Welded joints shall not be made
concrete is placed. They shall be at bends in reinforcement.
made of concrete with 10 mm Unless otherwise approved by the
maximum aggregate size and S.O., joints in parallel bars of the
they shall be of at least the same principal tensile reinforcement
strength and material source as shall be staggered in the
the adjacent concrete. Wire cast longitudinal direction at a
in the block for the purpose of distance not less than the end
tying it to the reinforcement shall anchorage length for the bar.
Cawangan Jalan, Ibu Pejabat JKR, K.L All welding shall be performed
by a competent welder approved
by the S.O.
Page 233
FOR INTERNAL USE ONLY advance of when welding is to be
carried out so that he may
The S.O. shall be informed in supervise and inspect the work.
Welding shall not be performed
in the field during rain or other Standard Specification For Road Works
adverse conditions.
Formwork (including supports)
9.8 FORMWORK AND SURFACE shall be sufficiently rigid to
FINISH FOR STRUCTURE maintain the forms in their
correct position, shape, profile
9.8.1 Design and Construction and dimensions. The supports
shall be designed to withstand the
9.8.1.1 Description worst combination of forces due
to self weight, formwork weight,
Formwork shall include all formwork forces, reinforcement
temporary or permanent forms weight, wet concrete weight,
required for forming the concrete, construction and wind loads,
together with all temporary together with all incidental
construction required for their dynamic effects caused by
support. placing, vibrating and
compacting the concrete.
The design and construction of
formwork shall be carried out by Where internal metal ties are
competent persons. Where permitted they or their removable
required by the S.O., strength parts shall be extracted without
and deflection calculations and damage to the concrete and the
drawings of the proposed form remaining holes filled with
work shall be submitted by the mortar of the same strength as the
Contractor for prior approval. cast concrete. No permanently
Not withstanding any approval embedded metal parts shall have
by the S.O. with respect to the less than the specified cover to
design submitted by the the finished concrete surface.
Contractor, the responsibility or Except for ties used for anchoring
the adequacy and safety of the void formers all ties shall be at
design shall remain with the least 1.2 metres apart and
Contractor. through bolts will not be
permitted on exposed faces. All
The formwork shall be holes left by ties shall be made
sufficiently rigid and tight to good within one day of the
prevent loss of grout or mortar removal of the formwork using a
from the concrete at all stages of mortar of the same strength as the
construction and shall be cast concrete.
appropriate for the methods of
placing and compacting. The formwork shall be so
arranged as to be readily
dismantled and removed from the
cast concrete without shock,
disturbance or damage. Where
necessary, the formwork shall be
so arranged that the soffit form,
Cawangan Jalan, Ibu Pejabat JKR, K.L properly supported, can be
retained in position for such
period as may be required by the
condition of the maturing
concrete or the Specification. If a
component is to be prestressed
Page 234
FOR INTERNAL USE ONLY form, provision shall be made to
allow for elastic deformation and
whilst still resting on the soffit any vibration in weight
distribution. As far as practicable,
formwork joints shall coincide Standard Specification For Road Works
with construction joints.
reinforcement and prestressing
9.8.1.2 Voids In Concrete cable ducts, to demonstrate that
the proposed methods of fixing
Voids, where shown on the the formers and placing concrete
Drawings, shall be formed with around them and the
non-recoverable void formers of reinforcement will produce voids
expanded polystyrene, or by within the tolerances, surrounded
other methods approved by the with properly compacted
S.O. They shall not deviate by concrete of the required strength.
more than 12 mm from the
positions shown on the Drawings, The attention of the Contractor is
nor shall the cross-section deviate drawn to the inflammation nature
from the specified shape by more of expanded polystyrene and he
than 12 mm. shall take all necessary
precautions to minimise the risk
Void formers shall be secured and of fire.
adequately anchored to prevent
movement or flotation outside the Concreting of voided slabs in
limits specified above, during the structures shall not commence
concreting operation. until the model test has been
completed and approved by the
Anchor ties secured to the soffit S.O.
form will be permitted providing
they comply with the 9.8.1.3 Form Lining
requirements of Sub-Section
9.8.1.1. The type and treatment of any
lining (plywood, metal, plastic,
Void formers of expanded etc.) of the forms shall be
polystyrene need not be vented. ppropriate to the concrete finish
Hollow void formers shall be required.
vented by the provision of 50
mm diameter holes between each 9.8.1.4 Projecting Reinforcement, Fixing
void and the soffit at positions Devices
Where holes are needed in form
As soon as possible and at least to accomodate projecting
three (3) months prior to the reinforcement or fixing devices,
casting of the first deck slab with care shall be taken to prevent loss
voids, the Contractor shall of grout when concreting or
construct a model of a size and damage when removing forms.
form to be agreed with the S.O.
using the proposed formers, 9.8.2 Finishes
method of fixing, and simulating
9.8.2.1 Formed Surfaces
Formed concrete surfaces shall
have one of the following classes
of finish. Unless otherwise
specified, all exposed concrete
surfaces shall be of Class F2, all
Page 235
FOR INTERNAL USE ONLY Class F1 and Class F3 finish
shall be used only where shown
unexposed surfaces shall be of on the Drawings.
(a) Class F1 Standard Specification For Road Works
This finish shall be obtained by After the concrete has been

the use of properly designed properly cured, the surface shall
formwork of closely jointed sawn be rubbed down where necessary,
timber or other approved to produce a smooth and even
material. Small blemishes caused surface.
by entrapped air or water may be
expected but the surface shall be 9.8.2.2 Unformed Surfaces
free from voids and
honeycombing. (a) Class U1
(b) Class F2 The concrete shall be uniformly

levelled and screeded to produce
This finish shall be obtained by a plain, ridged or broom
the use of properly designed roughened surface. No further
formwork of closely jointed work shall be applied to the
wrought boards, approved ply surface unless it is used as the
wood or other approved first stage for a Class U2 or
material. Only very minor surface Class U3 finish.
blemishes shall occur, with no
staining or discolouration. (b) Class U2
(c) Class F3 After the concrete has hardened

sufficiently, the concrete Class
This finish shall be obtained by U1 surface shall be floated by
the use of properly designed steel hand or machine to produce a
forms or plastic coated plywood uniform surface free from screed
or wrought boards or other marks.
approved material. The surface
shall be improved by carefully (c) Class U3
removing all fins and other
projections, thoroughly washing When the moisture film has
down and then filling the most disappeared and the concrete has
noticeable surface blemishes with hardened sufficiently to prevent
a cement and fine aggregate paste laitance from being worked to the
to match the colour of the surface, a Class U1 surface shall
original concrete. Form release be steeltrowelled under firm
agent shall be carefully chosen to pressure to produce a dense,
ensure that the surface shall not smooth uniform surface free from
be stained or discoloured. trowel marks.
9.8.2.3 Remedial Treatment of Surfaces
Any remedial treatment of

Cawangan Jalan, Ibu Pejabat JKR, K.L surfaces shall be agreed with the
S.O. following inspection
immediately after removing the
formwork and shall be carried out
without delay.
Page 236
Any concrete, the surface of

which has been treated before
being inspected by the S.O.,
shall be liable to rejection.
9.8.3 Preparation of Formwork Before

Concreting
Before concreting, all forms shall be

thoroughly cleaned out, free from
sawdust shavings, dust, mud or
other debris.
The inside surfaces of forms shall,

except for permanent formwork, or
unless otherwise agreed by the S.O.,
be coated with an approved non-
staining form oil or other approved
material to prevent adhesion of the Vertical faces of beams, wall
concrete. Such release agents shall columns, piles, foundation 3 days
plinths and precast items.
be applied strictly in accordance with
the manufacturer's instructions and
shall not come into contact with the Underside of slabs. 14 days
reinforcement or prestressing
tendons and anchorages. For any Underside of beams. 28 days
exposed surface only one release
agent shall be used throughout the
entire area.
All formwork shall be inspected by

the S.O. after preparation and
immediately prior to depositing
concrete and no concrete shall be
deposited until approval of the
formwork has been obtained from
the S.O.
9.8.4 Removal of Formwork
The Contractor shall inform the S.O.

and obtain his approval before
striking any formwork, but such
approval shall not relieve the
Contractor of his responsibilities for
the safety of the work.
The removal shall be done in such a

manner as not to damage the
concrete, and shall take place at
times to suit the requirements for its
curing.
Where the concrete compressive

strength is confirmed by tests on
concrete cubes stored under
conditions that simulate the field
conditions, formwork supporting
concrete in bending may be struck
when the cube strength is 10
N/sq.mm or twice the stress to
which it will be subjected, whichever
is the greater. In the absence of such
tests, the minimum periods between
concreting and the removal of forms
are given in Table 9.10.
TABLE 9.10 - MINIMUM PERIODS

BETWEEN CONCRETING AND REMOVAL
OF FORMS
Page 237
FOR INTERNAL USE ONLY is to be reused it shall be cleaned and
made good to the satisfaction of the
S.O.
The periods stated above are based
on the use of ordinary Portland Following the removal of formwork,
cement. They may be changed if no further loads shall be imposed
other types of cement are used, upon concrete until at least after the
subject to the S.O.'s agreement. completion of the curing period or
until such later time as in the opinion
For prestressed in situ decks, of the S.O. the concrete shall have
temporary supports shall not be attained sufficient strength to safely
removed until the deck is stressed to withstand such loads. Full design
the satisfaction of the S.O. loads shall not be applied to any
structure until all load bearing
Where it is intended that formwork concrete is at least 28 days old.

SECTION 10
PILING WORKS
SECTION 10 - PILING WORKS
Page
10.2 GENERAL REQUIREMENTS FOR TOLERANCE
10.2.1 Setting Out S10-245
10.2.2 Position S10-245
10.2.3 Verticality S10-245
10.2.4 Rake S10-245
10.2.5 Forcible Corrections S10-245
10.2.6 Piles Out of Alignment or Position S10-245
10.2.7 Records S10-245
10.3 PRECAST REINFORCED CONCRETE PILES

10.3.2.1 Concrete S10-246
10.3.2.2 Reinforcement S10-246
10.3.2.3 Pile Shoes S10-246
10.3.3 Manufacture and Storage of Precast Reinforced Concrete Piles S10-246

10.3.3.1 Casting S10-246
10.3.3.2 Handling and Storage S10-247
10.3.4 Installation of Precast Reinforced Concrete Piles S10-247

10.3.4.1 Pitching of Piles S10-247
10.3.4.2 Driving of Piles S10-247
10.3.4.3 Repair of Damaged Pile Heads S10-248
10.3.4.4 Lengthening of Piles S10-248
10.3.4.5 Cutting and preparation of Pile Heads S10-249

Page
10.4 PRESTRESSED SPUN CONCRETE PILES
10.4.2 Materials
10.4.2.1 Concrete S10-250
10.4.2.2 Reinforcement S10-250
10.4.2.3 End Plates S10-250
10.4.2.4 Pile Shoes S10-250
10.4.3 Manufacture and Storage of Prestressed Spun Concrete Piles S10-250

10.4.3.1 Casting S10-250
10.4.4 Installation of Prestressed Spun Concrete Piles S10-251

10.4.4.1 Pitching and Driving of Piles S10-251
10.4.4.2 Lengthening of piles S10-251
10.5 BORED CAST-IN PLACE PILES

10.5.2 Materials
10.5.2.1 Concrete and Reinforcement S10-252
10.5.2.2 Permanent Casings S10-252
10.5.2.3 Drilling Fluid S10-252
10.5.3 Boring Operations

10.5.3.1 Diameter of Piles S10-252
10.5.3.2 Boring S10-252
10.5.3.3 Temporary Casings S10-253
10.5.3.4 Stability of Piling Excavations Using Drilling Fluid S10-253
10.5.3.5 Spillage and Disposal S10-253
10.5.3.6 Pumping of Boreholes S10-253
10.5.3.7 Continuity of Construction S10-253
10.5.3.8 Enlarged pile Bases S10-254
10.5.3.9 Cleanliness of Pile Bases S10-254
10.5.3.10 Inspection S10-254
10.5.4 Placing of Reinforcement S10-254

10.5.4.1 Joints in Longitudinal Bars S10-254
10.5.4.2 Positions of Reinforcement S10-254

page
10.5.5 Concreting Operations S10-254

10.5.5.1 Placing Concrete S10-254
10.5.5.2 Workability of Concrete S10-254
10.5.5.3 Compaction S10-255
10.5.5.4 Placing Concrete In Dry borings S10-255
10.5.5.5 Placing Concrete Under Water or Drilling Fluid S10-255
10.5.6 Extraction of Casing

10.5.6.1 Workability of Concrete S10-256
10.5.6.2 Concrete Level S10-256
10.5.6.3 Vibrating Extractors S10-256
10.5.7 Construction of Pile Heads S10-257

10.5.7.1 Water levels S10-257
10.5.7.2 Cutting and preparation of Pile heads S10-257
10.5.7.3 Temporary Backfilling Above Pile Casting Level S10-257
10.6 STEEL H-SECTION PILES
10.6.3 Manufacture and Storage of Steel H-Section Piles S10-257

10.6.3.1 Manufacture S10-257
10.6.4 Installation of Steel H-Section Piles S10-258

10.7 STEEL PIPE PILES

10.7.3 Manufacture and Storage of Steel Pipe Piles S10-258
10.7.3.1 Welding S10-258
10.7.3.2 Fabrication of Piles S10-259
10.7.3.3 Matching of Pile Lengths S10-259
10.7.3.4 Straightness of Piles S10-259
10.7.3.5 Fabrication of Piles On Site S10-259
10.7.3.7 Marking of Piles S10-259

Page
10.9.4 Installation of Pressure-Treated Timber Piles

10.9.4.3 Cutting and preparation of Pile heads S10-265
10.10 BAKAU PILES
10.10.3 Delivery and Inspection of Bakau Piles S10-266
10.10.4 Installation of Bakau Piles S10-266

10.10.4.1 Pitching of Piles S10-266
10.10.4.2 Driving of Piles S10-266
10.10.4.4 Cutting and Preparation of Pile Heads S10-267
10.11 PILE TESTING
10.11.1 Test Piles S10-267
10.11.2 Preliminary Pile Load Tests S10-267
10.11.3 Production Pile Load Tests S10-267
10.11.4 Testing Procedure S10-267

10.11.4.1 Preparation of Test Pile S10-267
10.11.4.2 Method of Loading S10-267
10.11.4.3 Measurement of Settlement S10-268
10.11.5 Method of Testing S10-268

10.11.5.1 General S10-268
10.11.5.2 Maintained Load Test S10-269
10.11.5.3 Constant Rate of Penetration (CRP) Test S10-269
10.11.6 Submission of Results S10-269
10.11.7 Interpretation of Test Results S10-269

10.11.8 Load Testing of Bakau Piles S10-270

FOR INTERNAL USE ONLY maintained to attain the required
rake. The maximum permitted
SECTION 10 - PILING WORKS
10.1 DESCRIPTION
This work shall consist of the supply,

installation and testing of piles in
accordance with this Specification and
the lines, levels, grades and cross-
sections shown on the Drawings and as
10.2 GENERAL REQUIREMENTS

FOR TOLERANCES
10.2.1 Setting Out
Setting out shall be carried out using

the data and reference points as
Immediately before installation of
the pile, the pile position shall be
marked with suitable identifiable
pins, pegs or markers.
10.2.2 Position
For a pile cut off at or above ground

level the maximum permitted
deviation of the pile centre from the
centre points shown on the Drawings
shall not exceed 75 mm in any
direction. For a pile cut off below
ground level an increase in this
tolerance is permitted in accordance
with Sub-Sections 10.2.3 and
10.2.4 hereinbelow.
10.2.3 Verticality
The maximum permitted deviation

of the finished pile from the vertical
is 1 in 75.
10.2.4 Rake
The piling rig shall be set and

Standard Specification For Road Works the approval of the S.O. The cost of
such extraction and reinstallation or
deviation of the finished pile from any extra cost in the design and
the specified rake or the rake shown construction of a modified
on the Drawings is 1 in 25. foundation shall be borne by the
Contractor if, in the opinion of the
10.2.5 Forcible Corrections S.O., such extra works have been
made necessary due to the error
Forcible corrections to concrete piles and/or negligence of the Contractor.
shall not be permitted. Forcible
corrections may be permitted to 10.2.7 Records
other types of piles if approved by
the S.O. However, no forcible The Contractor shall keep records of
corrections shall be made to piles the installation of each pile as
which have deviated beyond the required by the S.O. and shall
permissible limits specified in Sub- submit two signed copies of these
Sections 10.2.2, 10.2.3 and 10.2.4 records to the S.O.not later than at
above. noon of the next working day after
the pile has been installed. The
10.2.6 Piles Out of Alignment or Position signed records shall form part of the
records for the Works.
The Contractor shall, if ordered by
the S.O., extract and reinstall any Any unexpected driving or boring
pile which has deviated out of conditions shall be noted in the
position or alignment by more than records.
the specified limit, or alternatively
the substructure shall be modified to Page 245
FOR INTERNAL USE ONLY used shall be as shown on the
Drawings.
10.3 PRECAST REINFORCED
10.3.2.2 Reinforcement
CONCRETE PILES
The main reinforcing bars in piles
not exceeding 12 m in length
10.3.1 Description
shall be in one continuous length
unless otherwise approved by the
This work shall comprise the supply
S.O.
and installation of precast reinforced
concrete piles, inclusive of pitching
In piles exceeding 12 m long,
and driving, lengthening and cutting
joints shall be permitted in main
and preparation of pile heads, all in
longitudinal bars at 12 m nominal
intervals. Joints in adjacent bars
and to the details shown on the
shall be staggered at least 1 m
Drawings.
apart along the length of the pile.
Joints shall be butt welded as
10.3.2 Materials
specified in Sub-Section 9.7.5 of
this Specification.
10.3.2.1 Concrete
Unless otherwise specified,

ordinary Portland cement shall be
used for the casting of piles. Cawangan Jalan, Ibu Pejabat JKR, K.L
The materials and workmanship

shall be as specified under
The grade of concrete and the
details of reinforcement to be
Standard Specification For Road Works Drawings. Rock shoes where
required shall consist of wrought
Other means of jointing iron shoes and mild steel straps
reinforcement, such as by means cast into "Chilled-hardened" cast
of mechanical couplings shall be iron blocks, as shown on the
to the approval of the S.O. Drawings.
10.3.2.3 Pile Shoes 10.3.3 Manufacture and Storage of Precast

Reinforced Concrete Piles
The type of pile shoes to be
used shall be as shown on the 10.3.3.1 Casting
Drawings and shall comply
with the following as relevant :- The length of piles to be cast
i) "Chilled-hardened" cast iron Drawings, subject to revision by
shoes as used for making grey the S.O. Based on the results of
iron castings to B.S. 1452, pile driving resistance and/or load
Grade 10; or tests carried out on piles driven
on the site, the S.O. may from
ii) Mild steel to B.S. 4360, time to time order the lengths of
Grade 50B; or piles to be modified.
iii) Cast steel to B.S. 3100, Grade

A.
Mild steel straps cast into the

shoes shall be as shown on the Page 246
FOR INTERNAL USE ONLY marked with indeletable marker
on the top surface and on the
Piles shall be cast on a horizontal head of the pile. In addition,
platform in approved moulds to each pile shall be marked at
the dimensions as shown on the intervals of 0.5 m along its length
Drawings. The concreting of before being driven.
each pile shall be completed in
one continuous operation and no 10.3.3.2 Handling and Storage
interruptions will be permitted.
Lifting holes shall be formed The method and sequence of
during casting in the positions lifting, handling, transporting and
and in accordance with the details storing piles shall be such that
shown on the Drawings. piles are not damaged. Only the
designed lifting and support
The cross-sectional dimensions of points shall be used. During
the pile shall not be less than transport and storage, piles shall
those shown on the Drawings and be placed on adequate supports
shall not exceed them by more located under the lifting points of
than 6 mm. Any face of a pile the piles. All piles within a stack
shall not deviate by more than 6 shall be in groups of the same
mm from a straight edge 3 m length. Packings of uniform
long laid on the face, and the
centroid of any cross-sections of Cawangan Jalan, Ibu Pejabat JKR, K.L
the pile shall not deviate by more
than 12 mm from the straight line
connecting the centroids of the
end faces of the pile.
After a pile has been cast, the

date of casting, reference number,
and the length shall be clearly
Standard Specification For Road Works continuously until the specified
set and/or depth has been
thicknesses shall be provided reached, unless otherwise
between piles at the lifting points. approved by the S.O. The
driving equipment used shall be
10.3.4 Installation of Precast Reinforced of such type and capacity to the
Concrete Piles approval of the S.O. A follower
(long dolly) shall not be used
10.3.4.1 Pitching of Piles unless otherwise approved by the
S.O.
Piles shall be pitched accurately
in the positions as shown on the A detailed record of the driving
Drawings. At all stages during resistance over the full length of
driving and until the pile has set each pile shall be kept. The log
or been driven to the required shall record the number of blows
length, all exposed piles shall be for every 0.5 m of pile
adequately supported and penetration. The Contractor shall
restrained by means of leaders, inform the S.O. without delay if
trestles, temporary supports or an unexpected change in driving
other guide arrangements to characteristics is encountered.
maintain position and alignment
and to prevent buckling and Where required by the S.O. set
damage to the piles. shall be taken at approved
intervals during the driving to
10.3.4.2 Driving of Piles establish the behaviour of the
piles.
Each pile shall be driven
Page 247
If a pile is to be subjected to
A set shall be taken only in the further driving, concrete in the
presence of the S.O. unless damaged pile head shall be cut
otherwise approved. The off square at sound concrete,
Contractor shall provide all and all loose particles shall be
facilities to enable the S.O. to removed by wire brushing, fol
check driving resistances. The lowed by washing with water.
final set of a pile other than as Care shall be exercised to ensure
friction pile, shall be recorded as that the reinforcement in the pile
the penetration in millimeters per head is not in any way damaged.
10 blows. The temporary Any damaged reinforcement
compression of the pile shall be shall be made good to the
recorded if required. satisfaction of the S.O. The head
shall be replaced with concrete of
Piles shall be driven in an an approved grade. The new
approved sequence to minimise head shall be cast truly in line
the detrimental effects of heave with the remainder of the pile and
and lateral displacement of the be properly cured and allowed to
ground. When required, careful harden sufficiently to develop
levelling from a datum unaffected the strength necessary for further
by the piling shall be made on
the pile heads already driven, Cawangan Jalan, Ibu Pejabat JKR, K.L
before and after driving
subsequent piles. Piles which
have been displaced as a result
of driving adjacent piles shall be
redriven to the required
resistance.
10.3.4.3 Repair of Damaged Pile Heads

Standard Specification For Road Works shall be spliced with bars of the
same diameter as the main pile
driving. If a pile has been driven bars, 60 diameters in length and
to the required set or depth but lapping the main bars for a
sound concrete of the pile is distance of 30 diameters above
below cut-off level, the pile shall and below the joint, and shall be
be made good to the cut-off level securely bound with 1.63 mm
as described above. soft annealed iron wire. New
binders of similar size shall be
10.3.4.4 Lengthening of Piles provided and spaced at half the
centres of the binders in the main
Where piles have to be body of the pile and shall be
lengthened, other than by means securely bound with 1.63 mm
of welding of steel plates as soft annealed iron wire and the
detailed on the Drawings, the pile extended by concreting in
reinforcement shall be stripped of properly constructed mounds to
all surrounding concrete for a the length required.
distance equal to thirty times the
diameter of the main
reinforcement measured from the
pile head for spliced joints and
300 mm for butt welded joints
and all lateral reinforcement shall
be removed. The lengthening
bars shall butt on the exposed
bars in true alignment and shall
be butt welded as specified or Page 248
The extension bars shall butt on
Care shall be taken to form the the projecting bars in true
joint between the old and new alignment and shall be
concrete as specified butt welded in accordance with
hereinbefore. The extension shall Sub-Section 9.7.3.5 of this
be truly in line with the Specification.
remainder of the pile, , and be
properly cured and allowed to
harden sufficiently to develop the
strength necessary for further
driving.
10.3.4.5 Cutting and Preparation of Pile

Heads
When a pile has been driven to

the required set or depth, the head
of the pile shall be cut off to the
level specified or shown on the
Drawings. The length of
reinforcing bars projecting above
this level shall be as shown or
specified on the Drawings. If the
length of reinforcing bars left
projecting is insufficient, then
they shall be extended by
either of the following
methods :-
(a) Butt Welding

Standard Specification For Road Works The concrete of the pile shall be
made good either before or
(b) Splicing together with the casting of the
pile cap, all to the satisfaction of
The projecting bars shall be the S.O.
stripped of all surrounding
concrete as necessary to allow Care shall be taken to avoid
splices of length 60 diameters cracking or otherwise damaging
with extension bars. The the rest of the pile. Any cracked
extension bars shall be securely or defective concrete shall be cut
bound to the projecting bars with away and made good with new
1.63 mm soft annealed iron wire. concrete properly bonded to the
old.

FOR INTERNAL USE ONLY shown on the Drawings.
10.4 PRESTRESSED SPUN 10.4.2.2 Reinforcement

CONCRETE PILES
The prestressing tendons and the
non-prestressing reinforcement of
the piles including workmanship
10.4.1 Description
shall be as specified under
Sections 11 and 9 respectively of
This work shall comprise the supply
this Specification and to the
and installation of prestressed spun
details as shown on the
concrete piles,inclusive of pitching
Drawings.
and driving, lengthening and cutting
and preparation of pile heads, all in
10.4.2.3 End Plates
Details of end plates of each
Drawings.
length of pile shall be as shown
on the Drawings.
10.4.2 Materials
Each end plate shall be machine-
10.4.2.1 Concrete
finished and provided with a
chamfer to accommodate the
Unless otherwise specified,
welding when two lengths of pile
ordinary Portland cement shall be
are jointed.
used for the casting of piles. The
materials and workmanship shall
be as specified under Section 9
of this Specification. The grade
of concrete to be used shall be as
Standard Specification For Road Works casting process. Moulds shall be
of metal, well braced and
10.4.2.4 Pile Shoes stiffened against deformations
caused by the hydrostatic
If specified, the type of pile shoes pressure of the wet concrete
to be used shall be as shown on while spinning. The metal forms
the Drawings and shall be in shall have smooth joints and
accordance with Sub-Section inside surfaces. The forms shall
10.3.2.3. be accessible for adequate
cleaning.
10.4.3 Manufacture and Storage of
Prestressed Spun Concrete Piles The spiral reinforcement shall be
securely held to the longitudinal
10.4.3.1 Casting reinforcement during casting and
spinning. Any welding used shall
The length of piles to be cast not affect the strength of the pre
shall be as shown on the stressing tendons.
Drawings, subject to revision by
the S.O. Based on the results of The pile shall not be removed
pile driving resistance and/or load from the moulds until after the
tests carried out on piles driven specified transfer strength is
on the site, the S.O. may from achieved.
time to time order the lengths of
piles to be modified. The external diameter and the
thickness of the pile shall not be
Piles shall be hollow cylinders
manufactured by the centrifugal Page 250
FOR INTERNAL USE ONLY shall be provided between piles at
the lifting points.
less than that shown on the
Drawings and shall be constant 10.4.4 Installation of Prestressed Spun
over the entire length of the pile Concrete Piles
and coaxial with the end plate at
each end. 10.4.4.1 Pitching and Driving of Piles
After a pile has been cast, the Pitching and driving of piles shall
date of casting, reference number be in accordance with Sub-
and length shall be clearly Sections 10.3.4.1 and 10.3.4.2.
marked with indeletable marking Piles shall not be driven until the
on the top surface and on the concrete has achieved the
head of the pile. In addition, each specified characteristic strength.
pile shall be marked at intervals
of 0.5 m along its length before
being driven.
10.4.3.2 Handling and Storage
The method and sequence of

lifting, handling, transporting and
storing piles shall be such that
piles are not damaged. Only the
designed lifting and support
points shall be used.
All piles within a stack shall be in

groups of the same length.
Packings of uniform thicknessess
Standard Specification For Road Works 10.4.4.3 Cutting and Preparation of Pile
Heads
10.4.4.2 Lengthening of Piles
When a pile has been driven to
Where lengthening of piles is the required set or depth, the
required, the details of the joint head of the pile shall be cut off to
shall be as shown on the the level specified or shown on
Drawings. When two lengths of the Drawings. The Contractor
pile are jointed, the end plates shall submit to the S.O. for
shall bear over their complete approval, his proposed method
areas. Shims for packing shall not for cutting of piles. Pile heads
be accepted. shall be constructed to details as

10.5.2.3 Drilling Fluid
10.5 BORED CAST-IN-PLACE
Drilling fluid material, bentonite,
PILES
shall comply with Specification
No. DF CP4 of the Oil
Companies Materials Association
10.5.1 Description
or its equivalent. A certificate
shall be obtained by the
This work shall comprise the boring
Contractor from the manufacturer
or grabbing, with or without casing,
of the bentonite powder, showing
and subsequently filling the hole
the properties of each
with plain or reinforced concrete to
consignment delivered to the site.
form bored cast-in-situ piles, all in
This certificate shall be made
available to the S.O. on request.
Drawings.
10.5.2 Materials
10.5.2.1 Concrete and Reinforcement
The concrete and reinforcement

to be used and workmanship
for bored cast-in-situ piles shall
be as specified under Section 9
of this Specification. The grade
of concrete and the details of
reinforcement to be used shall be
as shown on the Drawings.
10.5.2.2 Permanent Casings
Permanent casings which form

part of the designed pile shall be
as specified in the Drawings.
Standard Specification For Road Works less than the specified designed
diameter at any level throughout
Bentonite shall be mixed its length.
thoroughly with clean fresh water
to make a suspension which will 10.5.3.2 Boring
maintain the stability of the pile
excavation for the period Boring shall be carried down to
necessary to place concrete and the depth as required and
complete construction. directed by the S.O.
Preparation of the suspension
shall comply with the When deemed necessary by the
manufacturer's instructions. S.O., the Contractor shall take
undisturbed soil samples while
Where saline or chemically the pile is being bored. The
contaminated ground water samples shall be taken to an
occurs, special precautions shall approved Laboratory for testing.
be taken to modify the bentonite
suspension or prehydrate the Sampling and all subsequent
bentonite in fresh water to render handling and testing shall be
it suitable in all respects for the carried out in accordance with
construction of piles. B.S.5930.
10.5.3 Boring Operations
10.5.3.1 Diameter of Piles
The diameter of piles shall not be Page 252

Where the use of drilling fluid or
Piles shall not be bored close to a column of water is approved for
other piles which have recently maintaining the stability of
been cast and which contain boring, the level of fluid or
workable or unset concrete, such column of water in the
that a flow of concrete could be excavation shall be maintained
induced from or damage caused such that the fluid pressure
to any of the piles. always exceeds the pressure
exerted by the soil and external
10.5.3.3 Temporary Casings ground water and an adequate
temporary casing shall be used in
Temporary casings of approved conjunction with the method to
quality or an approved alternative ensure the stability of the strata
method shall be used to maintain near ground level until concrete
the stability of pile excavations has been placed. The fluid water
which might otherwise collapse. level shall be maintained at a
level not less than 1 metre above
Temporary casings shall be free the level of the external ground
from significant distortion. They water.
shall be of uniform cross-section
throughout each continuous
length. During concreting they Cawangan Jalan, Ibu Pejabat JKR, K.L
shall be free from internal
projections and encrusted
concrete which might prevent the
proper formation of the piles
being cast.
10.5.3.4 Stability of Piling Excavations

Using Drilling Fluid
Standard Specification For Road Works Pumping from the borehole shall
not be permitted unless a casing
In the event of a rapid loss of has been placed into the stable
bentonite suspension or water stratum to prevent the further
from the piling excavation, the ingress of water in significant
excavation shall be backfilled quantities from other strata into
without delay and the instructions the boring, or, unless it can be
of the S.O. shall be obtained prior shown that pumping will not
to resuming boring at that have a detrimental effect on the
location. surrounding soil or its properties.
10.5.3.5 Spillage and Disposal 10.5.3.7 Continuity of Construction
All reasonable steps shall be A pile constructed in stable soil,

taken to prevent the spillage of without the use of temporary
bentonite suspension or water on casings or other support, shall be
the site in areas outside the bored and concreted without
immediate vicinity of the boring delay to ensure that the soil char
operations. Discarded bentonite acteristics are not significantly
water shall be removed from the altered.
site without delay. The disposal
of bentonite water shall comply
with the regulations of the Local
Controlling Authorities.
10.5.3.6 Pumping of Boreholes

Page 253
FOR INTERNAL USE ONLY diameter exceeds 750 mm,
adequate equipment conforming
10.5.3.8 Enlarged Pile Bases to B.S. 5930 shall be provided to
enable the Contractor and the
The enlarged pile base shall not S.O. to descend into the borehole
be smaller than the dimensions for the purpose of inspection.
specified and shall be concentric
with the pile shaft diameter. A For wet boreholes, i.e. holes
sloping surface of the frustum filled with drilling fluid or water,
forming the enlargement shall a suitable probe shall be provided
make an angle to the horizontal to ascertain the evenness and
of not less than 55º. cleanliness of the pile base.
10.5.3.9 Cleanliness of Pile Bases 10.5.4 Placing of Reinforcement
On completion of boring, loose, 10.5.4.1 Joints in Longitudinal Bars

disturbed or remoulded soil or
fragments of rock shall be Reinforcement shall be such that
removed from the base of the the full strength of the bar is
pile. effective across the joint and the
joint shall be made so that there
10.5.3.10 Inspection is no relative displacement
For dry boreholes, each hole shall Cawangan Jalan, Ibu Pejabat JKR, K.L
be inspected prior to the placing
of concrete in it. The inspection
shall be carried out from the
ground surface in the case where
the borehole diameter is less than
750 mm. Where the borehole
10.5.5.1 Placing Concrete
of the reinforcement during the
construction of the pile and the The method of placing and the
Typical Conditions Slump Range
of Use (mm)
Placed into water-free unlined bore.

Widely spaced reinforcement leaving
room for free movement between bars 75 to 125
Where reinforcement is not spaced widely

enough to give free movement between
bars.
Where casting level of concrete is within

the casing.
Where pile diameter is less than 600 mm. 100 to 175
Where concrete is to be placed by tremie

under water or drilling fluid. 150 to collapse
spacing of the reinforcing bars workability of concrete shall be

shall be maintained in such a way such that a continuous monolithic
that proper concreting shall not concrete shaft of the full cross-
be impeded. section is formed.
10.5.4.2 Positions of Reinforcement 10.5.5.2 Workability of Concrete
Adequate spacer blocks, guide The workability of the concrete

tubes, and lifting wires shall be shall be determined by the slump
provided so as to maintain the test as described in M.S. 26.
reinforcing steel in the positions
as specified. The suggested slump details for
typical concreting situations shall
Where temporary casings are be as specified in Table 10.1
employed, the longitudinal below. The slump shall be
reinforcement shall extend at measured at the time of
least 1.0 metre below the bottom discharge into the borehole.
of the casing so that movement of
the reinforcement during
extraction of the casing is
minimised.
10.5.5 Concreting Operations

Page 254
TABLE 10.1 - SLUMP RANGE FOR TYPICAL CONCRETING SITUATIONS

10.5.5.3 Compaction diameter, an enriched mix shall
be used in the first few batches of
Internal vibrators shall not be concrete to minimise segregation.
used to compact concrete unless
it can be satisfied that they will 10.5.5.5 Placing Concrete Under Water or
not cause segregation or arching Drilling Fluid
of the concrete.
Concrete to be placed under
10.5.5.4 Placing Concrete In Dry Borings water or drilling fluid shall be
placed by tremie unless otherwise
Approved measures shall be approved and shall not be
taken to avoid segregation and discharged freely into the water
bleeding and to ensure that the or drilling fluid.
concrete at the bottom of the pile
is not deficient in grout. Before placing concrete,
measures shall be taken to ensure
Where piles are vertical, concrete that there is no accumulation of
may be poured through a funnel silt or other material at the base
with a length of tube so that the of the boring.
flow is directed and does not hit
reinforcement bars or the side of
the hole. Chutes extending to
near the base shall be employed
for raking piles of large diameter.
For raking piles of small

FOR INTERNAL USE ONLY or drilling fluid. The tremie pipe
shall at all times penetrate the
The hopper and pipe of the concrete which has previously
tremie shall be clean and been placed and shall not be
watertight throughout. The pipe withdrawn from the concrete
shall extend to the base of the until the completion of
boring and a sliding plug or concreting. At all times, a
barrier shall be placed in the pipe sufficient quantity of concrete
to prevent direct contact between shall be maintained within the
the first charge of concrete in the tremie pipe to ensure that the
pipe of the tremie and the water pressure from it exceeds that
from the water or drilling fluid. Standard Specification For Road Works
The internal diameter of the 10.5.6.2 Concrete Level

tremie pipe shall not be less than
150 mm for concrete made with When the casing is being
20 mm aggregate and not less extracted, a sufficient quantity of
than 200 mm for concrete made concrete shall be maintained
with 40 mm aggregate. The within it to ensure that the
tremie pipe shall be so designed pressure from external water,
that external projections are drilling fluid or soil is exceeded
minimised, allowing the tremie and that the pile is neither
pipe to pass through the reduced in section nor
reinforcing cage without causing contaminated.
damage or uplifting. The internal
face of the tremie pipe shall be No concrete shall be placed in the
from projections. boring once the bottom of the
casing has been lifted above the
10.5.6 Extraction of Casing top of the concrete; it shall be
placed continuously as the casing
10.5.6.1 Workability of Concrete is extracted until the desired head
of concrete is obtained.
Temporary casings shall be
extracted while the concrete Adequate precautions shall be
within them remains sufficiently taken in all cases where excess
workable to ensure that the heads of water or drilling fluid
concrete is not lifted. could be caused as the casing is
withdrawn because of the
displacement of water or fluid by
the concrete as it flows into its
final position against the wall of
the pile shaft. Where double
casings are used in the boring, the
proposed method of working
shall be with the approval of the
S.O.
10.5.6.3 Vibrating Extractors
The use of vibrating extractors

shall be permitted subject to the
condition that work shall be
carried out in such a manner and
at such times as to minimise
nuisance and disturbance.

FOR INTERNAL USE ONLY level being higher than the
required pile head casting level
10.5.7 Construction of Pile Heads shown on the Drawings, the
Contractor shall submit his
10.5.7.1 Water Levels proposals for approval prior to
placing concrete. The pile head
In the event of the ground water shall not be left below the ground
water level unless approved
precautions are taken. Standard Specification For Road Works
10.5.7.2 Cutting and Preparation of Pile 10.6.2 Materials

Heads
All steel H-section piles shall
The top of the pile shall be comply with B.S. 4 with regard to
brought above the cut-off level of sectional dimensions and the steel
the pile to permit all laitance and shall comply with the requirements
weak concrete to be removed and of B.S. 4360. The sections and
to ensure that it can be properly grades to be used shall be as
keyed into the pile cap. Pile specified or as shown on the
heads shall be constructed to the Drawings.
details shown on the Drawings.
10.6.3 Manufacture and Storage of
10.5.7.3 Temporary Backfilling Above Steel H-Section Piles
Pile Casting Level
10.6.3.1 Manufacture
After each pile has been cast, any
empty bore remaining shall be Unless otherwise approved by the
protected and shall be carefully S.O. the strengthening of the toe
backfilled as soon as possible in lieu of a shoe or the
with approved materials. strengthening of the head of a
pile shall be made from material
of the same grade as the pile and
10.6 STEEL H-SECTION PILES to the details as shown on the
Drawings.
10.6.1 Description For standard rolled sections the
deviation from straightness in
This work shall comprise the supply millimetres shall not exceed 1.04
and installation of steel H-section (L-4.5) where L is the length of
piles, inclusive of pitching and the pile in metres.
driving, lengthening and preparation
of pile heads, all in accordance with For proprietary sections made up
this Specification and to the details from rolled sections the deviation
shown on the Drawings. from straightness shall not exceed
1/1000 of the length of the pile.
Cawangan Jalan, Ibu Pejabat JKR, K.L Each pile shall be clearly marked
with white indeletable marking at
the flanged head showing its
reference number and overall
length. In addition, each pile
shall be marked at intervals of
0.5 m along its length before
being driven.
Page 257
FOR INTERNAL USE ONLY shall be as shown on the
Drawings subject to revision by
The length of piles to be supplied the S.O. Based on the results of
pile driving resistance and/or load
tests carried out on piles driven Standard Specification For Road Works
on the Site, the S.O. may from
time to time order the lengths of 10.6.4.3 Cutting and Preparation of Pile
piles to be modified. Heads
10.6.3.2 Handling and Storage When a pile has been driven to

the required set or depth and
All operations such as handling before encasing in concrete, the
and transporting of piles shall be piles shall be cut to within 20
carried out in such a manner that mm of the levels shown on the
damage to piles and their Drawings. Pile heads shall be
coatings is minimised. Piles constructed to the details as
that are damaged during handling shown on the Drawings.
and transporting shall be replaced
by the Contractor at his own The remaining section which can
expense. All damaged and be reused for lengthening of piles
rejected piles shall be removed shall be stored and protected as
from the Site forthwith. directed by the S.O.
Piles within a stack shall be in

groups of the same length and on 10.7 STEEL PIPE PILES
approved supports.
10.6.4 Installation of Steel H-Section Piles 10.7.1 Description
10.6.4.1 Pitching and Driving of Piles This work shall comprise the supply
and installation of steel pipe piles,
Pitching and driving of piles shall inclusive of pitching and driving,
be in accordance with Sub- lengthening and preparation of pile
Sections 10.3.4.1 and 10.3.4.2. heads, all in accordance with this
Specification and to the details
10.6.4.2 Lengthening of Piles shown on the Drawings.
Where lengthening of piles is 10.7.2 Materials

required, the piles shall be jointed
by butt welding. Butt welded All steel pipes shall comply with
joints shall be stiffened with B.S. 6323 with regard to sectional
plates fillet welded on all four dimensions and the steel shall
sides as detailed on the Drawings. comply with the requirements of
All weldings shall be continuous B.S. 4360.
and complying with B.S. 638,
B.S. 5135 and B.S. 5950 for arc 10.7.3 Manufacture and Storage of
welding and B.S. 4577 for Steel Pipe Piles
resistance welding as appropriate.
The type and size of weld shall 10.7.3.1 Welding
be as detailed on the Drawings.
Cawangan Jalan, Ibu Pejabat JKR, K.L Unless otherwise specified, all
welds shall be full penetration
butt welds complying with the
requirements of B.S. 5153.
Page 258
The root edge or root face lengths
10.7.3.2 Fabrication of Piles of piles that are to be butt welded
shall not differ by more than 25%
from the thickness of piles not Standard Specification For Road Works
exceeding 12 mm in thickness; or
by more than 3 mm for piles 10.7.3.4 Straightness of Piles
exceeding 12 mm in thickness.
When piles of unequal thickness Unless otherwise approved, the
are to be butt welded together, the deviation from straightness shall
thickness of the thinner material not exceed 1/600 of a length not
shall be the criterion. exceeding 10 m. When two or
more such lengths are joined, the
Pile lengths shall be set up so that deviation from straightness shall
the differences in dimensions are not exceed 1/960 of the
matched as evenly as possible. completed length.
The length of piles to be supplied 10.7.3.5 Fabrication of Piles on Site

Drawings subject to revision by When pile lengths are to be made
the S.O. Based on the results of up on Site, all test procedures and
pile driving resistance and/or load dimensional tolerances shall
tests carried out on piles driven conform to the Specification
on the Site, the S.O. may from for the supply of pipe materials.
time to time order the lengths of Adequate facilities shall be
piles to be modified. provided for supporting and
aligning the lengths of pile.
10.7.3.3 Matching of Pile Lengths
10.7.3.6 Handling and Storage
Longitudinal seam welds and
spiral seam welds of lengths of All piles within a stack shall be in
pipe piles forming a completed groups of the same length and on
pile shall, whenever possible, be approved supports. All
evenly staggered. However, if in operations such as handling,
order to obtain a satisfactory transporting and pitching of piles
match of the ends of piles or the shall be carried out in a manner
specified straightness, the such that damage to piles and
longitudinal seams or spiral their coatings is minimised. Piles
seams are brought closely to one that are damaged during handling
alignment at the joint, then they and transporting shall be replaced
shall be staggered by at least by the Contractor at his own
100 mm. expense. All damaged and
rejected piles shall be removed
from the Site forthwith.
10.7.3.7 Marking of Piles
Each pile shall be clearly marked

with white indeletable marking
showing its reference number and
Cawangan Jalan, Ibu Pejabat JKR, K.L overall length. In addition, each
pile shall be marked at intervals
of 0.5 metre along its length
before being driven.
Page 259
10.7.4.1 Welding Procedures
10.7.4 Workmanship
The Contractor shall submit for
approval, full details of the Standard Specification For Road Works
welding procedures and
electrodes with drawings and ii) for tubes of any wall
schedules as may be necessary. thickness, continuous
Tests shall be undertaken as may ultra-sonic examination over
be required by the S.O. and shall the whole weld, supplemented
be in accordance with the where necessary by
requirements of B.S. 4870. radiographs to investigate
defects revealed by the
10.7.4.2 Welders' Qualifications ultrasonic examination.
Only welders who are qualified 10.7.4.4 Acceptance Standards

in the approved welding
procedure shall be employed. If the results of any weld test do
Copies of certificates relating to not conform to the specified
welders' tests shall be made requirements, two additional
available to the S.O. on request. specimens from the same length
of pile shall be tested. In the case
10.7.4.3 Radiographs of failure of one or both of
these additional tests, the length
During production of welded of pile covered by the test shall
tube piles, at least one radiograph be rejected.
approximately 300 mm long shall
be required on each completed 10.7.5 Protective Coatings
length as a spot check on weld
quality. This shall be taken on a If protective coatings are specified,
circumferential or longitudinal the preparation of surfaces and the
weld and its position shall be as application of the coatings shall be
directed by the S.O. carried out by skilled labour having
experience in the preparation of the
For spirally welded piles, one of coatings specified.
the following tests shall be
carried out :- 10.7.5.1 Surface Preparation
i) for tubes of wall thickness 12 Unless otherwise specified, all

mm or less, three spot check surfaces to be coated shall be
radiographs, one at each end blast cleaned with an approved
of each length of the tube as abrasive in accordance with B.S.
manufactured and one at a 4232 or SIS 05 59 00 to remove
position to be chosen at the rust, mill scale and other adhering
time of testing by the S.O.; materials, to provide a finish to
and spot check radiographs as second quality (near white) of
required by the S.O. on the B.S. 4232 or SIS 05 59 00 grade
weld joints between strip Sa 2 1/2.
lengths;
10.7.5.2 Application and Type of Primer
Immediately after surface
preparation, the surface shall be
coated with an approved primer
or the specified coating to avoid
recontamination. No coat shall be
Page 260
FOR INTERNAL USE ONLY is not thoroughly dry.
applied to a metal surface which The primer shall be compatible

with the specified coating.
10.7.5.3 Part to be Welded
10.7.6 Installation of Steel Pipe Piles
The coating within 200 mm of a
weld shall be applied after 10.7.6.1 Pitching and Driving of Piles
welding.
Pitching and driving of piles shall
10.7.5.4 Thickness, Number and Colour be in accordance with Sub-
of Coats Sections 10.3.4.1 and 10.3.4.2.
The minimum dry film thickness 10.7.6.2 Lengthening of Piles

of the finished coating, including
the minimum dry film thickness Unless otherwise approved,
of each coat and the minimum where lengthening of piles is
number of coats that are to be required, the piles shall be jointed
applied, shall be as specified and by butt welding along the entire
shown on the Drawings. periphery as detailed on the
Coatings shall be applied in Drawings.
accordance with the
manufacturer's instructions. 10.7.6.3 Cutting and Preparation of
Pile Heads
10.7.5.5 Inspection of Coatings and
Acceptibility When a pile has been driven to
the required set or depth and
The finished coating shall be before encasing in concrete, the
generally smooth, of a dense and pile shall be cut to within 20 mm
uniform texture and free from of the levels shown on the
sharp protuberances or pin holes. Drawings and protective coatings
shall be removed from the
Any coat damaged by subsequent surfaces of the pile head 100 mm
processes or which has above the soffit of the concrete.
deteriorated to an extent such that Pile heads shall be constructed to
proper adhesion of the coating details as shown on the
may not be obtained or Drawings.
maintained, shall be recleaned to
the original standard and recoated 10.7.6.4 Concreting of Pile Shaft
with the specified sequence of
coats. If concreting is specified or
shown on the Drawings after the
The completed coating shall be pile has been cut off to the
checked for thickness and specified level, the shaft shall be
continuity by an approved filled with concrete in a
magnetic gauge or detector. Areas continuous operation. The
where the thickness is less than method of placing shall be
that specified shall receive approved by the S.O.
approved additional treatment.
Cawangan Jalan, Ibu Pejabat JKR, K.L The reinforcement cage in the
pile shall be made sufficiently
rigid and kept in its correct
position during concreting.
Page 261
FOR INTERNAL USE ONLY projecting above the pile cut off
level shall be as shown on the
The length of the reinforcing bars Drawings.
10.8 MICROPILES
10.8.3 Drilling Operations
10.8.1 Description 10.8.3.1 Diameter of Piles
This work shall comprise the drilling The diameter of piles shall not be
of a hole, placing of reinforcement less than the specified/designed
unit and subsequently filling the hole diameter at any level throughout
with grout to form micropiles, all in its length.
and to the details shown on the 10.8.3.2 Drilling
Drawings.
The Contractor shall submit to
10.8.2 Materials the S.O. details of drilling
equipment and drilling procedure
10.8.2.1 Reinforcement Unit for approval before
commencement of works.
The type of reinforcement unit to Drilling operations shall be
be used, the diameter and/or carried out in accordance with the
thickness, grade, yield strength relevant requirements of Sub-
and working stress shall be as Section 10.5.3.
specified or as shown on the
Drawings. 10.8.4 Grouting Operations
10.8.2.2 Grout 10.8.4.1 Mixing and Placing Grout
Unless otherwise specified, the The Contractor shall provide

grout shall be non-shrink cement details of the method and
grout. The grout mix design such equipment used in grout mixing.
as the water-cement ratio, the Further information such as
minimum cement and grout grouting pressure, grouting
strength at 7 and 28 days shall be procedure, grouting equipment
as specified and shown on the and techniques employed in
Drawings. grouting underwater shall also be
furnished for approval.
If admixtures are used, details of
admixtures shall be submitted to Grout shall be mixed on Site and
the S.O. for approval before shall be free from segregation,
commencement of works. The slumping and bleeding. Grout
use of the admixture shall fully shall be pumped into its final
comply with the manufacturer's position in one continuous
instructions. operation as soon as possible and
in no case more than half an hour
after mixing.
Cawangan Jalan, Ibu Pejabat JKR, K.L 10.8.4.2 Testing Grout
Grout shall be tested in

accordance with B.S. 1881 and
B.S. 4550.
Page 262
10.8.5.1 Lengthening of Piles
10.8.5 Construction of Pile Heads
Where lengthening is required,
the pile reinforcement unit shall Standard Specification For Road Works
be connected on Site to the
details shown on the Drawings. Pressure-treated timber piles shall
conform to M.S. 822 and shall be
Other means of jointing approved by SIRIM.
reinforcement shall be to the
approval of the S.O. 10.9.3 Manufacture and Storage of
Pressure-Treated Timber Piles
10.8.5.2 Cutting and Preparation of Pile 10.9.3.1 Manufacture
Heads
Before commencement of work
Pile heads shall be constructed to the Contractor shall notify the
the details as shown on the S.O. of the name of the supplier
Drawings. and manufacturer for approval.
The method of preservative

10.9 PRESSURE-TREATED TIMBER treatment for timber piles shall be
PILES the full-cell process as described
in M.S. 360. The preservative
used shall comply with M.S. 733.
10.9.1 Description The depth of penetration of
preservative shall be a minimum
This work shall comprise the supply of 25 mm and the net dry salt
and installation of pressure-treated retention in the treated part of the
timber piles, inclusive of pitching timber shall be a minimum of 16
and driving, lengthening and kg/cu.m.
preparation of pile heads, all in
accordance with this Specification Piles shall be within -2 mm and
and to the details shown on the +6 mm of their specified cross-
Drawings. The timber terms used in sectional dimensions. The
this Specification shall have the centroid of any cross-section of a
meanings assigned to them in M.S. pile shall not deviate by more
229. than 25 mm from the straight line
connecting the centroids of the
10.9.2 Materials end faces of the pile.
Unless otherwise approved by the Before the treated timber pile is

S.O., Kempas (Koompassia accepted for the work the
Malaccensis) shall be used and this Contractor shall obtain from the
shall not be of a lesser quality than manufacturer of the treated piles
the grading specified in Appendix A a warranty on an approved form
of M.S. 822. which provides, that for a ten
year period, the treated piles shall
be free from fungus and insect
attack.
Page 263
FOR INTERNAL USE ONLY permanently marked with
identifications which indicate that
Each treated pile shall be they comply with this
Specification, manufacturer's
trade mark, type of treatment, Standard Specification For Road Works
charge number and date of
treatment and the length of the The length of piles to be supplied
pile. The end plates of each pile shall be as shown on the
shall have SIRIM Control Labels. Drawings subject to revision by
the S.O. Based on the results of
The S.O. may require inspection pile driving resistance and/or load
and testing at the treatment plant tests carried out on piles driven
to observe and ensure that the on the Site, the S.O. may from
manufacturing process and time to time order the lengths of
control testings of the piles are piles to be modified.
carried out in accordance with
this Specification. Records of the 10.9.4 Installation of Pressure-Treated
actual treatment schedule shall be Timber Piles
kept during the treatment process,
and the Contractor shall furnish 10.9.4.1 Pitching and Driving of Piles
such records for the piles
supplied when requested by the Pitching and driving shall be in
S.O. accordance with Sub-Sections
10.3.4.1 and 10.3.4.2.
10.9.3.2 Delivery and Storage
Piles shall be provided in one
The Contractor shall notify the single length of 6.0 m each unless
S.O. of the delivery of timber otherwise approved. Any pile
piles to the Site, and provide the driven to the required set at a
necessary facilities to enable the depth of 6.0 m or less shall be in
S.O. to inspect each pile and take one continuous length.
random sampling for
determination of depth of The pile head shall be adequately
penetration and the net dry salt protected during driving, so that
retention. brooming and splitting do not
occur. The pile head shall be
Accepted piles shall be marked fitted with toothed metal plates as
and stacked in lengths on drained approved by the S.O. during
hard ground. Each pile shall be normal driving.
stacked clear of the ground and
have an air space around it. The In the case of hard driving, unless
piles shall be separated by sticks otherwise approved by the S.O., a
or blocks placed vertically one metal helmet shall be fitted to the
above the other and closely top of the pile. The top of the
spaced horizontally to avoid pile shall first be trimmed to fit
sagging of the piles. All rejected closely into the recess of the
piles shall be removed from the underside of the helmet. A hard
Site forthwith. wood dolly and, if necessary, a
packing piece shall be used above
the helmet.
If during driving the head of the
pile becomes excessively
broomed or otherwise damaged,
the damaged part shall be cut off
and the helmet refitted.
Page 264
FOR INTERNAL USE ONLY during driving, which in the
opinion of the S.O. will affect its
When fissures appear in a pile strength, the pile shall be rejected
and replaced at the Contractor's
expense. Standard Specification For Road Works
10.9.4.2 Lengthening of Piles i) the cut-offs or bored holes

shall be given two flood coats
If jointing is required, pile joints of 10% m/v solution of the
shall be made by using Mild preservative, or as specified in
Steel Welded Boxes 450 mm accordance with M.S. 360,
long fabricated from 5 mm thick allowing each application to
plates unless otherwise shown on soak thoroughly into the cut
the Drawings. Joint boxes shall or bored surface;
be painted with red lead paint or
otherwise protected against ii) immediately after the
corrosion to the satisfaction of the preservative solution has
S.O. The internal dimensions of dried, the pile heads shall be
the box shall be 3 mm undersize heavily coated with a
of the pile cross-sectional bituminous compound which
dimensions. The joint and the conforms to B.S. 3416 for the
ends of the piles to be jointed whole depth that the pile is to
shall be constructed so that the be enclosed in the pile cap.
necessary strength and stiffness
are developed at the joint.
10.10 BAKAU PILES
10.9.4.3 Cutting and Preparation of Pile

Heads 10.10.1 Description
When a pile has been driven to This work shall comprise the
the required set or depth, the head supply and installation of bakau
of the piles shall be cut off square piles, inclusive of pitching and
to sound wood and treated with driving, lengthening and
an approved preservative and a preparation of pile heads, all in
waterproof coating all in accordance with this
accordance with M.S. 822. The Specification and to the details
pile head shall be embedded for a shown on the Drawings.
depth of not less than 150 mm in
the concrete cap which shall be at 10.10.2 Materials
least 150 mm thick round the
piles. Unless otherwise approved by the
S.O. only Bakau Minyak
When piles are cut-off at the pile (Rhizophora Apiculapa) or Bakau
cap level, all cut-offs and bored Kurap (Rhizophora Mucronata)
holes shall be treated as follows :- shall be used. Bakau piles shall
be provided in one single length
of not less than 5.0 m each. The
diameter of piles at the small end
shall not be less than 75 mm
Cawangan Jalan, Ibu Pejabat JKR, K.L unless otherwise specified.
Page 265
FOR INTERNAL USE ONLY rot, fungal or pest attack and any
other defects. The piles shall be
All bakau piles shall be free from reasonably straight and circular in
cross-section with all branch
joints trimmed off to the general Standard Specification For Road Works
outline of the piles but leaving
the bark intact on the piles. Unless otherwise approved,
bakau piles shall be driven by
10.10.3 Delivery and Inspection of Bakau means of a drop hammer of at
Piles least 250 kg in mass, suspended
from a shear-leg or approved
The Contractor shall notify the pile-frame.
S.O. of the delivery of piles to the
Site and provide labour and Piles shall be driven in an
facilities to enable the S.O. to approved sequence to minimise
inspect and measure each pile at the detrimental effects of heave
the time of unloading. Accepted and lateral displacement of the
piles shall be stacked on an ground. When required, levels
approved surface in an approved and measurements shall be taken
area and kept constantly in a to determine the movement of the
damp condition. Rejected piles ground or any pile resulting from
shall be removed from the Site the driving process. If any pile
forthwith. rise occurs as a result of adjacent
piles being driven, the Contractor
10.10.4 Installation of Bakau Piles shall submit to the S.O. for
approval, his proposals for
10.10.4.1Pitching of Piles correcting this and to avoid the
same in subsequent work.
Piles shall be pitched accurately
in the positions and at spacings as The pile head shall be flat and at
shown on the Drawings or as right angles to the axis of the pile,
approved by the S.O. its edges chamfered to minimise
splitting during driving. The
10.10.4.2Driving of Piles Contractor shall take precautions
to avoid damage to the pile head
The length of piles to be driven during hard driving by providing
shall be as shown on the a suitable metal helmet. A hard
Drawings. Based on the results wood dolly and, if necessary, a
of pile driving resistance and/or packing piece shall be used above
load tests carried out on piles the helmet. If during driving the
driven on the site, the S.O. may, head of the pile becomes
from time to time order the excessively broomed or
lengths or spacing of piles to be otherwise damaged, the damaged
modified. part shall be cut off, the head
retrimmed and the helmet
refitted.

FOR INTERNAL USE ONLY The two pile ends to be
jointed shall be of the same
10.10.4.3 Lengthening of Piles diameter and each shall be cut
at right angles to its axis to
Where a pile has to be jointed, make contact over the whole
it shall be to the details as cross-section when the two
shown on the Drawings. Only timbers are co-axial. A mild
one joint shall be allowed. steel tube connector of No. 9
gauge to B.S. 6323 shall be
used to join the two pile ends. Standard Specification For Road Works
The steel tube connector shall
be painted with red lead paint 10.11.2 Preliminary Pile Load Tests
or otherwise protected against
corrosion all to the Preliminary pile load tests shall be
satisfaction of the S.O. The carried out before the S.O. issues to
pile ends shall be trimmed or the Contractor, in writing,
packed in the connector to instructions on the pile length and
provide a tight fit. pile length combinations for the
manufacture and supply of the piles.
10.10.4.4 Cutting and Preparation of The Contractor shall not proceed to
Pile Heads manufacture or supply the piles until
he has received instructions in
When the piles have been writing to do so from the S.O.
driven to the required depth,
the top of the piles shall be The lengths of the piles for the
cut off to a uniform level. preliminary load tests shall be
The cut-off level shall be determined by the S.O.
below the lowest dry season
ground water level as shown 10.11.3 Production Pile Load Tests
on the Drawings or as
approved by the S.O. Load tests shall also be carried out
during the installation of piles for the
10.11 PILE TESTING permanent Works. Such pile load
tests shall be referred to as
10.11.1 Test Piles production pile load tests.
In order to determine the required 10.11.4 Testing Procedure

length of pile at each location, the
Contractor shall drive test piles as 10.11.4.1Preparation of Test Pile
shown on the Drawings and/or as
instructed by the S.O. Test piles The pile head shall be cut off or
shall be driven with the same built up to the necessary elevation
hammer that is used for driving and shall be capped appropriately
foundation piles. to produce a bearing surface
perpendicular to the axis of the
Cawangan Jalan, Ibu Pejabat JKR, K.L pile. The arrangement shall be
such that none of the test load is
carried by the ground under the
cap.
10.11.4.2Method of Loading
The test load shall be applied in

one of the following ways :-
i) by means of a jack which

obtains its reaction from
kentledge heavier than the
required load;
Page 267
FOR INTERNAL USE ONLY obtains its reaction from
tension piles or other suitable
ii) by means of a jack which anchors.
The load shall be measured Standard Specification For Road Works
using a calibrated load gauge
and also a calibrated pressure wires. The reference beam
gauge in the hydraulic system. supports shall be located at least
The jack and load gauge shall 3 m from the load test pile,
be carefully aligned so that reaction pile or piles supporting
the load applied is co-axial reaction loads. The reference
with the pile. beams or wires shall be protected
from the effects of temperature
When method (i) is used, care changes.
shall be taken to ensure that
the centre of gravity of the 10.11.5 Method of Testing
kentledge is on the axis of the
pile. The nearest edge of the 10.11.5.1General
crib supporting the kentledge
stack shall not be closer than Maintained Load Tests shall be
1.3 m to the surface of the test conducted on test piles as
pile. Kentledge shall not be selected by the S.O. The
used for testing raked piles. loading tests shall be carried out
in accordance with Sub-Section
When method (ii) is used, all 10.11.5.2.
anchor piles shall be at a
distance of at least three (3) When instructed or approved by
pile shaft diameters from the the S.O., Constant Rate of
test pile, centre to centre, and Penetration Tests shall also be
in no case shall they be less conducted on other piles. The
than 2 m from the test pile. tests shall be carried out in
accordance with Sub-Section
If the anchor piles are to be 10.11.5.3.
permanent working piles,
their levels shall be observed Prior to the performance of any
during application of the test load test, the Contractor shall
load to ensure no residual submit to the S.O. for his
uplift occurs. approval, working drawings
showing the method and
10.11.4.3Measurement of Settlement equipment he proposes to use in
the performance of the load test
Settlements shall be measured by and the measurement of
use of a reference beam or wire settlements. Such submission
supported independantly of the shall include design calculations
load test pile, reaction pile or of lateral supports or other
piles supporting reaction loads. methods to be used in ensuring
Settlements shall be measured to against buckling. Horizontal
the nearest 0.1 mm for reference supports to ensure buckling
beams or 0.5 mm for reference stability shall be provided to the
pile to be loaded whenever the
Cawangan Jalan, Ibu Pejabat JKR, K.L ratio of the unsupported height to
the least cross-sectional
dimension is 20 or more.
Horizontal supports shall provide
full support without restraining
the vertical movement of the pile
in any way.
Page 268
The Maintained Load Test shall
10.11.5.2Maintained Load Test be carried out as follows :-
i) the full test load on a pile Standard Specification For Road Works
shall be twice the design load
noted on the Drawings and it corresponding loads shall be
shall be applied in twelve made in the loading process.
equal increments. At least two
hours shall elapse between the After attaining a test load equal to
addition of each load twice the design load, the load
increment, i.e. until the rate of shall gradually be released and at
settlement is reduced to less least four readings of settlement
than 0.25 mm/hour and and their corresponding loads
slowing down; shall be made during the
unloading process. The
ii) the full test load shall be settlement obtained when the
maintained on the pile for at load has been completely
least 48 hours and settlements released shall also be recorded.
shall be recorded at An interval of at least 15 minutes
intervals of not more than 12 shall elapse before the next CRP
hours. The test pile shall test is commenced.
then be unloaded in four
equal increments at one hour 10.11.6 Submission of Results
intervals until the full load
is removed. Settlement Full test data and results shall be
readings shall be made jointly signed by the S.O.'s
immediately after and before representative and the Contractor's
every load increment is authorised agent immediately upon
applied or removed. completion of the test, and shall
consist of the following :-
10.11.5.3Constant Rate of Penetration
(CRP) Test
i) for the Maintained Load Test, for
For each pile load test, three each stage of loading, the period
cycles of pile loading test at a for which the load was held, the
constant rate of penetration shall load and the maximum
be carried out to a full test load settlement. These are to be
equal to twice the design load. plotted as time-settlement graphs.
The rate of loading shall be such ii) for the CRP test, the maximum
that a constant rate of penetration load reached and a graph of load
is maintained throughout the test against penetration;
insofar as is practicable. The rate
of movement of each pile to be 10.11.7 Interpretation of Test Results
tested shall be agreed upon with
the S.O. prior to the start of the The S.O.'s interpretation and
test. At least twelve readings of conclusions on the test results shall
settlements and their be final. Unless otherwise specified,
the pile so tested shall be deemed to
Cawangan Jalan, Ibu Pejabat JKR, K.L have failed if :-
i) the residual settlement after

removal of the test load exceeds
6.50 mm; or
Page 269
FOR INTERNAL USE ONLY Working Load exceeds 12.50
mm; or
ii) the total settlement under the
iii) the total settlement under
twice the Working Load Standard Specification For Road Works
exceeds 38.0 mm, or 10% of
pile diameter/width whichever Bakau piles shall be tested to
is the lower value. failure by the Maintained Load
Test as described hereinbefore.
10.11.8 Load Testing of Bakau Piles The load on the pile group shall
be applied in 2 to 4 equal
In general, all relevant Sub-Sections increments as directed by the
stated hereinbefore shall apply to the S.O. until the failure load is
load testing of bakau piles, except reached. The failure load (i.e.
that what is understood as single test ultimate load) is that load at
piles in these Sub-Sections shall which the piles continue to settle
mean a group of test piles for bakau at a constant rate without further
piles. increase of applied load.
The load testing of bakau piles shall For each increment of load, the
be carried out on a group of nine settlement readings shall be
bakau piles, made up of three rows recorded at 15 minute intervals
of piles, three in a row. until the rate of settlement is less
than 0.25 mm per hour. The load
An approved reinforced concrete pile at each increment shall be
cap with a loading pedestal shall be maintained at a constant value
cast centrally over the group of piles throughout the test.
to be tested. The loading pedestal
shall be short to ensure stability, and Graphs of time-settlement, load-
it shall have an approved mild steel time and load-settlement, to a
bearing plate cast on top. The load suitable scale, shall be plotted
shall be applied centrally on to the and submitted to the S.O. with all
steel plate. records of the readings.

Road Spec

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FOR INTERNAL USE ONLY Standard Specification For Road Works

CAWANGAN JALAN KETUA PENGARAH KERJARAYA

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 1

Mix Type Wearing Course Binder Course

Mix ACW 20 ACB 28

B.S Sieve % Passing by weight

ACW 20 ­ Wearing Course 4.5 ­ 6.5 %

ACW 28 ­ Binder Course 4.0 ­ 6.0

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 2

All retro-reflective sheeting used on the same

The edges of all the retro-reflective sheeting

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 3

Observation Angle ( ° ) Entrance Angle ( ° ) Orange

6.2.6.1 FLUORESCENT ORANGE WIDE ANGLE PRISMATIC RETRO-

6.2.6.1.1 Description 6.2.6.1.2 Requirements

The flurescent orange wide angle prismatic i) Photometric - Coefficient of

Minimum Coefficient of Retroreflection RA

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 4

Orange .583 .416 .523 .397 .560 .360 .631 .369 20 45

iii) Nighttime Color.

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 5

The retroreflective sheeting applied

Cawangan Jalan, Ibu Pejabat JKR, K.L

STANDARD SPECIFICATION FOR ROADS WORKS

SECTION 1 General S1-11 to S1-31

SECTION 2 Earthworks S2-1 to S2-20

SECTION 3 Drainage Works S3-1 to S3-31

SECTION 4 Flexible Pavement S4-1 to S4-55

SECTION 5 Portland Cement Concrete Pavement S5-1 to S5-21

SECTION 6 Road Funiture S6-1 to S6-22

SECTION 7 Street Lighting S7-1 to S7-19

SECTION 8 Traffic Signals S8-1 to S8-33

SECTION 9 Concrete S9-1 to S9-39

SECTION 10 Piling Works S10-1 to S10-35

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 7

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 8

1.1 GENERAL DESCRIPTION OF THE PROJECT S1-11

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 9

APPENDIX 1A GENERAL DESCRIPTION OF PROJECT S1-22

APPENDIX 1B SCOPE OF WORKS S1-23

APPENDIX 1C VEHICLES FOR S.O. AND HIS STAFF S1-24

APPENDIX 1D LIST OF LABORATORY EQUIPMENT

APPENDIX 1E SURVEY EQUIPMENT S1-30

FIGURE 1-1 APERTURE CARD FOR MICROFILM S1-31

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 10

1.3 NOTES, ABBREVIATIONS AND

d) A.S.T.M. means The American

e) M.D.D. means Maximum Dry

f) O.M.C. means Optimum Moisture

g) C.B.R. means California Bearing

h) S.O. means Superintending Officer.

i) B.Q. means Bill of Quantities.

1.3.3 Units of Measurement

All units of measurement used in this

Where British Imperial units are shown

1.4 PROGRAMME OF WORKS Should the Contractor require additional

Unless otherwise provided in the

Where a relocatable site office is to be Sanitary facilities with disposal to

1.17 CONTRACTOR'S OFFICE AND 1.18 MATERIAL TESTING

On completion of the Works, the

1.20.1 Maintenance of Existing Roads, Upon failure on the part of the

On completion of the Works, the

The Contractor shall also microfilm the

ACW 20 Wearing Course 4.5 6.5 %

ACW 28 Binder Course 4.0 6.0