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Ref. Title Page No. Ref. Title Page No.
1.1 Scope of Section 1-1 1.6 Control of Site 1-6
1.1.1 Description 1-1 1.6.1 Keeping Site Clear of Water 1-6
1.1.2 Standard Specifications Generally 1-1 1.6.2 Site Cleaning 1-6
1.1.3 Abbreviations, Title and Terms 1-1 1.6.2.1 Site Cleaning During Progress of Works 1-6
1.1.4 Units of Measurement 1-1 1.6.2.2  Final Clean Up on Completion 1-6 
1.6.3 Measurement and Basis of Payment 1-6
1.1.5 Standards 1-2
1.7 Control of Traffic and Access 1-6 
1.2 Project Works 1-2
1.7.1 Maintenance and Protection of Traffic 1-6
1.2.1 The Works 1-2
1.7.2 Maintenance of One-Way Traffic 1-6
1.2.2 Intent of Contract 1-2
1.7.3 Temporary Structures 1-6
1.2.3 Silence of Specifications 1-2
1.7.4 Haul Routes for Heavy Vehicles 1-6
1.3 Project Site 1-2  1.7.5 Measurement and Basis of Payment 1-7
1.7.6 Items in the Bill of Quantities 1-7
1.3.1 The Site 1-2
1.3.2 Contractor’s Work Areas 1-2 1.8 Control of Works 1-7
1.3.3 Site Survey and Investigation 1-3
1.8.1 Setting out of Works 1-7
1.3.4 Measurement and Basis of Payment 1-3
1.8.2 Surveying Equipment and Accessories 1-7
1.3.5 Items in the Bill of Quantities 1-3
1.8.3 Existing Underground Services and
1.4 Contractor’s Site Facilities 1-3  Obstructions 1-7
1.8.3.1  Notices to Concerned Authorities 1-7 
1.4.1 Contractor's Compound and Buildings 1-3
1.8.3.2 Categories of Obstructions 1-7 
1.4.2 Measurement and Basis of Payment 1-3
1.8.3.3  Existing Utilities 1-8 
1.4.3 Items in the Bill of Quantities 1-3
1.8.4 Measurement and Basis of Payment 1-8
1.5 Engineer’s Facilities 1-3
1.9 General and Contractual
1.5.1 General 1-3 Obligations 1-8 
1.5.2 Site Facilities for the Engineer/Employer: 1-3
1.9.1 Health, Safety and Environmental Program 1-8
1.5.3 Computers for the Engineer 1-4
1.9.1.1  Health, Safety and Environmental Plan 1-8 
1.5.4 Telephones for the Engineer / Employer 1-4
1.9.1.2  Health, Safety and Environment
1.5.5 Car Port for the Engineer 1-4
Representatives: 1-9 
1.5.6 Cameras for the Engineer 1-4
1.9.2 Use of Explosives 1-9
1.5.7 Thermometers 1-5
1.9.2.1  Control Measures 1-9 
1.5.8 Test Equipment 1-5
1.9.2.2  Blasting Procedures 1-9 
1.5.9 Inspection Facilities 1-5
1.9.2.3  Explosives Inventory 1-9 
1.5.10 Surveying Equipment for Engineer 1-5
1.9.3 Fire Precautions 1-9
1.5.11 Measurement and Basis of Payment 1-5
1.9.4 Measurement and Basis of Payment 1-9
1.5.12 Items in the Bill of Quantities 1-5

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Ref. Title Page No. Ref. Title Page No.
1.10 Management Procedures 1-10 1.13.2 Contractor's Schedule of Plant and
Equipment 1-17
1.10.1 Commencement, Program and Progress 1-10
1.13.3 Provision and Use of Plant
1.10.2 Records and Measurements 1-11
and Equipment 1-17 
1.10.3 Project Administration 1-11
1.13.4 Measurement and Basis of Payment 1-17
1.10.4 Progress Photographs/ Videos 1-11
1.10.5 Measurement and Basis of Payment 1-12 1.14 Contractor’s Temporary Works
1.10.6 Items in the Bill of Quantities 1-12 and Services 1-17
1.11 Submittals 1-12 1.14.1 Temporary Facilities 1-17
1.14.1.1  Generally 1-17 
1.11.1 General 1-12
1.14.1.2  Temporary Site Facilities 1-18 
1.11.2 Action Submittals 1-13
1.14.2 Scaffolding and False Work 1-18
1.11.3 Informational Submittals 1-14
1.14.3 Water Supply 1-18
1.11.4 Contractor's Review and Approval 1-14
1.14.4 Electricity Supply 1-18
1.11.5 Engineer's Action 1-14
1.14.5 Directional and Warning Signs 1-18
1.11.6 Record (As-Built) Drawings 1-15
1.14.6 Project Sign Board 1-18
1.11.7 Measurement and Basis of Payment 1-15
1.14.7 Measurement and Basis of Payment 1-18
1.11.8 Items in the Bill of Quantities 1-15
1.14.8 Items in the Bill of Quantities 1-19
1.12 Control of Materials and Standards
1.15 Commemorative Plaque and
for Sampling and Testing 1-15
Opening Ceremony 1-19
1.12.1 Storage of Materials 1-15
1.15.1 Commemorative Plaque 1-19
1.12.2 Handling Materials 1-15
1.15.2 Opening ceremony 1-19
1.12.3 Materials Supplied by Employer 1-15
1.15.3 Measurement and Basis of Payment 1-19
1.12.4 Local Material Sources 1-15
1.15.4 Items in the Bill of Quantities 1-19
1.12.5 Sources of Supply and Quality
Requirements 1-16 1.16 Measurement and Payment 1-19
1.12.6 Certificates of Guarantee and Production
1.16.1 General Method of Measurement 1-19
Plant Inspections 1-16
1.16.2 Scope of Payment 1-19
1.12.7 Sampling and Testing Procedures 1-16
1.12.7.1  Sampling 1-16 
1.12.7.2  Source Tests 1-16 
1.12.7.3  Quality Control Tests 1-16 
1.12.7.4  Control Tests 1-16 
1.12.7.5  Check Tests 1-16 
1.12.7.6  Precedence of Materials and Testing
Specifications 1-17 
1.12.8 Unacceptable Materials 1-17
1.12.9 Measurement and Basis of Payment 1-17

1.13 Contractor’s Plant

and Equipment 1-17
1.13.1 General 1-17

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1.1 Scope of Section hwy - highway
ht - height
1.1.1 Description H:V - horizontal:vertical
IEC - International Electrical Commission
1 This Section describes the general requirements IEE - Institution of Electrical Engineers (UK)
that apply to all sections of the Specification where ISO - International Organization for
relevant. All sections of the Specification are to be read Standardization
in conjunction with this Section. LEED - Leadership in Energy and Environmental
Design
1.1.2 Standard Specifications Generally L.L. - liquid limit
L.S. - lump sum
1 The Standard Specification is generic. The max - maximum
requirements of each section are intended to provide MCCB - molded case circuit breaker
sufficient information and instruction to the Contractor min - minimum (or minute)
unless additional requirements are stated in the Special MUTCD - Manual on Uniform Traffic Control
Specification. Particular requirements are stated in the Devices
Standard Special Specification, which is to be read in MV - Medium Voltage
conjunction with the sections of this Standard N.C. - Normally Closed (electrical contact)
Specification. In the event of any conflict between this NEC - National Electrical Code (UK)
Standard Specification and the Special Specification, the NEMA - National Electrical Manufacturers'
Special Specification shall govern. Association (USA)
N.O - Normally Open (electrical contact)
1.1.3 Abbreviations, Title and Terms OS - Omani Standards
pav't - pavement
1 The following abbreviations used in the
P.C. - prime cost
Specification and on the Drawings shall have the
PCC - Portland cement concrete
meanings ascribed to them below:
PE - polyethylene
AASHTO - American Association of State Highway PFA - Pulverized fly ash
and Transportation Officials P.I. - plasticity index
ABS - Acrylonitrile-Butadiene-Styrene P.L. - plastic limit
ACI - American Concrete Institute PLMCS - Public Lighting Management and Control
AISC - American Institute of Steel Construction System
AISI - American Iron and Steel Institute PTFE - Polytetrafluoroethylene
ANSI - American National Standards Institute PVC - polyvinyl chloride
API - American Petroleum Institute qty - quantity
ASTM - American Society for Testing and RC - reinforced concrete
Materials RCP - reinforced concrete pipe
AV. - average rdwy - roadway
AWG - American wire gauge ROW - right-of-way
AWS - American Welding Society SBSC - single bituminous seal coat
bit. - bitumen/bituminous SCM - Supplementary cementing material/s
BS - British Standard S.G. - specific gravity
BSSC - bituminous slurry seal coat SI - Système International D'Unités
BST - bituminous surface treatment Sta - Station (location along a survey line)
BS EN - British Standard harmonized with SWG - standard wire gauge (UK)
European Norm/ Standard TBSC - triple bituminous seal coat
CB - circuit breaker uPVC - unplasticized polyvinyl chloride
CBR - California Bearing Ratio VDE - Verband Deutscher Electrotechniker
conc - concrete wgt - weight
CIE - Commission Internationale de l'Eclairage
CISPR 15 - Limits and Methods of Measurement of
1.1.4 Units of Measurement
Radio disturbance characteristics of
Electrical Lighting and Similar Equipment Throughout the documentation units of measurement
DBSC - double bituminous seal coat are referred to by symbols as follows:
DIN - Deutsches Institute Fur Normalizieung nr - number
EN - European Norm/ Standard mm - millimeter/s
Equiv - equivalent cm - centimeter/s
FSS - Federal Standard Specification (USA) m - meter/s
GGBFS - Ground-granulated blast-furnace slag lin.m - linear meter/s
km - kilometer/s

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sq.mm - square millimeter/s 1.2 Project Works
sq.cm - square centimeter/s
sq.m - square meter/s 1.2.1 The Works
ha - hectare/s
cu.m - cubic meter/s 1 The Works comprised by the Project are as shown
gm - gram/s on the Drawings and defined in the Special Specification.
kg - kilogram/s Except where otherwise stated, the Contractor shall
t - metric ton (1,000 kg) construct and complete the whole of the Works and
ml - milliliter/s provide everything necessary for such construction and
ltr - liter/s completion.
Pa - Pascal/s
Mpa - Mega Pascal/s = N/sq.mm 1.2.2 Intent of Contract
N - Newton/s
kN - kilo Newtons 1 The intent of the Contract is to provide for the
construction and completion in every detail, and the
MN - mega Newtons
subsequent maintenance of the Works described. The
A - amperes
mA - milli amperes Contractor shall furnish all labor, materials, tools,
equipment, transportation, supplies and facilities and
V - volt/s
shall carry out all Permanent and Temporary
W - Watt
kW - kilowatt 2 Works and all other items necessary for the proper
kj - kilojoule/s completion of the Works in accordance with all
C - Celsius (Centigrade) requirements of the Contract.
Hz - Hertz (Frequency) 3 Where the Specifications or Drawings describe any
rpm - revolutions per minute portions of the Works in outline only, and not in
km/h - kilometers per hour complete detail, the best current engineering practice
sec - seconds shall prevail and only first quality materials and
min - minute/s (or minimum) workmanship shall be used.
h - hour/s
mS - milli Siemens
1.2.3 Silence of Specifications
dB - decibel/s
dBA - decibels absolute The apparent silence of the Specifications, Drawings or
ppm - parts per million other Contract Documents as to any detail or the
in. - inch/inches (1 in. = 25.4 mm) apparent omission from them of a detailed description
ft - foot/feet (1ft = 0.3048 m) concerning any Works or requirements, shall be
sq.in - square inch/inches regarded as meaning that current best engineering
sq.ft - square foot/feet practice shall apply and shall be to the approval of the
cu.ft - cubic foot/feet Engineer.
lb. - pound/s (weight)
psi - pounds per square inch 1.3 Project Site
gal - gallon/s (U.S.)
gal(Imp) - gallon/s (Imperial) 1.3.1 The Site
mph - miles per hour
HP - horsepower 1 The Site of the Works is as shown on the Drawings
USG - American gage and described in the Special Specification. The
Contractor will be given possession of such parts of the
1.1.5 Standards Site as are required to execute the Works in accordance
with the agreed Program or as are reasonably required
1 Reference to Standards and Codes of Practice shall for him to progress the Works.
be taken as those versions current at the date of issue of
the Tender Documents. 1.3.2 Contractor’s Work Areas
2 Where the Specification states that the
1 The Contractor shall make all necessary
recommendations of a Code of Practice or a Standard
arrangements, including payment if need be, regarding
must be complied with, then the recommendations
any land outside the Site that may be needed as work
become mandatory. Where there are alternative
areas. The Employer will not accept any liability in
recommendations the Contractor may adopt any of them
respect of such land.
unless otherwise instructed by the Engineer.
2 The Contractor shall locate and select sites outside
the right-of-way for the use of his plant and equipment,
and for siting his site offices, workshops, other
accommodation and Temporary Works, or any other

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uses which are essential for execution of the Contract. 1.3.5 Items in the Bill of Quantities
The Contractor shall take the necessary measures for
using these sites and shall be responsible for all i. Soil investigation and report (L.S.)
expenses that may become due in return for such use.
Prior to using any land owned by public or private 1.4 Contractor’s Site Facilities
owners outside the Site, the Contractor shall obtain the
approval of the concerned authorities and the Engineer. 1.4.1 Contractor's Compound and
3 The Contractor, if so required by the Engineer, Buildings
whether before or after completion of the Works, shall
1 The Contractor shall establish a compound for his
remove his construction plant, properly clean and
facilities at a location to be approved by the Engineer. He
remove all debris from the site and shall, wherever
shall provide, furnish and equip as necessary, all
applicable, remedy all damage and pay all money due to
buildings and facilities as required for his own and
land owners in return for using their land.
Subcontractors' use; including but not limited to site
offices and mess rooms with appropriate sanitary
1.3.3 Site Survey and Investigation facilities; workshops, sheds and stores; site toilets,
1 Before commencing work on Site, the Contractor latrines and the like.
shall carry out a topographical survey of the Site, in
conjunction with, or as directed by the Engineer. This 1.4.2 Measurement and Basis of Payment
survey shall include such parts of the Site as the
1 The Contractor shall be paid a two stage sum for
Engineer may direct, to record the Site limits,
the mobilization and demobilization of his facilities equal
dimensions, ground levels, obstructions and other
to the Lump Sum in the Bill of Quantities. 60% of the
features and the survey shall establish base lines and
sum will be paid at the completion of the mobilization
points for future setting out and also record the basis for
and the remaining 40% on issuance of the Certificate of
re-measurement of excavation and earthwork, where
Completion for the Whole of the Works.
applicable. The Contractor shall submit the site survey
drawings to the Engineer for approval. 2 The Contractor shall be paid a monthly sum for
maintaining his facilities. No payment for maintenance
2 The Contractor shall inspect the Site to identify
of the facilities will be made beyond the end of the
obstacles above and below ground such as fences,
Contract period (after approved extensions of Time for
services, walls, paved areas, underground tanks, utilities
Completion have been included).
and pits, and shall record them on the site survey
drawing and photographically if instructed.
3 The Contractor shall carry out sub-surface and
1.4.3 Items in the Bill of Quantities
other site investigations as are necessary to verify any i. Mobilization and demobilization of Contractor’s
information provided to him by the Employer and to facilities (Lump Sum)
ascertain the nature of the ground and facilitate ii. Maintenance of Contractor’s facilities
execution of the Works. It is the Contractor's (type) (nr of units) (nr of months)
responsibility to verify the stability of side slopes in cut
areas by specialized staff. The Contractor, at his own 1.5 Engineer’s Facilities
expense shall execute any required site investigation
prior to cutting in the relevant areas. The proposal for
1.5.1 General
the site investigation program as well the final
recommendation shall be approved by the Engineer. 1 All facilities provided for the Engineer's and/or
Employer's staff shall remain available until three
1.3.4 Measurement and Basis of Payment months beyond the issuance of the Certificate of
Completion or until such earlier time as the Engineer
1 No separate measurement or payment will be may decide.
made, for any part of Sub-section 1.3 except as stated
2 All buildings, equipment and utilities provided by
below. All other work is considered to be subsidiary to
the Contractor shall remain the property of the
other sections and the costs are deemed to be included
Contractor and will be returned to him on completion or
in the prices for other items stated in the Bill of
when no longer required, unless stated otherwise in the
Quantities.
Special Specifications.
2 If the Engineer specifically orders that a sub-surface
soil investigation shall be done by the Contractor,
1.5.2 Site Facilities for the
payment will be made at the rate stated in the Bill of
Quantities for the complete work, including provision of Engineer/Employer:
all equipment, performance of tests and provision of a 1 The Contractor shall provide service and maintain,
report. and remove when instructed, the offices, other
accommodation, services, surveying equipment and

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laboratory facilities for the use of the Engineer and
Employer as described below and in the Special
Specification.
2 Offices shall be of proprietary manufacture, of
insulated and weather tight construction, with lockable
entrances and operable windows, hard-wearing easy-
clean surfaces and robust and secure fittings:
- Incorporate sanitary facilities to the extent
required for the number and gender of
personnel to be accommodated.
- Support on suitable foundations.
3 The Contractor shall provide and maintain all
necessary services for the offices and facilities, including
but not necessarily limited to the following:
- Heating and air-conditioning.
- Electric lighting and power.
- Water supply.
- Potable water supply.
- Drainage system.
- Fire fighting appliances.
- Cleaning facilities and services and general
attendance.
- Telephone.
- Computers
- Camera
- Thermometers
- Colored Photocopiers.
- Fax machines.
4 The Contractor shall provide new furniture and
equipment suitable for the intended user.
5 All office accommodation and facilities, services
and equipment shall be continuously available to the
Engineer in full working order within four weeks of the
start of the mobilization period unless otherwise stated
in the Special Specifications, and before any permanent
construction operations are commenced. However, the
Engineer may permit work to commence before the full
facilities are available if adequate facilities are provided
by the Contractor. If the Contractor fails to provide the
required facilities he shall bear the cost of alternative
arrangements made by the Engineer.
6 Maintenance of the offices shall include supplies of
pencils, pens, drawing paper, other stationery, survey
pegs, brushes, paint and similar consumable materials,
as required by the Engineer.
7 The Contractor shall submit fully detailed proposals
for all facilities to the Engineer and obtain approval prior
to hire or purchase and delivery to the Site.
8 The Contractor shall service and maintain and clean
the Engineer’s offices on a daily basis; provide all
consumables and supplies as and when requested,
including drinking water, gas and stocks for making tea
and coffee beverages.
♦ 1-4 ♦
1.5.3 Computers for the Engineer
1 The Contractor shall provide for the exclusive use
of the Engineer's staff, new PC equipment, original
licenses and peripheral hardware together with latest
versions of all associated Microsoft software (Excel,
Word, PowerPoint and AutoCAD) Primavera and
Antivirus programs with required regular updates and
user licenses for software and accessories, necessary
cabling and workstation desks, all as detailed in the
Special Specification.
2 The Contractor shall service and maintain computer
equipment regularly and provide all associated
consumables, stationery and paper supplies as and
when requested.
1.5.4 Telephones for the Engineer /
Employer
1 The Contractor shall provide and maintain for the
exclusive use of the Engineer's and/or Employer's staff,
appropriate and adequate telephone/fax facilities and
services as detailed in the Special Specification, for the
duration of the project.
2 The Contractor shall pay for all connection, service
and user charges and costs arising in connection with
the provision of telephone/fax facilities for the Engineer,
including the cost of all local calls.
3 The telephone/fax service shall provide a separate
exclusive connection ensuring privacy of conversation
for the Engineer.
1.5.5 Car Port for the Engineer
1 The Contractor shall provide a car port shade structure
adjacent to the Engineer's offices, sufficiently sized and
arranged to accommodate a minimum of 10 vehicles
unless stated otherwise in the Special Specifications.
The Contractor shall provide appropriate hard standing
and adjoining walkways, and submit detailed proposals
to the Engineer and obtain approval prior to fabrication
and erection.
1.5.6 Cameras for the Engineer
1 The Contractor shall provide for the exclusive use
of the Engineer's staff new cameras as detailed in the
Special Specification, each equipped with the following
features:
- Digital camera minimum 8 mega pixels
- Auto focus (Not fixed) lens
- Self wind and rewind
- Built-in flash.
2 The Contractor shall submit a proposal for approval
prior to purchase.
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1.5.7 Thermometers
1 The following shall be provided on Site:
- Maximum and minimum thermometer for
measurement of atmospheric temperature.
- Thermometer/s for measurement of concrete,
asphalt and ground temperature.
1.5.8 Test Equipment
1 The Contractor shall make available to the Engineer
all test equipment required for carrying out tests on
materials, Plant or finished work required by the
Specification.
1.5.9 Inspection Facilities
1 The Contractor shall provide all ladders, access
lighting, facilities, etc. and such other assistance as the
Engineer may require enabling full access to inspect any
part of the works in a safe manner.
1.5.10 Surveying Equipment for Engineer
1 The Contractor shall supply and maintain a
separate set of surveying equipment and accessories in
full working order for the sole use of the Engineer, and
shall replace any equipment and accessories whenever
directed by the Engineer during the progress of the work,
as detailed in the Special Specification.
1.5.11 Laboratory
1 The Contractor shall provide, furnish, equip,
maintain, staff and clear away on completion materials
testing laboratories in approved locations, manned by
suitably qualified personnel as detailed in the Special
Specification, and shall carry out all site testing required
under the Specification or as directed by the Engineer.
2 The Contractor shall provide skilled technicians and
unskilled laborers of the types and numbers stated in the
Special Specifications. Personnel once assigned to the
laboratory shall not be removed except at the direction,
or with the approval, of the Engineer.
3 The laboratory shall be an approved weather tight
air conditioned movable or stationary building or trailer
as required by the Contract and shall be located on Site
as agreed with the Engineer.
4 The Contractor shall provide and maintain the
laboratory equipment, apparatus and consumable
supplies, including stationery and test forms, needed for
execution of all standard tests required by the Contract.
The Contractor shall submit to the Engineer for his
approval within 15 days of the start of mobilization a
complete listing of the equipment, apparatus and
supplies. The list shall include names of the
manufactures, and descriptive literature shall be
attached as necessary or appropriate.
1.5.12 Measurement and Basis of Payment
1 Provision of the Engineer’s office and other,
accommodation, furnished and equipped as specified,
and provision of laboratory fully furnished and
operational as specified, shall each be measured and
paid for at the monthly rate per building stated in the Bill
of Quantities.
2 Maintenance of the Engineer’s office, other
accommodation, equipment and provision of the
required services shall be measured and paid for
monthly during the period which the facilities are
available in full working order.
3 No payment for maintenance of the Engineer’s
office and accommodation will be made for any period
of delay beyond the Time for Completion or extended
Time for Completion if relevant.
4 Maintenance of the site laboratory and mobile site
laboratory shall be measured and paid for monthly and
shall include for chemicals and other consumables. No
payment will be made for any period of delay beyond
the end of the Time for Completion or extended Time for
Completion if relevant.
5 If the Specification does not call for provision of a
site laboratory, no separate payment will be made for
samples and tests on materials, the cost of which will be
deemed to be included in the rates for the relevant items
in the Bill of Quantities.
6 Provision and maintenance of surveying equipment
for the Engineer is measured as a monthly item for the
whole period of the Contract.
7 No separate measurement or payment will be
made, for any other items in this Sub-section, including
computers, telephones, digital camera, thermometers,
test equipment, fax machine and colored photocopier,
inspection facilities and car port, all of which costs are
deemed to be included in the rates for other items stated
in the Bill of Quantities.
1.5.13 Items in the Bill of Quantities
i Provision of Engineer’s office
(type) (nr of units) (nr of months)
ii Maintenance of Engineer’s office
(type) (nr of units) (nr of months)
iii Provision of surveying equipment
(type) (nr of units) (nr of months)
iv Maintenance of surveying equipment (type)
(nr of units) (nr of months)
v Provision of Engineer’s accommodation
(type) (nr of units) (nr of months)
vi Maintenance of Engineer’s accommodation
(type) (nr of units) (nr of months)
vii Provision of laboratory
(type) (nr of months)
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 viii Maintenance of laboratory
(type) (nr of months)
1.6 Control of Site
1.6.1 Keeping Site Clear of Water
1 The Contractor shall take all measures to keep the
Site free from standing, flowing or tidal water, including
temporary drainage, pumping and dewatering if
necessary.
1.6.2 Site Cleaning
1.6.2.1 Site Cleaning During Progress of Works
1 All parts of the Site, and adjacent roads affected by
the Works, shall be maintained in a clean and tidy
condition throughout the Works. All waste and surplus
materials and other rubbish resulting from the Works or
otherwise, shall be cleared away at intervals as directed
by the Engineer.
2 If the Contractor fails to remove any surplus or
waste materials from the Site within 3 days after being
instructed to do so by the Engineer, these materials may
be removed by others at the Contractor's expense.
1.6.2.2 Final Clean Up on Completion
1 The entire Site shall be delivered up on completion
of the Works, in a clean, neat and presentable new
condition, all as specified hereunder and as described in
the General Conditions of Contract.
2 Spoil tips, borrow pits and deposited materials
shall be trimmed and regularized to profiles and levels
as directed. Flow of water courses affected by the tips or
pits shall be maintained without interruption and any
agreement concerning these sites, existing between the
Employer and the persons or authorities concerned,
shall be observed.
3 Temporary markings, coverings and protection
shall be removed unless otherwise instructed by the
Engineer.
1.6.3 Measurement and Basis of Payment
1 No separate measurement or payment will be
made, for any part of Sub-section 1.6, all of which work
is considered to be subsidiary to other sections. The
costs are deemed to be included in the prices for other
items stated in the Bill of Quantities
1.7 Control of Traffic and Access
1.7.1 Maintenance and Protection of
Traffic
1 In order to facilitate movement of traffic safely
through and around the construction area, the
Contractor shall supply, erect and maintain signs,
♦ 1-6 ♦
delineators, signal lights, traffic barricades and other
facilities necessary for safe and efficient directing and
handling of traffic on or around the work site by
diversions. Adequate safety zones and protective
barriers shall be provided around working areas.
2 The Contractor shall draw up his proposals for
protection of traffic based on the provisions described in
the Special Specification and after coordination with and
approval of the Royal Oman Police and other Concerned
Authorities. The Contractor shall submit the proposals
with drawings and programs to the Engineer for his prior
approval.
3 Movement of equipment from the one part of the
Site to another along routes being used by the public
(whether public highway or diversions provided by the
Contractor) shall be in accordance with the Traffic
Regulations. Material falling on the road as a result of
operations shall be removed immediately.
4 The Contractor shall provide flagmen with the sole
duty of directing public traffic through or around the Site.
5 Sign faces for temporary signs shall comply with
the Highway Design Standards.
1.7.2 Maintenance of One-Way Traffic
1 Whenever it becomes necessary to operate one-way
traffic along a section of road the Contractor shall
provide a single-lane of not less than 3.5m wide and
keep it permanently open for traffic. The length of any
single-lane working shall not exceed 500m. If
construction is going on at more than one adjacent
section, the Contractor shall organize the work in a way
that results in the minimum amount of obstruction and
delay to traffic. No two single lane working sections shall
be closer than 1km.
1.7.3 Temporary Structures
Temporary traffic bearing structures shall be capable of
carrying the same live loads as permanent structures.
1.7.4 Haul Routes for Heavy Vehicles
1 The Contractor shall prepare proposals for routes
to be used by heavy vehicles particularly for hauling fill
materials. Routes shall where possible, avoid existing
roads and built-up areas. Signs shall be provided and
maintained to direct construction traffic to and from haul
routes. Details of haul routes and signage shall be
submitted to the Engineer for approval within a period
not exceeding one month prior to the commencement of
work in the relevant area and the signs shall be erected
prior to actual commencement of the work.
2 Haul routes shall operate using one-way or two-
way traffic systems as required by the Engineer. If at
any time the Engineer considers that any section of the
route needs repair work, the Engineer may withdraw his
approval until the Contractor has executed the necessary
repairs to the Engineer's satisfaction.
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3 If and where it is necessary for Contractor's plant or
vehicles to cross public highways and where required by
the Engineer, all such crossings shall be equipped with
manually controlled traffic lights. During extended
periods when the Contractor's plant is not using the
crossing, the traffic signals shall be switched off and the
advance warning signs obscured.
4 Stationary vehicles, equipment, huts, stockpiles of
materials, etc., shall be kept well clear of crossing points
so that persons using the highway and the haul road
shall have adequate sight distance at all times.
1.7.5 Measurement and Basis of Payment
1 Maintenance and protection of traffic is measured
as a monthly item which is deemed to cover for all costs
of this Sub-section 1.7 and to be full compensation for all
labor, materials and equipment and any other costs,
including laying and removal of road material, unless
stated otherwise.
2 Where diversions are required by the Engineer (or
by the Royal Oman Police through the Engineer) to be
surfaced with bituminous materials, the bituminous
surfacing, the sub-base shall be paid per cubic meters
(cu.m), and the prime coat will be paid by square meter
applied (sq.m).
1.7.6 Items in the Bill of Quantities
i. Maintenance and protection
of traffic (months)
ii. Supply and compacting of
sub-base on diversions where
ordered by the Engineer (cu.m).
iii. Supply and compacting of
bituminous base course on
diversions where ordered by
the Engineer (cu.m).
iv. Prime coat (rate of application) (sq.m)
1.8 Control of Works
1.8.1 Setting out of Works
1 The Contractor shall, prior to any setting out,
submit a planned method of operations for setting out
the Works to the Engineer for his approval. The plan
shall include the accuracy, positions of the various types
of stakes, method of marking stakes, and methods to be
used for protecting stakes, etc. No survey work shall
proceed without to the Engineer's approval of the
Contractor's plan.
2 The Contractor shall give written notice to the
Engineer at least 24 hours before he intends to survey
and set out any portion of the Works. Such notice shall
include the time, location and type of work to be set out.
3 The Contractor shall set out the Works, inform the
Engineer when setting out is complete and obtain
Engineer's approval before proceeding with construction.
If, in the opinion of the Engineer, modification of the
lines or grade is required, before or after survey, the
Engineer will issue detailed instructions to the
Contractor who shall revise the setting out accordingly.
4 Setting out utility works shall be as shown on the
Drawings or as instructed on Site. Stake-out shall be
revised if, in the opinion of the Engineer, modifications
of line or grade are required.
5 The Contractor shall be responsible for preserving
all existing stakes, marks and monuments and if any
construction stakes or marks are destroyed or disturbed,
the Contractor shall replace them at his own expense.
6 The Contractor shall record details of all grid lines,
existing ground levels, setting-out stations, bench marks
and profiles on the site setting-out drawing. This
drawing shall be retained on the Site throughout the
duration of the Contract and handed over to the
Engineer upon completion of the Works.
7 All dimensions and levels on the Drawings and the
Site, shall be checked particularly the correlation
between components and the work in place. Materials
and components shall not be ordered, or work carried
out, until discrepancies have been resolved with the
Engineer.
1.8.2 Surveying Equipment and
Accessories
1 The Contractor shall provide sufficient and suitable
surveying instruments and other equipment and
accessories for his own use in setting out and leveling of
the Works, and also to enable the Engineer to check the
setting out.
2 The accuracy of survey equipment and accessories
may be verified at any time by the Engineer and any
unsatisfactory equipments/instruments shall be
promptly calibrated or removed and replaced by the
Contractor at its own expense.
1.8.3 Existing Underground Services and
Obstructions
1.8.3.1 Notices to Concerned Authorities
1 Before any clearing and excavation is started, the
Contractor shall issue suitable written notice of his
intentions and work programs to all relevant authorities
and public bodies and in return shall obtain a permit of
no-objection. The respondents shall be requested to
indicate on the working drawings provided by the
Contractor the position of any underground services in
which they have an interest.
1.8.3.2 Categories of Obstructions
Obstructions shall be classified as follows:
- Existing private and public owned utilities, above
and below ground, which are required to be
protected, adjusted, relocated or removed.
♦ 1-7 ♦
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- Obstacles, above and below ground (other than
utilities), which are required to be taken down,
dismantled, demolished or excavated, relocated
and removed, as appropriate.
1.8.3.3 Existing Utilities
1 Utilities shall include, but are not be limited to,
existing water lines, gas lines, telephone lines, falaj, fiber
optics, wire lines, service connections, water and gas
and oil meters and valve boxes, light poles and masts,
pylons, cableways, signals, and all utility appurtenances
within the limits of the proposed construction.
2 The costs of all work concerning verification and
identification of existing utilities, including excavating
any trial pits, detection means, mapping detailing of
drawings and co-ordination with respective authorities
shall be fully borne by the Contractor
3 Utility diversions may be specified or directed by
the Engineer to be carried out by the Contractor, or
alternatively the Employer may make arrangements for
such works to be executed by other parties.
4 The Contractor shall:
i. Take into account that the diversion work
shall be carried out to the requirements and
approval of the utility authorities and/or
under their supervision, and also, where
required by the utility authorities, specialist
diversion works shall be carried out by
accredited specialist contractors.
ii. Verify and identify the existing utilities by
excavating trial pits and other measures
including detection means and shall liaise
with the relevant authorities and map these
utilities and prepare detailed and accurate
existing utilities drawings, identifying the
utilities that are in service and those that are
dead or abandoned. Submit these existing
utilities drawings, which shall be accurate
and detailed, giving location of utilities in
plan and section, with all pertinent data of the
respective utility, to the Engineer and to the
utility authority.
iii. Work out and develop, in coordination with
the utility authority and the Engineer, the
approved utilities diversion schemes that will
be required to enable the execution of the
work and also maintain continued operation
of utilities services in the area for the users.
iv. Provide superintendence for the execution of
the utility diversions whether they are carried
out by the Contractor directly or by other
parties employed by the contractor.
v. Provide accurate As-Built Drawings of all
permanent utility diversions that are
executed under the Contract.
5 The Contractor shall take into account, in his
Program of Work, the time effort involved in the
♦ 1-8 ♦
execution of work pertaining to all utility adjustments,
relocations and removals. The Contractor shall schedule
construction activities so as to avoid or minimize any
potential delays, inconvenience or damage to the Works
that may result from utility interference or the operations
of adjustment, relocations and removals.
6 The Contractor shall be responsible for safeguarding
and protecting all utilities and appurtenances
encountered during the Works. The Contractor shall be
responsible for the costs of making good any damage
arising out of its own negligence.
1.8.4 Measurement and Basis of Payment
1 No separate measurement or payment will be made,
for any part of Sub-section 1.8, which work is considered
to be subsidiary to other sections. The costs are deemed
to be included in the prices for other items stated in the
Bill of Quantities.
1.9 General and Contractual
Obligations
1.9.1 Health, Safety and Environmental
Program
1 In addition to the requirements of the provisions of
the General Conditions of Contract and other contract
requirements, the Contractor shall provide the Engineer
the necessary safety personal protective equipment
(PPE) in compliance with international standards
including but not limited to safety shoes, reflective vests,
helmets, and safety harnesses, etc…, and shall submit
for the Engineer's approval, within 15 days after the
effective date of the notice to proceed for the Works, a
proposed Safety Program covering the matters
described below:
1.9.1.1 Health, Safety and Environmental Plan
1 The Health, Safety and Environmental Plan shall
contain but not be limited to the following:
i. Safety Policy and Strategy.
ii. Statutory and Contractual Framework for
Safety.
iii. Management Safety Responsibilities.
iv. Safety Training and awareness.
v. Safety Reviews.
vi. Safety Method Statements.
vii. Reporting and Investigation.
viii. Contingency Arrangements.
ix. Safety Inspections and Audits.
x. Accident Procedures.
xi. Site cleanliness and removal of rubbish.
xii. Labor messing facilities.
xiii. Monthly Report.
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 xiv. Compliance with current applicable national
and local environmental legislation and
contractual environmental obligations.
2 The Contractor shall take into account that the
works under this Contract may be undertaken
simultaneously with other contracts. The Contractor is to
coordinate safety procedures with the Engineer and
Safety Representatives from other contractors to
implement and maintain a common safety strategy.
3 If in the opinion of the Engineer there is an
infringement or breach in the approved Health and
Safety Plan, the Engineer reserves the right to instruct
the Contractor to undertake immediate corrective action
without any liability for any additional costs or time
implication incurred by the Contractor in undertaking the
corrective action.
4 Upon the Engineer's approval of the Safety
Program the Contractor shall, for the full term of the
Contract, operate the Safety Program, maintain accurate
records of safety activities and accident, and submit
safety and accident reports to the Engineer on the
approved forms.
1.9.1.2 Health, Safety and Environmental
Representatives:
1 The Contractor shall include within the Health,
Safety and Environmental Plan the name of the
company’s qualified Safety Officer. He shall also submit
the name and qualification of a Health, Safety and
Environment representative on site, responsible for the
implementation of the Health, Safety and Environmental
Plan on site. This site representative shall remain on site
during operational working hours and shall coordinate
with the safety representatives of other package
Contractors.
2 Appointment of the site Health, Safety and
Environment Manager will be subject to the Engineer’s
approval.
1.9.2 Use of Explosives
1.9.2.1 Control Measures
1 The Contractor shall not use explosives without the
express permission from the Engineer and controlling
authority. The Contractor shall abide by all rules and
regulations of the concerned authorities regarding
purchasing, transportation, storing, handling and using
the explosive materials.
2 Explosives and detonators shall be stored in special
buildings as approved by the concerned authorities.
These secured buildings shall be located and clearly
marked in English and Arabic "DANGER - EXPLOSIVES"
as approved by the Concerned Authorities. Explosives
and detonators shall be stored in separate buildings.
3 All possible precautions shall be taken against
accidental fire or explosion, and to ensure that the
explosives and detonators are kept in proper and safe
condition.
4 Explosives and detonators shall always be
transported in separate special vehicles and kept apart
until the last possible moment. Metallic tools shall not
be used to open boxes of explosives.
1.9.2.2 Blasting Procedures
1 Ensure that blasting is only carried out by
experienced personnel. Priming, charging, stemming
and shot firing shall be carried out with greatest regard
for safety and in strict accordance with the rules and
regulations of the concerned authorities. Adequate
warning of blasting shall always be given and all
persons confirmed as clear from the area before blasting
takes place.
2 Ensure that police and other concerned authorities
are kept fully informed of the blasting program so that
they may be present when blasting takes place if they so
require.
3 Ensure that explosive charges are not excessive,
charged boreholes are properly protected, and proper
precautions are taken for the safety of persons and
property.
4 The Contractor shall prepare a survey report for the
surroundings evident with photos for status before and
after blasting.
1.9.2.3 Explosives Inventory
1 The Contractor shall maintain an up-to-date
inventory of all explosives and explosive devices and
shall submit a monthly report to the Engineer, detailing
the use of all explosives by date and location.
1.9.3 Fire Precautions
1 The Contractor shall take all necessary measures to
prevent personal injury or death or damage to the Works
or other property from fire. Fire fighting arrangements
shall be made as required by the concerned authorities.
2 Adequate and fully operational firefighting
equipment shall be furnished and maintained by the
Contractor in all vulnerable areas and as instructed by
the Engineer. Workmen shall be trained in the operation
of such equipment and provision of fire fighting facilities
3 Adequate water for firefighting shall be available
and outlets located so as to be readily accessible.
4 All equipment shall be regularly tested and
properly maintained.
1.9.4 Measurement and Basis of Payment
1 No separate measurement or payment will be
made, for any part of Sub-section 1.9, which work is
considered to be subsidiary to other sections. The costs
are deemed to be included in the prices for other items
stated in the Bill of Quantities.
♦ 1-9 ♦
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1.10 Management Procedures
1.10.1 Commencement, Program and
Progress
1 Commencement: After receipt of the Order to
Commence, the Contractor shall inform the Engineer's
Representative, at least 7 days in advance, of the
proposed date for commencing work on Site.
2 Co-ordination: The Contractor shall co-ordinate the
construction activities to assure efficient and orderly
installation of each part of the Works. The Contractor
shall co-ordinate construction operations included under
differing sections of the Specifications that are
dependent upon each other for proper execution.
i. Where installation of one part of the work is
dependent on the installation of other
components, either before or after its own
installation, schedule construction activities
in the sequence required to obtain the best
results.
ii. Where availability of space is limited or
restricted by access or security, co-ordinate
installation of the different components to
assure maximum accessibility at desired
times for required maintenance service and
repair.
iii. Make adequate provisions to accommodate
items scheduled for later installation.
3 Program: Unless stated in the Special Specification
that the Contractor may submit a program in bar chart
form only, the Contractor shall provide for the Engineer's
review in accordance with Conditions of Contract, a
computer-based program in critical path network (CPN)
form, showing at least the following information:
i. Contract milestones (Engineer's Notice to
Commence, Commencement Date, date for
completion of Sections of the Works, date for
completion of the whole of the Works, etc.)
ii. Duration of each construction activity in
working days
iii. Earliest/latest start and completion dates for
each construction activity
iv. Free float time for each activity
v. Total float time for each activity
vi. Cost of each activity as Contract rates
vii. Duration and earliest/latest dates for
procurement of materials and plant
viii. Duration and earliest/latest dates for activities
to be performed by Subcontractors
ix. Number of working days per week
x. Number of working shifts per day for each
construction activity
♦ 1-10 ♦
xi. Activities for Temporary Works to be
supplied and constructed and the dates for
supply, construction and removal
xii. Dates for submission by the Contractor of
shop drawings/working drawings, samples
and the like and dates for approval by the
Engineer, in accordance with Conditions of
Contract.
xiii. Dates for submission of the cross-sections.
xiv. Dates and times for work to be performed by
other Contractors or for materials and plant
to be supplied by the Employer
xv. Duration and earliest/latest dates for testing
and commissioning plant and engineering
installations.
xvi. Bar chart showing earliest dates and total
float of activities.
4 Guidance: The Contractor shall abide by the
following:
i. The Engineer will guide the Contractor in the
determination of the level of detail to
included in the CPN
ii. Construction activities will not be scheduled
to exceed twenty-five (25) consecutive
working days without the approval of the
Engineer
iii. One day will be the smallest time unit used
5 Hardware: The computer hardware shall be PC
compatible.
6 Computer Software: Project management software
shall be of the professional high-end type (i.e.
"Primavera" project management software latest version
or of similar capabilities).
7 Resource Schedules: The computer program used
for preparing the program shall also be used for
preparation of resource schedules to be submitted to the
Engineer with the program. The resource schedules
shall show at least the following information:
i. Quantity of materials to be used for each
activity
ii. Numbers and classes of workmen to be
employed on the Site for each activity
iii. Numbers and classes of equipment to be
used for each activity
iv. Histogram for workmen by class and overall
classes
v. Histogram for equipment by class and overall
classes.
8 Cash Flow Estimate: The computer program used
for preparing the program shall also be used to prepare
the cash flow estimate to be submitted by the Contractor.
9 Monitoring: The Contractor shall monitor progress
of the Works and the supply of resources and cash flow
compared with the program, schedules and estimate,
update the program with actual progress data monthly
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and shall revise the program, schedules and estimate as
required by Conditions of Contract. Copies of revised
program etc. and notices of actual and forecast delays
and shortfalls shall be promptly given to the Engineer.
10 Computer Program: The Contractor shall provide
the Engineer with a copy of the computer diskette of the
target program, updated and new target program,
schedules and estimates.
1.10.2 Records and Measurements
1 Labor Record: The Contractor shall provide each
week a record showing the number and description of
workmen employed each day on the Works including
those employed by Subcontractors.
2 Materials and Plant Record: The Contractor shall
provide each week a record showing the quantity and
description of all materials and plant delivered to the
Site complete with copies of delivery notes.
3 Equipment Record: The Contractor shall provide
each week a record showing the number, type and
capacity of all Contractor's Equipment, excluding hand
tools, daily employed on the Works.
4 Daily Work Record: The Contractor shall provide
each day a record showing activities performed and
locations in which work has been carried out and any
other matter requested by the Engineer's Representative.
5 Monthly Report: The Contractor shall provide
monthly reports which summarize the daily and weekly
reports and deliver to the Engineer's Representative not
later than one week following the end of each month.
6 Wages Books and Time Sheets: The Contractor
shall keep accurate and proper wage books and time
sheets showing wages paid to and time worked by
workmen and, when required, produce such wage books
and time sheets for inspection by the Engineer's
Representative. Separate records should be kept of
Omani and expatriate staff.
7 Climatic Conditions: The Contractor shall measure
and keep an accurate daily record of and submit to the
Engineer's Representative at the end of each week:
i. Air temperatures: maximum and minimum
ii. Humidity
iii. Rainfall: total in mm and hours.
1.10.3 Project Administration
1 Engineer’s Site Meetings: The Engineer's
Representative will hold site meetings once a month or
more frequently if he deems necessary for the efficient
management of the Works and he will distribute minutes.
The Contractor shall attend all such meetings and secure
the attendance of Subcontractors and others if requested
by the Engineer's Representative.
2 Contractor’s Site Meetings: The Contractor shall hold
such meetings as are necessary for co-ordination of
work and Subcontractors and review of progress.
3 Co-ordination of Trades and Subcontractors: The
Contractor shall co-ordinate the work of all trades and
Subcontractors so as to avoid delay and disruption or
abortive work. The Contractor shall provide all drawings,
dimensions and other information required for the
proper execution of subcontract works and of associated
builder's work and accept responsibility for the accuracy
and fitness of subcontract works.
4 Quality Control: The Contractor shall prepare and
submit for approval by the Engineer a proposal for the
quality control management of the project. This proposal
shall incorporate the requirements set out in B.S.5750 or
its equivalent and shall be incorporated into the
Procedures Manual and will form an integral part of the
Contractor’s management procedures for the project.
This proposal shall include, but not be restricted to:
i. Provision and maintenance of a quality
control program throughout the project,
ii. Inspection and testing of products, both on
and off Site, by independent professional
inspection and testing companies,
iii. Provision of inspection and testing
equipment,
iv. Verification of affidavits and certificates that
selected material meets the specified
standards,
v. Maintenance of quality control
documentation in accordance with the
various procedures identified in these
documents.
5 Procedures Manual: The Contractor shall prepare and
agree with the Engineer a Procedures Manual for the
administration of the Project.
1.10.4 Progress Photographs/ Videos
1 The Contractor shall submit each month progress
photographs of at least five different subjects taken from
approved locations agreed by the Engineer. A minimum
of twenty photographs shall be taken each month and
five (5) colored gloss prints of each provided to the
Engineer.
2 Format: 200 x 250-mm smooth-surface color prints
on single-weight commercial-grade stock, enclosed
back- to-back in clear plastic sleeves that are punched for
standard ring binding.
3 Identification: On back of each print, provide an
applied label or rubber-stamped impression with the
following information:
i. Name of Project.
ii. Name of Employer.
iii. Name of Engineer.
iv. Name of Contractor.
v. Date photograph was taken.
vi. Description of vantage point, indicating
location, direction (by compass point), and
♦ 1-11 ♦
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 elevation or area of construction,
applicable.
4 Digital Images: Submit a complete set of
corresponding digital image electronic files with each
submittal of prints. Identify electronic media with date
photographs were taken.
Digital image files shall be for the Engineer's and
Employer's free and unrestricted use.
5 The Contractor shall, if requested by the Engineer,
submit progress videos as required.
1.10.5 Measurement and Basis of Payment
1 No separate measurement or payment will be
made, for any part of Sub-section 1.10 except for the
progress photographs and videos. All other activities
and submittals are considered to be subsidiary to other
sections and the costs are deemed to be included in the
unit rates for other items stated in the Bill of Quantities.
2 Progress Photographs will be measured and paid
as an item at each month of the construction period at
the unit rate in the Bill of Quantities
3 Videos will be measured and paid as an item at
each month of the construction period at the rate in the
Bill of Quantities
1.10.6 Items in the Bill of Quantities
i. Provision of 5 sets of photos (month)
ii. Provision of 2 sets of videos (type) (month)
1.11 Submittals
1.11.1 General
1 Submittals Schedule: Submit list of submittals and
time requirements for scheduled performance of related
construction activities. Submittals shall include: shop/
working drawings, as-built drawings, cross sections,
materials, testing, method statements and any other
required submittal in compliance with the Specifications
and other Contract Documents.
2 Processing Time: Allow enough time for submittal
review, including time for re-submittals, as follows.
Time for review shall commence on the Engineer's
receipt of submittal.
i. Initial Review: Allow a maximum of twenty
one (21) days for initial review of each
submittal of cross sections or as-built
drawings, and seven (7) days for all other
submissions including shop drawings or
working drawings. Allow additional time if
processing must be delayed to permit
coordination with subsequent submittals.
The Engineer will advise the Contractor when
a submittal being processed must be delayed
for coordination.
♦ 1-12 ♦
as ii. Concurrent Review: Where concurrent
review of submittals by sub-consultants, the
Employer, or other parties is required, allow a
maximum of thirty five (35) days for initial
review of each submittal of cross sections or
as-built drawings, and fourteen (14) days for
all other submissions including shop
drawings or working drawings.
iii. If intermediate submittal is necessary,
process it in the same manner as the initial
submittal.
iv. Allow Fourteen (14) days for processing each
re-submittal.
3 Identification: Place a permanent label or title block
on each submittal for identification.
i. Indicate name of firm or entity that prepared
each submittal on label or title block.
ii. Provide a space approximately 100 x 125 mm
on label or beside title block to record the
Contractor's review and approval markings
and action taken by the Engineer.
iii. Include the following information on label for
processing and recording action taken:
a. Contract name.
b. The Employer's name.
c. Date.
d. Name and address of the Engineer.
e. Name and address of the Contractor.
f. Name and address of subcontractor.
g. Name and address of supplier.
h. Name and address of manufacturer.
i. Unique identifier, including revision
number.
j. Number and title of appropriate
Specification Section.
k. Drawing number and detail references,
as appropriate.
l. Other necessary identification.
4 Deviations: Highlight, encircle, or otherwise
indicate and identify on submittals, deviations from the
Contract Documents.
5 Additional Copies: Unless additional copies are
required for final submittal, and unless the Engineer
observes non-compliance with provisions of the Contract
Documents, initial submittal may serve as final submittal.
i. For submittals requiring concurrent review,
submit one extra copy in addition to specified
number of copies to the Engineer.
6 Transmittal: Package each submittal individually
and appropriately for transmittal and handling. Transmit
each submittal using a transmittal form attached to a
cover letter. The Engineer will discard, without review,
submittals received from sources other than the
Contractor.
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 i. Cover Letter: On attached, numbered, b. Final Submittal: Submit four (4) copies,
separate sheet(s), prepared on the unless otherwise indicated. Submit
Contractor's letterhead, record relevant additional copies where copies are
information, requests for data, revisions required for operation and maintenance
other than those requested by the Engineer manuals. The Engineer will retain two
on previous submittals, and deviations from copies; remainder will be returned.
requirements of the Contract Documents, Mark up and retain one returned copy
including minor variations and limitations. as a Record (As-Built) Document.
Include the same label information as the 2 Shop and Work Drawings: Produce newly prepared,
related submittal. contract-specific, information, drawn accurately to scale.
a. Include the Contractor's certification Shop drawings should not be based on reproductions of
stating that information submitted the Contract Documents or standard printed data.
complies with requirements of the i. Preparation: Include the following
Contract Documents. information, as applicable:
ii. Transmittal Form: Use a form acceptable to a. Dimensions; in SI units unless
and approved by the Engineer. Provide otherwise indicated or directed.
locations on form for the following
b. Roughing-in and setting diagrams.
information:
c. Schedules.
a. Contract name.
d. Compliance with specified standards.
b. The Employer's name.
e. Notation of coordination requirements.
c. Date.
f. Notation of dimensions established by
d. Destination (To :).
field measurement.
e. Source (From :).
ii. Sheet Size: Except for templates, patterns,
f. Names of subcontractor, manufacturer, and similar full-size drawings, submit shop
and supplier, as applicable. drawings on sheets at least A4 size, and no
g. Category and type of submittal. larger than A1 size, unless otherwise
h. Submittal purpose and description. approved.

i. Submittal and transmittal distribution iii. Number of Copies: Submit copies of each
record. submittal, as follows:

j. Remarks. a. Initial Submittal: Submit one (1)

k. Signature of transmitter.
I. Distribution: Furnish copies of final
submittals to manufacturers,
subcontractors, suppliers, fabricators,
and installers, authorities having
jurisdiction, and others as necessary for
performance of construction activities.
Show distribution on transmittal forms.
7 Use for Construction: Permit only final submittals
with appropriate approved stamp, or other mark
indicating action taken by the Engineer, to be used in
connection with construction.
1.11.2 Action Submittals
1 General: Prepare and submit action submittals
required by individual Specification Sections.
i. Number of Copies: Submit copies of each
submittal, as follows, unless otherwise
indicated:
a. Initial Submittal: Submit a preliminary
single copy of each submittal where
selection of particular characteristics is
required. The Engineer will return
submittal with options selected.
correctable, translucent, reproducible
print and one (1) blue- or black-line
print. The Engineer will return the
reproducible print.
b. Final Submittal: Submit three (3) blue-
or black-line prints, with one (1)
separate electronic file, format of which
will be advised by the Engineer, unless
otherwise indicated. Submit additional
prints where prints are required for
operation and maintenance manuals.
The Engineer will retain two (2) prints;
remainder will be returned. Mark up
and retain one returned print as a
Record (As-Built) Drawing with two (2)
electronic files on CD-Rom.
3 Subcontract List: Prepare and submit a list
identifying subcontractor individuals or firms proposed
for principal portions of the Works, including those who
are to fabricate products or equipment to a special
design. Include the following information in tabular
form:
i. Name, address, and telephone number of
entity performing subcontract.
ii. Number and title of related Specification
Section(s) covered by subcontract.

♦ 1-13 ♦
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 iii. Drawing number and detail references, as
appropriate, covered by subcontract.
1.11.3 Informational Submittals
1 General: Prepare and submit informational
submittals required by other Specification Sections.
i. Number of Copies: Submit two copies of each
submittal, unless otherwise indicated. The
Engineer will not return copies.
ii. Certificates and Certifications: Provide a
notarized statement that includes signature of
the Contractor, testing agency, or design
professional responsible for preparing
certification. Certificates and certifications
shall be signed by an officer or other
individual authorized to sign documents on
behalf of the company.
2 Qualification Data: Prepare written information that
demonstrates capabilities and experience of firm or
person. Include lists of completed projects with project
names and addresses, names and addresses of
engineers and employers, and other information
specified.
3 Material Certificates: Prepare written statements
on manufacturer's letterhead certifying that material
complies with requirements.
4 Material Test Reports: Prepare reports written by a
qualified testing agency, on testing agency's standard
form, indicating and interpreting test results of material
for compliance with requirements.
5 Preconstruction Test Reports: Prepare reports
written by a qualified testing agency, on testing agency's
standard form, indicating and interpreting results of tests
performed before installation of product, for compliance
with performance requirements.
6 Compatibility Test Reports: Prepare reports written
by a qualified testing agency, on testing agency's
standard form, indicating and interpreting results of
compatibility tests performed before installation of
product. Include written recommendations for primers
and substrate preparation needed for adhesion.
7 Field Test Reports: Prepare reports written by a
qualified testing agency, on testing agency's standard
form, indicating and interpreting results of field tests
performed either during installation of product or after
product is installed in its final location, for compliance
with requirements.
8 Product Test Reports: Prepare written reports
indicating current product produced by manufacturer
complies with requirements. Base reports on evaluation
of tests performed by manufacturer and witnessed by a
qualified testing agency, or on comprehensive tests
performed by a qualified testing agency.
♦ 1-14 ♦
1.11.4 Contractor's Review and Approval
1 Review each submittal and check for compliance
with the Contract Documents. Note corrections and field
dimensions. Mark with approval stamp before
submitting to the Engineer.
2 Approval Stamp: Stamp each submittal with a
uniform, approval stamp. Include Contract name and
location, submittal number, Specification Section title
and number, name of reviewer, date of the Contractor's
approval, and statement certifying that submittal has
been reviewed, checked, coordinated and approved for
compliance with the Contract Documents.
1.11.5 Engineer's Action
1 General: The Engineer will not review submittals
that do not bear the Contractor's approval stamp and
will return them without action.
2 Engineer's Action: The Engineer's review is
limited only to checking conformance with information
given and the design concept expressed in the Contract
Documents. It is not conducted for the purpose of
determining the accuracy and completeness of details,
dimensions or quantities, nor substantiating integrity or
compatibility, or confirming instructions for installation
or performance. The Engineer's approval does not in
any way relieve the Contractor of responsibility for
compliance with specified provisions and the Contract
Document requirements.
3 Action Submittals: The Engineer will review each
submittal, make marks to indicate corrections or
modifications required, and return it to the Contractor.
The Engineer will stamp each submittal with an action
stamp and will mark stamp appropriately to indicate
action taken, as follows:
i. Final Unrestricted Release: Where the
submittal is marked "APPROVED", the work
covered by the submittal may proceed
provided it complies with the Contract
Documents. Final acceptance of the work will
depend on that compliance.
ii. Final-but-Restricted Release: Where the
submittal is marked "APPROVED AS NOTED",
the work covered by the submittal may
proceed provided it complies with both the
Engineer's notations and corrections on the
submittal and the Contract Documents. Final
acceptance of the work will depend on that
compliance.
iii. Returned for Re-submittal: Where the
submittal is marked "NOT APPROVED, REVISE
AND RESUBMIT", do not proceed with the
work covered by the submittal, including
purchase, fabrication, delivery, or other
activity for the product submitted. Revise or
prepare a new submittal according to the
Engineer's notations and corrections.
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 iv. Rejected: Where the submittal is marked
"NOT APPROVED, RESUBMIT" or "REJECTED",
do not proceed with the work covered by the
submittal. Prepare a new submittal for a
product that complies with the Contract
Documents.
4 Submittals not required by the Contract Documents
will not be reviewed and may be discarded.
1.11.6 Record (As-Built) Drawings
1 Within 1 month of completion of each section of
the Works, the Contractor shall submit 3 copies of the
relevant drawings showing all details of permanent
works as constructed. The Engineer will approve these
as ‘As-Built’ drawings or instruct corrections as
appropriate.
2 Record Drawings: Submit copies of record
drawings as follows:
i. Initial Submittal: Submit two sets of plots
from record CAD drawing files and the
original marked-up record prints. The
Engineer will initial and date one set of plots
and mark whether general scope of changes,
additional information recorded, and quality
of drafting are acceptable. The Engineer will
return one set of plots and record prints
together with review comments, for
completing, printing, binding, and final
submittal.
ii. Final Submittal: After incorporating the
Engineer's initial submittal review comments,
submit original marked-up record prints set.
3 Submit sets of as-built drawings as follows:
One (1) set electronic format: (in CD-ROM)
One (1) set of PDF format: (in CD-ROM)
One (1) bound sets of prints (A1 Size)
One (1) set of any other document/report about the
project, Test results and any other
information/documents.
4 Record Specifications: Submit two (2) copies of
record specifications, including addenda and contract
modifications.
5 Miscellaneous Records: Submit two (2) sets of
original miscellaneous records.
1.11.7 Measurement and Basis of Payment
1 No separate measurement or payment will be
made, for any part of Sub-section 1.11 except for As-
Built Drawings. All other submittals are considered to be
subsidiary to other sections and the costs are deemed to
be included in the rates for other items stated in the Bill
of Quantities
2 The As-Built Drawings shall be measured and paid
as Lump Sum (L.S.) in the Bill of Quantities.
1.11.8 Items in the Bill of Quantities
i. Provide as-built drawings, record
drawings and record specifications and
miscellaneous records as specified (Lump Sum)
1.12 Control of Materials and
Standards for Sampling and
Testing
1.12.1 Storage of Materials
1 Materials shall be so stored as to assure the
preservation of their quality and suitability for the Works.
Stored materials, approved before storage, may again be
inspected prior to their use in the Works. Stored
materials shall be located so as to facilitate their prompt
inspection.
2 Where materials are stockpiled on Government or
private property, such sites shall be abandoned
immediately upon consumption of all stockpiled
materials and the natural surface shall be restored as far
as practicable to the original condition by the Contractor
and to the satisfaction of the Engineer.
1.12.2 Handling Materials
1 All materials shall be handled in such manner as to
preserve their quality and suitability for the Works.
Aggregates shall be transported to the Works in vehicles
which are constructed to prevent loss or undue
segregation of materials after loading and unloading.
1.12.3 Materials Supplied by Employer
1 The Contractor shall be responsible for all materials
furnished by the Employer and shall make good any
shortages or deficiencies, from any cause whatsoever, or
any damage which may occur, after delivery of such
materials.
1.12.4 Local Material Sources
1 When material sources are not designated on the
Drawings, or in other documents, the Contractor shall be
responsible for locating and providing suitable materials
from approved sources.
2 Any information provided in the tender documents
about sources of local materials is considered as a
guideline only and does not relieve the Contractor of his
responsibility in respect of investigation and supply of
suitable materials as specified.
3 Materials, regardless of their source, shall not be
incorporated in the Works until approved by the
Engineer.
♦ 1-15 ♦
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1.12.5 Sources of Supply and Quality
Requirements
1 All materials, including manufactured articles, and
machinery incorporated in the Works, shall meet all
specified quality requirements and be approved by the
Engineer. Priority will be given to locally produced
Omani material, where applicable.
2 The Contractor shall, before placing any purchase
order for any materials intended for incorporation in the
Works, submit for approval a complete description of all
such materials, names of the firms from whom he
proposes to purchase them and copies of all test reports
verifying conformity with the provisions of the
Specifications. Materials shall not be ordered without
the approval of the Engineer. When directed by the
Engineer or otherwise specified, the Contractor shall
submit suitable samples for approval.
3 The Engineer shall have the right to retest all
materials which have been tested and accepted at the
source of supply after delivery to the Site and prior to
incorporation into the Works and to reject any such
materials which are clearly defective or, when retested,
do not conform with the Specifications.
1.12.6 Certificates of Guarantee and
Production Plant Inspections
1 All shipments of materials shall be accompanied by
a Manufacturer's Certificate of Guarantee or Test
Certificate from an approved independent qualified
laboratory approved by the Engineer. All certified
materials delivered to the Site shall undergo additional
laboratory testing if required by the Engineer.
2 Issuance of an invalid or erroneous Certificate of
Guarantee shall be just cause for rejection of the
materials without further testing.
1.12.7 Sampling and Testing Procedures
1.12.7.1 Sampling
1 Samples of all materials shall be submitted to the
Engineer for inspection, testing and acceptance before
incorporation in the Works. All materials being used will
be subject to inspection, testing, or rejection at any time
prior to such incorporation.
2 Where untested and unaccepted materials have
been used without approval of the Engineer, such use
shall be at the Contractor's risk and the work may be
rejected by the Engineer.
1.12.7.2 Source Tests
1 All source samples shall be taken by the Contractor
in the presence of the Engineer, using approved
sampling procedures. All source approval tests shall be
performed under the supervision of the Engineer or,
when so specified, by an independent laboratory
♦ 1-16 ♦
approved by the Engineer and engaged by the
Contractor.
2 After approval of any source of materials, the
Contractor shall produce from such source only to the
extent that materials produced are of substantially the
same quality as the approved samples.
3 The Engineer will periodically order retesting of
previously approved sources to verify that they continue
to conform to the Specifications and may order retesting
at the same or at a different laboratory from the one
performing the original source approval tests. If
retesting indicates that a previously approved source no
longer conforms with the Specifications, the Contractor
shall forthwith cease production from such source.
1.12.7.3 Quality Control Tests
1 Quality control tests for materials shall be
performed by the Contractor prior to submitting any
materials to the Engineer for approval. The Contractor
shall submit details to the Engineer of his quality control
testing program.
2 The Engineer may declare the Contractor's quality
control testing program unacceptable if frequent
rejections of submitted materials occur when subjected
to the project control tests.
1.12.7.4 Control Tests
1 All control samples shall be taken jointly by the
Engineer and the Contractor. Tests shall be performed
in the site laboratory, or in situ as appropriate, under the
supervision of the Engineer.
2 The Engineer may order retesting of any material if
there has been a significant delay in the construction
operations or if he determines that the material has
deteriorated since its original acceptance. Material
which does not conform to the Specifications will be
rejected and shall be removed from the Works and
replaced or corrected by the Contractor. The Engineer
may order additional testing to ascertain the extent of
unacceptable material.
1.12.7.5 Check Tests
1 The Engineer may periodically order check tests to
verify the accuracy of project control testing and
equipment. The Engineer may direct that check tests be
performed by qualified persons other than those
normally responsible for project control testing, or he
may direct that the samples be sent to the Employer's
central laboratory or to an approved independent
laboratory for testing.
2 The Contractor shall provide the Engineer with all
necessary test report forms and expendable materials
required to perform all required tests. Copies of all test
results will be issued to the Contractor.
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1.12.7.6 Precedence of Materials and Testing used items, the manufacturer's brochures, catalogues
Specifications and specifications.

1 All references to methods of testing or
specifications of AASHTO, ASTM and others will be
deemed to refer to the latest methods of testing as
specified in the Contract Documents.
2 Unless otherwise specified, AASHTO methods of
sampling and testing shall be adopted where available.
In the case of absence of an appropriate AASHTO
specification, the ASTM or BS specification shall govern.
1.12.8 Unacceptable Materials
1 All materials not conforming to the requirements of
the Specifications at the time they are used will be
rejected and shall be removed immediately from the Site
unless otherwise instructed by the Engineer.
2 If defect from rejected materials, has been
corrected, such remedied materials, shall not be used
until Engineer’s approval has been given.
1.12.9 Measurement and Basis of Payment
No separate measurement or payment will be made, for
any part of Sub-section 1.12, which work is considered to
be subsidiary to other sections. The cost of the work is
deemed to be included in the rates for other items in the
Bill of Quantities.
1.13 Contractor’s Plant and
Equipment
1.13.1 General
1 Plant and equipment used on the Works shall be of
sufficient size and in such mechanical condition as to
meet the requirements of the Contract Documents and
shall be available for use when required by the Engineer.
The Engineer may order removal and replacement of
unsatisfactory plant or equipment.
2 Wherever plant or equipment of a particular size or
type is specified, the Contractor may request permission
to use an alternative type in place of that specified. In
such cases, the Contractor shall furnish evidence to the
Engineer that the production of the plant or equipment
proposed is at least equal to that of the specified type.
1.13.3 Provision and Use of Plant and
Equipment
1 The Contractor shall furnish all plant and
equipment listed in his schedule and necessary for
construction of the Works. Such plant and equipment
shall be delivered to the Site, inspected, and approved
by the Engineer prior to commencement of the particular
work for which it is intended. Any plant or equipment,
or part thereof, which becomes excessively worn or
defective shall be promptly repaired or replaced, as
required by the Engineer.
2 The Contractor shall not remove from the Site and
shall not use for other projects any approved plant or
equipment without the permission of the Engineer.
1.13.4 Measurement and Basis of Payment
No separate measurement or payment will be made, for
any part of Sub-section 1.13, which work is considered to
be subsidiary to other sections. The cost of the work is
deemed to be included in the unit rates for other items in
the Bill of Quantities.
1.14 Contractor’s Temporary Works
and Services
1.14.1 Temporary Facilities
1.14.1.1 General
1 The Contractor shall provide all Temporary Works
and services and Contractor's Equipment and tools
required for the efficient and safe execution of the Works,
including but not limited to:
i. Temporary roads, hard standings, sleeper
tracks and the like.
ii. Temporary fences, gates and barriers.
iii. Temporary offices, stores, mess rooms,
latrines and compounds.
iv. Scaffold, ladders, hoists, cranes and the like.
v. Temporary screens, chutes, coverings, roofs
and rainwater pipes for protection of the
Works and personnel.

1.13.2 Contractor's Schedule of Plant and vi. Transport and vehicles on and off Site.
Equipment vii. Fixed and movable mechanical plant and
equipment.
1 The Contractor shall submit together with his Tender,
viii. Small tools.
a detailed schedule of the numbers and types of plant
and equipment which he proposes to use on Site to ix. Temporary water and power supplies and
carry out the Works. The schedule shall contain full site lighting.
details for each item, including type, manufacturer, x. Temporary drainage.
model, identification number, year of manufacture, 2 Locations: The Engineer's approval shall be
number of years in use, and, for all new and previously obtained for the intended locations of all spoil heaps,
Temporary Works and services.

♦ 1-17 ♦
copy 249
3 Standards and details: Temporary Works shall be
constructed to recognized standards and codes of
practice so that they are fit for their purpose. Drawings
and details of proposed Temporary Works shall be
provided by the Contractor if requested by the Engineer.
Consent of such arrangements by the Engineer in no
way relieves the Contractor from his sole responsibility
for their sufficiency and safety.
4 Temporary works: Temporary Works and services
shall be maintained, altered and adapted and as
necessary cleared away on completion or when no
longer required.
1.14.1.2 Temporary Site Facilities
1 Roads: Permanent roads, hard standings and
footpaths on the Site may be used provided they are
adequately maintained and thoroughly cleaned and
made good after use and left in unimpaired condition.
2 Trench crossings: Are to be provided for free and
safe passage of vehicles and pedestrians over pipe and
other trenches.
3 Temporary site fence: The Contractor shall provide
suitable and secure temporary site fencing and gates
where necessary or as directed by the Engineer. Design
of the fencing and gates, including location, construction
details, etc. is to be submitted to the Engineer for
approval prior to fabrication and erection.
1.14.2 Scaffolding and False Work
1 The Contractor shall provide scaffolding and false
work to facilitate carrying out construction of the Works
in the required sequence. Scaffolding and false work
shall be properly designed and constructed specifically
for the loads intended. Full details of the proposed
arrangements shall be submitted to the Engineer for his
approval. Such approval, however, shall not relieve the
Contractor of his responsibility with regard to the
adequacy of all scaffolding and false work used in the
Works.
1.14.3 Water Supply
1 The Contractor shall be deemed to have carried out
adequate investigations relating to the availability of
water for the purpose of the Works and to have
consulted and arranged with the appropriate authorities
and taken into consideration all legal aspects.
2 The Contractor shall be responsible for the supply
of sufficient clean, fresh water at all times during
progress of the Works, including making temporary
arrangements for storing and distributing the water on
the Site.
1.14.4 Electricity Supply
1 The Contractor shall make his own arrangements
for the supply of all electrical power and all lighting and
electrical equipment required for execution of the Works,
♦ 1-18 ♦
including supplies for commissioning engineering
services and Plant at required voltages.
2 The Contractor shall make provision for temporary
connections to the public electricity system and pay all
charges and/or provide generators. All temporary
electric supply and distribution shall conform with the
requirements of the concerned authorities.
3 The Contractor shall provide and maintain
adequate efficient lighting for execution of the work and
for safety and security purposes. Without prejudice to
his liability under the General Conditions of Contract, the
Contractor shall, with respect to the supply of electricity
for power or lighting, take all necessary precautions to
ensure the safety of his workmen and others.
1.14.5 Directional and Warning Signs
1 The Contractor shall provide all signs required for
directing traffic and pedestrians around or through the
Site and to provide information on location of facilities
on the Site.
2 The Contractor shall provide warning and
informational signs required by law and good practice
for the safety of all personnel.
1.14.6 Project Sign Board
1 Sign Boards: The Contractor shall provide suitably
sized project sign boards, bearing the names of the
Employer and Engineer together with any corresponding
logos, the name of the project, the name of the
Contractor and such other names and information as the
Engineer may request. The design and style of the sign
boards shall be submitted to the Engineer for approval
prior to fabrication. Sign boards are to be written in
Arabic and English and erected at suitable locations as
directed by the Engineer.
2 Each sign board shall be erected in a prominent,
approved position. Sign boards shall be maintained in
good order at all times and sign boards and supports
shall be dismantled and removed from the site upon
completion of the Works.
1.14.7 Measurement and Basis of Payment
1 No separate measurement or payment will be
made, for any part of Sub-section 1.14 except for project
sign boards as stated below. All other work in this sub-
section is considered to be subsidiary to other sections
and the costs are deemed to be included in the unit rates
for other items stated in the Bill of Quantities.
2 Each project sign board is measured as an item.
The rates shall include for design, fabrication, erection,
relocation if required, maintenance and removal.
copy 249
1.14.8 Items in the Bill of Quantities
i. Provision, erection, relocation,
maintenance and removal
of project signboard (type) (nr).
1.15 Commemorative Plaque and
Opening Ceremony
1.15.1 Commemorative Plaque
The Contractor shall erect a commemorative plaque if
required by, and of the type and design described in, the
Special Specifications. The location shall be as shown on
the Drawings or agreed with the Engineer.
1.15.2 Opening ceremony
At the location of the erected plaque the Contractor shall
make arrangements for the opening ceremony, including
grading the designated area for the ceremony and for
car parking, spreading with suitable gravel, marking the
area with painted stones and colored ribbons and posts,
erecting a temporary pavilion in the national flag colors,
providing armchairs for the presiding authorities and
seats for the invited guests, and providing a microphone
and adequate amplification equipment with suitable
power supply. The Contractor shall also provide
appropriate refreshment for the guests, including Omani
halwa and coffee.
1.15.3 Measurement and Basis of Payment
1 The commemorative plaque shall be measured as a
Lump Sum (L.S.) item in the Bill of Quantities.
2 The Opening Ceremony shall be measured as a
Lump Sum (L.S.) item in the Bill of Quantities.
1.15.4 Items in the Bill of Quantities
i. Supply and erection of
commemoration plaque (Lump Sum).
ii. Opening ceremony
including all facilities (Lump Sum).
1.16 Measurement and Payment
1.16.1 General Method of Measurement
1 The method of measurement and computations to
be used in determining quantities of materials furnished
and of work performed shall be as defined in the Method
of Measurement and Basis of Payment clause for each
Sub-section and in the Preambles to the Bill of Quantities.
2 All field measurements of quantities for monthly
certificates and for final payment shall be made by the
Contractor in the presence of the Engineer. Original
copies of the field measurement notes, signed by the
Contractor, will be retained by the Engineer.
3 If the Contractor fails to measure any work, the
Engineer may, at his discretion, estimate quantities of
such items for the monthly Payment Certificate or
recommend that no payment be made for the items not
measured and quantities not computed until they are
properly measured and computed.
4 All work shall be measured net and in accordance
with the General Conditions of Contract. The units of
measurement shall be in accordance with SI
recommendations and the latest revision of ISO 1551.
5 Structures shall be measured according to the lines
shown on the Drawings, or as altered by direction of the
Engineer to meet site conditions.
6 The term ‘lump sum’ when used as an item of
payment shall mean complete payment for the work
described.
7 When a complete item or structural unit (in effect
‘lump sum’) is specified as unit measurement the unit
shall be taken to include all necessary fittings and
accessories.
8 Cost of rental of plant and equipment is deemed to
be included in the rates and prices for the relevant work.
Only when specific plant is required to perform daywork
specifically ordered by the Engineer, will payment be
made. Payment shall be for the hours of actual working
time of the equipment and travelling time within the Site.
Where plant and equipment has to be brought
specifically to Site to carry out work paid for under day
works, travel time and transportation to the site will be
measured.
9 Manufactured Items
Whenever standard manufactured items are specified,
such as fence wire, plates, rolled shapes, pipe conduit,
etc. and these items are identified by gauge, unit weight,
section dimensions, etc., such identifications shall be
deemed to be nominal weights or dimensions. Unless
controlled by tolerances in cited specifications,
manufacturing tolerances established by the industries
involved may be accepted by the Engineer at the
recommendation of the concerned authorities.
10 Transport
Costs of haul or transport of any material or item is
neither measurable nor payable unless specifically
stated.
1.16.2 Scope of Payment
1 The Contractor shall receive and accept
compensation provided for in the Contract as full
payment for supplying materials and for performing
work under the Contract in a complete and acceptable
manner and for all risks, losses, damages or expenses
arising out of the nature or execution of the work subject
to the provision of the Conditions of Contract.
2 For detailed information on the item coverage and
costs to be included in the unit rate of the Contractor, the
Contractor should refer to the relevant clauses of each
♦ 1-19 ♦
copy 249
sub-section of the Specification and to the Preamble to
the Bill of Quantities and to the item descriptions in the
Bill of Quantities.
3 If the measurement and payment clause in the
Specification relating to a unit rate under the Contract
that the unit rate be considered compensation for certain
work or material essential to the item, this same work or
material will be neither measured nor paid for under any
other pay item appearing elsewhere in the Contract.

♦ 1-20 ♦
copy 249
Ref. Title Page No. Ref. Title Page No.
2.1  Clearing and Grubbing 2-1  2.3.4 Method of Measurement 2-6
2.3.5 Basis of Payment 2-6
2.1.1  Description 2-1 
2.3.6 Items in the Bill of Quantities 2-7
2.1.2 Construction Requirements 2-1
2.1.3 Method of Measurement 2-1 2.4  Borrow Materials 2-7 
2.1.4 Basis of Payment 2-1
2.4.1 Description 2-7
2.1.5 Items in the Bill of Quantities 2-1
2.4.2 Location of Borrow Pits 2-7
2.2  Removal of Structures and 2.4.3 Borrow Material 2-7
Obstructions 2-1  2.4.4 Method of Measurement 2-7
2.4.5 Basis of Payment 2-7
2.2.1 Description 2-1
2.4.6 Items in the Bill of Quantities 2-7
2.2.2 Construction Requirements 2-1
2.2.2.1  General 2-1  2.5  Embankments 2-7 
2.2.2.2  Removal of Bridges, Culverts
2.5.1 Description 2-7
and Ditches 2-2 
2.5.2 Materials 2-8
2.2.2.3  Removal of Pipes 2-2 
2.5.3 Construction Requirements 2-8
2.2.2.4  Removal of Walls, Rocks and Boulders 2-2 
2.5.3.1  General 2-8 
2.2.2.5  Removal of Fences and Gates 2-2 
2.5.3.2  Trial Embankments Sections 2-9 
2.2.2.6  Removal of Wells and Shafts 2-2 
2.5.3.3  Foundation Preparation 2-10 
2.2.2.7  Removal of Utilities 2-2 
2.5.3.4  Embankment Construction 2-10 
2.2.2.8  Removal of Existing Pavement 2-3 
2.5.4 Testing 2-11
2.2.3 Method of Measurement 2-3
2.5.4.1  General 2-11 
2.2.4 Basis of Payment 2-3
2.5.4.2  Standards of Compaction for Soil
2.2.5 Items in the Bill of Quantities 2-3
and Granular Materials 2-11 
2.3  Roadway Excavation 2-4  2.5.4.3  Degree of Compaction for Rock Fill
Materials 2-11 
2.3.1 Description 2-4
2.5.4.4  Monitoring Settlement of Rockfill 2-12 
2.3.2 Classification of Roadway Excavation 2-4
2.5.5 Method of Measurement 2-12
2.3.3 Construction Requirements 2-4
2.5.6 Basis of Payment 2-12
2.3.3.1  Utilization of Excavated Materials 2-4 
2.5.7 Items in the Bill of Quantities 2-12
2.3.3.2  Drainage of Excavation Areas 2-4 
2.3.3.3  Obliteration of Disused Roadways 2-4  2.6  Subgrade Construction 2-12 
2.3.3.4  Rock Blasting 2-5 
2.6.1 Description 2-12
2.3.3.5  Excavation of Unsuitable Material 2-5 
2.6.2 Materials 2-13
2.3.3.6  Slopes, Subgrade and Ditches 2-5 
2.6.3 Construction Requirements 2-13
2.3.3.7  Unstable Materials outside
2.6.3.1  Subgrade in Cut 2-13 
Right-of-Way 2-6 
2.6.3.2  Subgrade in Embankment 2-14 
2.3.3.8  Disposal of Unsuitable and Surplus
2.6.3.3  Surface Tolerances 2-14 
Material 2-6
2.6.3.4  Maintenance of Finished Subgrade 2-14

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Ref. Title Page No.
2.6.3.5 Drainage Blanket 2-14 
2.6.3.6 Subgrade Construction on Sabkha
and Gypsum Rich Soils 2-14
2.6.3.7 Subgrade Construction on top
of Dune Sand 2-15
2.6.4 Method of Measurement 2-15
2.6.5 Basis of Payment 2-15
2.6.6 Items in the Bill of Quantities 2-15

2.7  Excavation and Backfilling

for Structures 2-15 
2.7.1 Description 2-15
2.7.2 Excavation 2-15
2.7.2.1  General 2-15 
2.7.2.2  Temporary Support System 2-16 
2.7.2.3  Excavation for Major Structures 2-16 
2.7.2.4  Excavation for Box Culverts, Pipe
Culverts and Miscellaneous Structures 2-16 
2.7.3 Backfilling 2-17
2.7.3.1  General 2-17 
2.7.3.2  Backfilling for Box Culverts, Pipe
Culverts and Miscellaneous Structures 2-18 
2.7.4 Method of Measurement 2-19
2.7.5 Basis of Payment 2-19
2.7.6 Items in the Bill of Quantities 2-19

2.8  Earthwork for Pipe Trenches 2-19 

2.8.1 Description 2-19
2.8.2 Materials 2-20
2.8.2.1  Backfill Material 2-20 
2.8.3 Construction 2-20
2.8.3.1  Excavation for Pipe Trenches 2-20 
2.8.3.2  Backfilling 2-21 
2.8.3.3  Restoration of Surfaces 2-21 
2.8.4 Method of Measurement 2-21
2.8.5 Basis of Payment 2-21
2.8.6 Items in the Bill of Quantities 2-22

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2.1 Clearing and Grubbing
2.1.1 Description
1 This Sub-section describes removal and satisfactory
disposal of all vegetation, surface debris and scattered
stones and rocks within the limits of the actual road width
(including the toes of fill and cut slopes and an additional
5m wide band from both sides), easement areas and
borrow pits.
2 Removal of structures and similar obstructions and
removal of utilities are specified in Sub-section 2.2 -
"Removal of Structures and Obstructions".
2.1.2 Construction Requirements
1 The Contractor shall set out the approved
construction limits and the Engineer will designate all
trees, shrubs, plants, vegetation, etc and other items that
are to remain within the right-of-way (ROW). The
Contractor shall carefully preserve all such items from
damage or defacement. Trees to be removed and
delivered for replanting shall be carefully handled.
2 All surface objects, trees, stumps, roots, stones and
rocks (up to 0.2 cu.m. or 500 kg individual size or weight),
and other protruding obstructions not designated to be
retained shall be cleared or grubbed to ground level. Non-
perishable solid objects (such as boulders, rocks, concrete
blocks, etc.) which will be a minimum of 2m below the
sub-grade or finished ground level may be left
undisturbed at the Engineer’s discretion. If such non-
perishable objects are encountered within 2m below the
sub-grade or finished ground level, they will be removed
and considered as unsuitable material, paid under
Unclassified Excavation.
3 Stump holes and other holes from which
obstructions are removed within the limits of construction,
shall be backfilled with suitable material and compacted in
accordance with Sub-section 2.5 - "Embankments". Small
holes that are inaccessible to compaction / tamping
equipment shall be filled and tamped manually using a
steel rod with a 10-15cm diameter steel disc attached to its
end.
4 Perishable material shall be disposed of or burned
under the constant care of competent watchmen at such
times and in such a manner that any vegetation or other
items designated to remain in the ROW, or other adjacent
property, will not be jeopardized. Burning shall be carried
out in accordance with applicable laws and ordinances.
5 Materials, stones, rocks, and debris which cannot be
burned and perishable materials, shall be removed from
the ROW and disposed of at dumping areas off the Site,
approved by the concerned authorities, provided
permission of the respective property owners has been
obtained in writing to dump such materials on their land.
The Contractor shall make all necessary arrangements
with property owners for obtaining such written
permission at his own expense.
2.1.3 Method of Measurement
1 Clearing and grubbing is measured in square meters
of the cleared area within the limits described in Item 1 of
Clause 2.1.1 above and approved by the Engineer.
2 Trees with a trunk diameter 300mm or more when
measured 750mm above existing ground level are
measured by the number removed and delivered to the
Employer or disposed of as directed by the Engineer.
2.1.4 Basis of Payment
1 The area of completed and accepted clearing and
grubbing work measured as provided for above, will be
paid at the unit rates stated in the Bill of Quantities, which
rates shall be full compensation for labor, equipment and
other items necessary for completion of the work..
2 Removal of trees with trunk 300mm diameter or
greater will be paid for by the number removed as stated
above. Removal of trees with trunk less than 300mm
diameter is deemed to be included in the rate for clearing
and grubbing
3 Rates for all clearing and grubbing and tree removal
shall include for filling holes and depressions with
material as specified
2.1.5 Items in the Bill of Quantities
i. Clearing and grubbing
ii. Removal and delivery or disposal of trees of
300mm trunk diameter or greater
2.2 Removal of Structures and
Obstructions
2.2.1 Description
1 This Sub-section describes the removal, wholly or in
part, and satisfactory disposal of all buildings, fences,
structures, abandoned pipelines, and any other
obstructions, as shown on the Drawings or directed by the
Engineer, which are not designated or permitted to remain,
including salvaging of designated materials and backfilling
the resulting trenches, holes and pits.
2 The Contractor shall examine the Site and record for
himself all obstructions and utilities before the
commencement of the Works.
2.2.2 Construction Requirements
2.2.2.1 General
1 The Contractor shall raze, remove and dispose of all
buildings, foundations, structures, fences and other
obstructions, any portions of which are on the ROW,
except utilities and items for which other arrangements for
removal have been made. All designated salvageable
material shall be removed, without causing unnecessary
damage, and in sections or pieces which may be readily
♦ 2-1 ♦
copy 249
transported, and shall be stored by the Contractor at
approved locations, for later use or possession of others.
2 Unusable perishable material shall be destroyed.
Non-perishable material may be disposed of off the Site,
provided permission of the respective property owners
has been obtained in writing to dump such materials on
their land.
3 Basements or cavities left by structure removal shall
be filled to the level of the surrounding ground and, if
within the prism of construction, shall be compacted to
the type of compaction within the range for the adjacent
roadway embankment as specified in Sub-section 2.5 –
‘Embankments’.
4 Salvaged pipe culverts and other re-usable materials
shall be stored at accessible approved locations on Site
and shall become the property of the Employer.
2.2.2.2 Removal of Bridges, Culverts and Ditches
1 Bridges, culverts and other drainage structures in
locations traversed by traffic shall not be removed until
arrangements, detours and traffic management plans have
been made by the Contractor and approved by ROP to
maintain the flow of traffic.
2 Substructures in watercourses shall be removed
down to the level of the natural stream bed. Those parts
outside the stream shall be removed to 300 mm below
natural ground surface. Where such portions of existing
structures lie wholly or in part within the limits for a new
structure, they shall be removed to the extent necessary to
accommodate construction of the proposed structure.
3 Steel bridges and timber bridges, designated to be
salvaged shall be dismantled without causing unnecessary
damage. Steel members shall be match marked, unless
this requirement is waived by the Engineer. All salvaged
material shall be stored as previously specified for reuse
or possession of others.
4 Blasting or other operations necessary for removal of
existing structures or other obstructions, and which may
damage new construction in the vicinity, shall be
completed prior to commencing the new construction.
Explosives shall be used only as permitted by the
appropriate security authorities and shall be approved by
the Engineer. The Contractor shall observe the
requirements of Section 1, Sub-section 1.9, Clause 1.9.2
for all blasting operations
5 The Contractor shall carry out a structural survey of
all the existing buildings and structures located within the
blasting influence distance. The survey shall include
detailed photographic records for the adjacent buildings
and structures before and after blasting, in order to avoid
later claims by public.
2.2.2.3 Removal of Pipes
1 All pipes unless otherwise directed shall be removed
and precautions taken to avoid breaking or damaging the
pipes. The Contractor shall exercise utmost care during
the removal of pipes so as to avoid unnecessary damage.
♦ 2-2 ♦
2.2.2.4 Removal of Walls, Mortared and Loose Riprap,
Gabions, Rocks and Boulders
1 Masonry walls, mortared and loose riprap, gabions
and accumulated stones, large rocks and boulders of
individual size greater than 0.2 cu.m.or greater than 500 kg
in weight which lie within the limits of the Works, shall be
removed and disposed of as directed.
2.2.2.5 Removal of Fences and Gates
1 When fences and gates enclosing pasture land or
farm land are to be removed, the Contractor shall notify
the Engineer sufficiently in advance to permit the property
owner reasonable time to construct alternative fencing or
make other suitable arrangements.
2.2.2.6 Removal of Wells, Shafts and Falajs
1 Existing wells and shafts, abandoned or active, which
lie within the limits of the Works, shall be dismantled,
backfilled, and compacted. All salvageable materials shall
be removed and stored at approved locations on Site. All
salvageable material shall become the property of the
Employer. Wells shall be filled to the level of the
surrounding ground and, if within the prism of
construction, shall be compacted after obtaining the
Engineer's permission to the type of compaction within
the range designated.
2.2.2.7 Removal of Utilities
1 The Contractor shall liaise with the Engineer and
shall notify all Utility Authorities and co-operate and
coordinate with them in respect of removals and
relocations.
2 Unless shown otherwise on the Drawings,
realignment or relocation of active utilities will be to the
approval of the respective authorities and such work shall
be coordinated by the Contractor. The Contractor shall
perform the necessary coordination with the relevant
utility authorities ahead of time in order to avoid
unnecessary delay to the Works.
3 The removal of all disconnected or abandoned
utilities within the ROW shall be performed by the
Contractor as directed by the Engineer, unless the utility
authorities indicate their intention to carry out such
removal and salvaging of materials, fittings, parts, etc.
4 The Contractor shall liaise with the Engineer and
shall advise each affected utility authority in writing of his
proposed construction schedule and shall arrange for
inspection, disconnection or interruption of services by the
utility authorities as appropriate.
5 The Contractor shall be responsible for supporting
and protecting realigned utilities and existing utilities that
are to remain in place, for the duration of the Contract and
shall provide all necessary Temporary Works in this
respect, all in compliance with Section 1, Sub-section 1.8,
Clause 1.8.3…..and the requirements of the relevant utility
owner. Any damage caused to utilities and attributable to
the Contractor shall be repaired at his expense.
copy 249
6 All excavation and backfill shall conform to the will not be paid for directly but will be considered as
requirements of Sub-sections 2.3 - ’Road Excavation‘, 2.5 – subsidiary work related to other items in the Bill of
’Embankments’ and Sub-section 2.7 - ’Excavation and Quantities.
Backfilling for Structures‘, as appropriate.
2.2.4 Basis of Payment
2.2.2.8 Removal of Existing Pavement
1 The quantities of completed and accepted work,
1 The Contractor shall remove, wholly or in part, as measured as provided for above, will be paid for at the
shown on the Drawings or directed by the Engineer, relevant unit rates stated in the Bill of Quantities , which
existing asphalt, tiles and/or concrete pavement layers, rates shall be full compensation for equipment, tools,
and any granular or stabilized base courses., including labor, materials, transporting and dumping, and for other
disposal of debris and salvaging of designated materials, items necessary for the proper completion of the work.
and backfilling the resulting holes where and as instructed
by the Engineer. 2.2.5 Items in the Bill of Quantities
2 The Contractor shall examine the Site and record all
i. Removal of existing building (type and
obstructions and utilities that may be affected by removal
description), (Nr. or Length /
of existing pavements at the commencement of the Works.
Area / Volume as appropriate).
3 The Contractor shall raze, remove and dispose of old
ii. Removal of reinforced concrete (type,
pavement of different types, (i.e. down to the bottom of location, and dimensions), (cu.m).
the base course) or as directed by the Engineer, for the
iii. Removal of mass concrete (type, location
portions which are within the limit of Works.
and dimensions), ( cu.m).
4 Unusable perishable material shall be disposed of in iv. Removal of pre-stressed concrete (type,
accordance with the applicable laws and ordinances. Non- location and dimensions), ( cu.m.)
perishable material may be disposed of off the Site, v. Removal of curbs (Type), (lin.m.)
provided permission of the concerned authorities and/or vi. Removal of Tiles (Type and Size), (sq.m).
the respective property owner has been obtained in vii. Removal of pipe culverts (type
writing to dump such materials on their land. and diameter) , (lin.m.)
5 Cavities left by pavement removal shall be filled to viii. Removal of existing pavement
the level of the surrounding ground and, if within the (description and type), (cu.m).
prism of construction, shall be compacted to the type of ix. Removal of reusable road studs, (nr).
compaction specified in Sub-section 2.6 – ‘Subgrade x. Removal of steel safety barrier including
Construction’. post and foundations (dimensions and
Type), (lin.m).
6 The Contractor shall be responsible for supporting
xi. Removal of concrete safety barrier
and protecting existing Utilities that are to remain in place,
including foundations
for the duration of the Contract and shall provide all
(dimensions and Type), (lin.m.)
necessary Temporary Works in this respect. Any damage
xii. Removal of sign boards including
caused to utilities and attributable to the Contractor shall
post and foundations (size), (nr).
be repaired at his expense.
xiii. Removal of Floodway marker posts and
7 The Contractor shall be responsible for and shall foundations (size), (nr.)
ensure that pavement removal operations are completed xiv. Removal of re-usable steel safety barrier
without applying extreme vibration and heavy loading that including post and foundations
might damage the existing underground utilities. (dimensions and Type), (lin.m.)
2.2.2.9 Removal of Existing Road Furniture xv. Removal of re-usable concrete safety
barrier including foundations (dimensions
1 Road Furniture items such as curbs, tiles, steel and and Type), (lin.m).
concrete safety barriers, lighting poles, sign boards, etc. xvi. Removal of re-usable sign board including
which lie within the limits of the Works, shall be removed post and foundations (size), (nr.)
and disposed of as directed. xvii. Removal of reusable Floodway marker
posts including foundations (size), (nr).
2.2.3 Method of Measurement xviii. Removal of drainage protection
works (type), (sq.m.)
1 Removal of structures and obstructions is measured
xix. Removal of existing fences and
by number, length, area or volume as appropriate for the
gates (description and type), (lin.m.)
relevant work, unless Item 2.2.3 (2), applies. The rates
xx. Removal of existing block and
shall include in full for the removal, storage, protection
masonry walls (Size and Type) (cu.m)
and disposal of the structure or obstruction, including
xxi. Removal of ditches (Type and
items necessary for the proper completion of the work.
width), (lin.m).
2 If the Bill of Quantities does not contain separate xxii. Removal of bridges (dimensions,
items for removal of structures and obstructions, this work

♦ 2-3 ♦
copy 249
 type and description) (nr).
xxiii. Removal of rocks and boulders
larger than 0.2cu.m. or 500 kg
(description), (cu.m).
xxiv. Removal of wells and shafts (description
and location), (nr).
xxv. Removal of sand dunes (location
and description) (cu.m.)
xxvi. Removal of Light Poles including
cabling and foundation (Size), (nr).
2.3 Roadway Excavation
2.3.1 Description
1 This Sub-section describes excavation in the cut
sections of the roadway, including watercourses, ditches
and wadi relocations (but excluding borrow pits and
structural excavation) all as and where shown on the
Drawings, and hauling the excavated material either to
locations for roadway embankments or to stockpiles or to
waste.
2 The work also includes any necessary excavations
outside the ROW ordered by the Engineer to safeguard
and protect the Works, including diversion of existing
wadi channels; excavation of materials obstructing or
impairing the flow along stream channels; and excavation
of unstable materials which may slide or encroach into
ditches or onto the ROW. Disposal of all such excavated
materials shall be as instructed by the Engineer.
2.3.2 Classification of Roadway Excavation
1 Road excavation shall be considered as ’Unclassified
Excavation’ which includes all materials encountered of
any nature including silts, clays, sand, gravel, granular
materials, all cohesive and fractured, jointed cohesionless
materials and/or massive rock and unsuitable material.
2 Any information concerning properties of the soil
which may be shown on the Drawings, in the Bill of
Quantities, in supplementary reports, or as a result of
discussion with the Engineer or others shall be considered
as gratis and shall not be a basis for the Contractor's
determination of his bid prices.
2.3.3 Construction Requirements
2.3.3.1 Utilization of Excavated Materials
1 All materials removed from the excavation shall be
used in the formation of the embankment, sub-grade,
shoulder, dykes, and at such other places as directed,
unless it is declared unsuitable and ordered to be wasted
by the Engineer.
2 Unsuitable material shall include:
i. Unstable materials incapable of being
compacted to the specified density using
mechanical compaction methods at optimum
moisture content for the equipment being used
for compaction.
♦ 2-4 ♦
ii. Material too wet to be compacted and where
circumstances prevent suitable in-place drying
prior to incorporation into the work.
iii. Materials which are otherwise unsuitable for
use in or under the embankment.
3 No excavation material shall be wasted without
written permission from the Engineer.
4 If the Contractor chooses to excavate suitable
material to waste or put it to other uses, and replace it by
borrow excavation for embankment areas, this shall be
undertaken at no extra cost to the Employer.
5 Excavated rock which is not immediately suitable for
incorporation in the works can either be broken down to
acceptable sizes or wasted at Contractor's own expense. If
such material is wasted or used in concrete, granular
subbase, aggregate base, asphalt mixtures or any other
works, the Contractor shall replace it by borrow
excavation for embankment at no extra cost to the
Employer.
6 Where shown on the Drawings or directed by the
Engineer, salvaged materials such as existing concrete,
bituminous or other pavements shall, be stockpiled for a
specific purpose or for future use. Such materials shall be
excavated and handled in a manner that will exclude
foreign or undesirable material. Stockpiles shall be neatly
formed and maintained in an approved manner.
7 Where specified or directed by the Engineer, suitable
topsoil material shall be stockpiled during excavation
operations and shall subsequently be spread and
compacted on embankment slopes and elsewhere as
directed, to facilitate re-growth of vegetation.
2.3.3.2 Drainage of Excavation Areas
1 During construction, surfaces in excavation areas
shall be adequately drained at all times. Side ditches or
gutters emptying from cut to embankment shall be so
constructed as to avoid damage to embankments by
erosion.
2 The Contractor shall, at an early stage of the Works,
provide adequate drainage by scheduling ditch and other
construction so as to prevent saturation or erosion of
embankments and cut slopes. All such drainage ditches
and construction grades shall be cleaned and trimmed at
regular intervals and when directed to maintain an
unobstructed runoff of stormwater during construction.
3 Damage to the Works attributable to saturation or
erosion of slopes during the period of execution through
failure to provide adequate drainage shall be repaired by
the Contractor at his own expense.
4 Whenever groundwater is encountered which may
adversely affect construction, the Contractor shall advise
the Engineer who will evaluate the situation and order
necessary remedial measures.
2.3.3.3 Obliteration of Disused Roadways
1 Obliteration of roadways which are no longer in use
shall include filling of all ditches and rough grading of the
copy 249
old roadway to produce within the ROW a neat and well
drained ground surface.
2.3.3.4 Rock Blasting
1 Rock blasting explosives may comprise a diversity of
systems, including dynamite explosives, watergels, slurry
explosives and slurry blasting agents, pumpable blasting
agents, emulsion explosives and aluminized explosives.
Whenever instructed by the Engineer, blasting shall be
carried out after pre-splitting the rock mass by using small
localized charges in pre-drilled holes.
2 When blasting of rock slopes is carried out, a
reasonably uniform face shall be left, regardless of
whether or not the excavation is carried beyond the
specified side slopes as shown on the Drawings. All
breakage and slides shall be removed and disposed of as
directed. A dust control system shall be designated by the
Contractor and shall be implemented during rock blasting
after obtaining the Engineer’s approval.
3 All drilling and blasting shall be done in such a
manner as will most nearly complete the excavation to the
required grade lines, and produce the least possible
disturbance of the material to be left in place. Blasting by
means of drill holes, tunnels, or any other methods shall
be entirely at the Contractor's risk. Explosive materials
shall be stored and kept under the constant surveillance of
the Royal Oman Police.
4 Where necessary or directed, the Contractor shall
provide heavy mesh blasting mats or controlled blasting
for protection of persons, properties, and the Works. If, in
the opinion of the authorities and the Engineer, blasting
would be dangerous to persons or adjacent structures, or
is being carried out in an unsafe or unacceptable manner,
the Engineer may prohibit blasting and order the rock to
be excavated by other means.
5 During explosion works, traffic shall be suspended
from the routes linking to the Site and all diversions and
other arrangements shall be carried out in full
coordination with the Royal Oman Police. The Contractor
shall secure approval of his schedule for such
interruptions and his proposed methods for safeguarding
the public and property.
6 Excessive blasting will not be permitted.
Overbreakage and the backfilling thereof shall be at the
Contractor’s expense. Any material outside the approved
cross section limits which may be shattered or loosened
because of blasting shall be removed by the Contractor at
his own expense. All rock slopes with loose material shall
be scaled by workmen and all loose material removed at
the Contractor’s expense.
7 Backfilling of overbreakage shall be carried out as
directed, using approved soil or crushed materials or other
special aggregate or cyclopean concrete, as shown on the
Drawings or as directed by the Engineer. Undrained
pockets shall not be left in the surface of the rock.
8 Following blasting, cleaning and scaling rock slopes,
the face, benches and back of the slope shall be inspected
for potential failure planes and the necessary remedial
measures shall be taken, as approved by the Engineer, at
the Contractor’s expense.
2.3.3.5 Excavation of Unsuitable Material
1 Unsuitable materials are materials that do not
comply with the requirements for suitable materials as
described under Clause 2.5.2 below.
2 Where excavation to finished grades and cross
sections exposes unsuitable material in the sub-grade,
slopes or ditch inverts, etc the Engineer may require the
Contractor to remove the unsuitable material and backfill
the excavated areas using approved material. The
Contractor shall plan his operations so that necessary
cross section measurements are taken before such backfill
is placed.
3 Unsuitable material shall be disposed off as directed.
Wasted unsuitable material shall not be deposited on any
cropland.
4 When the Contractor is directed to excavate
unsuitable material below the surface of the original
ground in fill areas, other than that required for clearing
and grubbing, the depth to which unsuitable material shall
be removed will be determined by the Engineer. The
Contractor shall plan the excavation so that cross sections
are taken before and after material has been removed.
2.3.3.6 Slopes, Sub-grade and Ditches
1 All excavated slopes, sub-grade and ditches shall be
finished true to lines, grades and cross sections as shown
on the Drawings.
2 Slopes, except in massive rock or other material
which require special treatment, shall be trimmed to
slopes not steeper than the specified slope angles and
rounded at top and bottom to a smooth profile to blend in
with the adjacent terrain. Material shall not be loosened
beyond the specified slope lines. High cut areas shall
continuously be monitored by an engineering geologist or
a geotechnical engineer.
3 In cuts where earth overlays a rock formation, slopes
shall be benched in an approved manner.
4 Ditches of all types shall be excavated and trimmed
neatly in conformity with the specified grades and cross
sections. All projecting rock, stumps, roots or similar shall
be removed. Ditches include side ditches, interception
ditches in the berm of cut slopes, furrow ditches, irrigation
ditches, wadi relocations, etc.
5 Where the sub-grade is composed of rock as defined
in Sub-section 2.6 – ‘Sub-grade Construction’, it shall be
undercut to a depth of 200 mm below top of sub-grade to
allow for subsequent placing and compaction of the
leveling sub-grade layer in accordance with Sub-section
2.6 – ‘Sub-grade Construction’, paragraph 2.6.3.1.
6 The sub-grade in cut, where the soil is unsuitable for
retention as the sub-grade layer, shall be sub-excavated to
a depth of 200 mm below top of sub-grade to allow for
subsequent placing and compaction of the sub-grade layer.
♦ 2-5 ♦
copy 249
If the material of the sub-grade is suitable for retention as
sub-grade layer then it shall be scarified to the required
depth, watered and compacted in accordance with Section
2.6 – ‘Sub-grade Construction’, paragraph 2.6.3.1.
7 The Engineer will periodically check all or any part of
the work, to determine conformance to the correct lines,
grades and elevations. Tolerances on finished sub-grade
levels and on levels of the surface at the underside of the
sub-grade layer shall be as specified in Sub-section 2.6 –
‘Sub-grade Construction’, Paragraph 2.6.3.3.
8 In cases where rock or soil excavations reveal that
the adopted cut slopes are not suitable and if failures
occur during or after completion of the excavation works
and while the Contractor is still on Site, the Engineer may
request the Contractor to re-excavate according to the
newly established cut slopes, the extra work will be
measured and valued as Unclassified Excavation at the
same rate given in the Contract. However, in such case,
the Contractor may submit a proposal for any other
alternative solution for the stability of the cut slopes, for
the Engineer’s appraisal and final decision.
2.3.3.7 Unstable Materials outside Right-of-Way
1 Materials outside the ROW or ditch slopes which, in
the opinion of the Engineer, are potentially unstable and
liable to slide or encroach into the ROW or into the ditches,
shall be excavated and disposed of as specified for
unsuitable material, unless it is approved for use as
embankment fill.
2.3.3.8 Disposal of Unsuitable and Surplus Material
1 Unsuitable and surplus materials disposed of within
approved areas shall be spread, leveled and shaped as
directed so as to present a neat and tidy appearance. No
materials shall be disposed of in such a way as to
adversely affect natural drainage courses or to cause
damage to the highway or adjacent public or private
property.
2 If approved by the Employer, Government land may
be used for disposal to the maximum extent practicable. If
private land is used for disposal, the Contractor shall
secure the consent of the landowner or tenant and, if
necessary, and at his own expense, pay for the use of such
land. The use of cropland for disposal purposes will not
be permitted.
2.3.4 Method of Measurement
1 All excavated material of whatever type (except for
unauthorized undercut below top of sub-grade or
excavations taken wider than required) shall be measured
as ‘Unclassified Excavation’ which shall be deemed to
include all materials encountered of any nature, including
silts, clays, sand, gravel and granular materials and
fractured, jointed and massive rock, whether weak or
strong, and unsuitable material, as approved and
instructed by the Engineer.
♦ 2-6 ♦
2 Unclassified Excavation shall be measured by cu.m.
of material excavated, hauled away and either wasted,
stockpiled, or deposited on or in vicinity of roadway
embankments and dykes. Measurements shall be of
volumes computed from the cross sections shown on the
Drawings and the original ground elevations taken jointly
by the Engineer and the Contractor after clearing and
grubbing operations. Rates shall include for costs of
supporting sides of excavation where necessary, keeping
excavations free from water, proper formation of
embankments, trimming of slopes, preparation and
completion of the roadway, sub-grade, dykes and
shoulders and scarifying for suitable sub-grade material.
3 Excavation of unstable material (from areas outside
the ROW) shall be measured by cu.m. of material
excavated, hauled away and disposed of as directed,
completed and accepted. Measurements shall be of
volumes computed from surveyed cross sections of
original and final ground elevations. When cross
sectioning is impractical in the opinion of the Engineer,
approval may be given to measure volumes in the
vehicles removing such excavated material.
4 Ditch excavation and excavation of unstable material
are considered part of the unclassified excavation.
5 Rock blasting, backfilling of overbreakage, trimming
and grading of cut slopes, ditches and of other below-sub-
grade surfaces, drainage of excavation areas, obliteration
of disused roadways, and other ancillary excavation
Works shall not be measured for direct payment, but shall
be considered as subsidiary work the costs of which will
be deemed to be included in the rates for Unclassified
Excavation
6 Excavation under water shall be measured by cu.m.
of material excavated, hauled away and disposed of as
directed, completed and accepted (including any side
support or other enabling works). Measurements shall be
of volumes computed from surveyed cross sections of
original and final ground elevations. When cross
sectioning is impractical in the opinion of the Engineer,
approval may be given to measure volumes in the
vehicles removing such excavated material.
7 Hauling of excavated materials shall not be
measured for direct payment, but shall be considered as
subsidiary work the cost of which will be deemed to be
included in the rates for Unclassified Excavation,
regardless of the distance required for hauling the
materials to an approved dumping area.
8 Excavation, Stockpiling and recompaction of suitable
topsoil material shall be measured by cubic meter, laid,
completed and accepted as directed by the Engineer.
2.3.5 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities,
which rate shall be full compensation for equipment, tools,
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labor, materials, transporting and hauling, and for other
items necessary for the proper completion of the work.
2.3.6 Items in the Bill of Quantities
i. Unclassified Excavation
ii. Excavation of unstable material
outside Right-of-Way
iii. Unclassified Excavation under water
iv. Excavate and Stockpile Suitable topsoil and
recompact as directed
2.4 Borrow Materials
2.4.1 Description
1 This Sub-section describes excavation of suitable
material from borrow pits, channels and designated
borrow areas and hauling to locations of embankments or
to stockpiles, all as shown on the Drawings, or as directed
by the engineer.
2 The Contractor shall be responsible for locating
suitable borrow pits and for the suitability and sufficiency
of borrow materials to meet the specified embankment
and other backfilling requirements.
3 Borrow pits shall be utilized if there is insufficient
suitable excavated material to satisfy the embankment
and other backfilling requirements or if the Contractor
chooses to excavate suitable material to waste or put it to
other uses, and replace it by suitable material excavated
from borrow pits at the Contractor’s expense.
2.4.2 Location of Borrow Pits
1 Generally, the borrow pits shall not be located within
50 m from the toe of embankment slope or top of cut or
formed slope, unless otherwise approved by the Engineer.
2 In no case shall borrow pits be located within 200 m
downstream of a drainage structure without the written
approval of the Engineer. Unauthorized borrow pits shall
be backfilled and compacted, as directed by the Engineer,
at the Contractor's expense.
3 In each case where a borrow pit is proposed within
privately-owned property, the Contractor shall secure the
consent of the landowner in writing, if necessary, and
shall, pay for the use of the material and land. The
Contractor shall be solely responsible for any claims for
compensation or complaints arising out of borrow pit
operations.
4 The Contractor shall be responsible for the stability
of the side slopes of borrow pits and channels at all times,
until the pit or channel is abandoned.
5 Details of the Contractor's proposed haul routes and
traffic arrangements in relation to borrow pit operations
shall be submitted for approval before any borrow
excavation commences.
6 Overburden and any unsuitable top layers within
each borrow pit shall be completely removed and
stockpiled in the vicinity, ready for re-use prior to
abandonment of the pit.
7 Prior to abandonment of any borrow pit or borrow
area, the Contractor shall spread and level the original
overburden over the exposed surfaces and clean up, grade
and contour the pit or area and the adjoining properties
occupied during execution of borrow operations, whether
Government, or privately-owned, all to the satisfaction of
the Engineer.
2.4.3 Borrow Material
1 Borrow shall be material approved by the Engineer
as meeting the requirements for the particular
embankment, backfill or other use for which the material
is intended.
2 The Contractor shall submit representative samples
of materials from each of the proposed borrow pits or
borrow areas. A minimum of three sets of tests shall be
performed for each borrow area for each type of material.
No borrow material shall be brought to the site or used in
the Works before its approval.
3 The Engineer will periodically require follow-up
testing of borrow materials to verify that no change in
quality has occurred since the original approval.
2.4.4 Method of Measurement
1 Borrow Excavation shall be measured by cu.m. of
suitable material excavated, hauled and used in the proper
formation of embankments, including trimming of slopes,
preparation and completion of the roadway sub-grade,
shoulders and dykes.
2 The quantity of borrow excavation shall be
determined by calculating the total quantity of filling after
compaction and deducting therefrom the total quantity of
unclassified excavation less an allowance for material
condemned by the Engineer as unsuitable for filling.
2.4.5 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for borrow excavation in the Bill of Quantities ,
which rate shall be full compensation for equipment, tools,
labor, materials, transporting hauling and placing, and for
other items necessary for the proper completion of the
work.
2.4.6 Items in the Bill of Quantities
i. Borrow excavation.
2.5 Embankments
2.5.1 Description
1 This Sub-section describes construction of roadway
embankments, including preparation of the areas upon
which they are to be placed; placing and compacting
approved material within areas where unsuitable material
has been removed; and placing and compacting approved
♦ 2-7 ♦
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embankment material in holes, pits and other depressions
within the constructed area, all in accordance with the
lines, grades and cross sections shown on the Drawings.
2.5.2 Materials
1 Materials suitable for embankment shall be of classes
A-1, A-2-4, A-2-5 or A3 ‘when confined’ groups as in
AASHTO M145 and complying with Table 2.5.2.1, and
shall be used when available, except for rock fill
embankments. If material of this character is not available,
then material from A-2-6, A-2-7, A-4, A-5, groups (AASHTO
M145) may be used provided it complies with the
requirements of Table 2.5.2.1; however, special attention
shall be given to its suitability for the particular
construction
Requirements
1 Maximum dry density not less than 1.7
(AASHTO T-180 Method D)
2 Organic matter not more than 5% (AASHTO T-
267)
3 thickness
Gypsum content not more than 5%.
4 Passing 0.42mm (Sieve # 40) ........25% maximum
No use of A-6, A-7 soil (AASHTO M-145)
5 Maximum size not more than 1/2 of the layer
thickness
6
Plasticity Index (P.I.) less than 20%
4-day soaked C.B.R. should not be less than 8%
. 7 (AASHTO T-193) when compacted at 100%
maximum dry density in accordance with
AASHTO T-180 Method D.
Table 2.5.2.1: Soil Suitable for Embankment
2 The 200 mm depth of embankment sub-grade layer
immediately below the bottom of sub base shall consist of
selected sub-grade material having a 4-day soaked C.B.R.
of at least 25% when tested in accordance with AASHTO
T193 and when compacted at 100% Modified Proctor
Density in accordance with AASHTO T-180D, with a
gradation and P.I. as specified under Sub-section 2.6 –
‘Sub-grade Construction’.
3 The 600 mm depth of embankment immediately
below the sub-grade layer shall consist of suitable
material having a 4-day soaked C.B.R of at least 15% when
compacted to 95% maximum dry density in accordance
with AASHTO T-180D and tested in accordance with
AASHTO T-193 with a P.I. not more than 15%. If rockfill is
used for the bottom 400 mm depth then these
requirements shall apply to the top 200 mm depth below
the sub-grade layer.
4 Rockfill shall not be used in the top 200 mm of the
embankment below the sub-grade. If found necessary and
if approved by the Engineer, water may be added as
required to achieve maximum compaction.
5 In areas subject to flooding and prolonged inundation
of the embankment, such as at bridge and culvert sites,
the material used in embankment shall conform to
AASHTO M 145, Class A-1-a, A-1-b, A-2-4. Rockfill can
♦ 2-8 ♦
also be used in these conditions, except for the top
600mm of the embankment.
6 Where embankments are to be constructed using
material classified as A3 (AASHTO M 145) or other
material subject to side slope erosion or requiring
confinement for stabilization purposes, the embankment
plating or confining layer shall be constructed using
AASHTO M 145 Class A-1-a, A-1-b, or A-2-4 materials or as
otherwise approved.
7 The material used in rockfill embankments shall
consist predominantly of rock fragments of such size that
the material can be placed in layers of the thickness
prescribed conforming to the requirements stated in Table
2.5.2.2. The size distribution of rockfill shall be determined
according to CIRIA Special Publication 83: Manual on the
use of Rock in Coastal and Shoreline Engineering –
Appendix 2.
Requirements
1 Maximum particle size ........1/2 loose layer
2
Uniformity coefficient, Cu.......5 minimum, where
Cu = D60/D10
3 D60 = the Particle size at which 60% passes
D10 = the Particle size at which 10% passes
Table 2.5.2.2: Rock Suitable for Embankment
8 Rockfill material shall be obtained from quarries and
shall be sound, dense, hard and durable rock capable of
being spread and compacted as specified. Individual
pieces are to be clean and angular. It shall be the
Contractor's responsibility to excavate material from rock
cuts, whether by blasting or other means, so that all
excavated materials are of suitable size.
9 When suitable materials of widely divergent
characteristics are drawn from different sources, such
materials may, if approved, be mixed to meet the
embankment requirements. Rock and other materials shall
be incorporated in such manner as to avoid segregation
and an accumulation of boulders, etc., at the toe of
embankment slopes.
10 Logs, trees, stumps, weeds, heavy grass, vegetable
matter or other undesirable and non compatible materials
shall not be placed in embankments.
11 Rocks larger than 100 mm in any dimension shall not
be used as fill material in areas where piling works are to
be carried out.
2.5.3 Construction Requirements
2.5.3.1 General
1 Prior to placing embankment material on any area,
the ground shall have been cleared and grubbed as
specified in Sub-section 2.1 – ‘Clearing and Grubbing’, and
the foundation prepared as specified herein.
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2 Equipment used for foundation preparation and for
placing, spreading and compacting embankment materials
shall be of approved types and furnished in sufficient
numbers for the purposes intended. Provision and use of
such equipment shall conform with Section 19 ‘Plant and
Equipment’
3 Draglines shall not be used to construct embankment
unless approval is given and only when special
procedures are adopted to keep the layers uniform and the
embankment properly graded and well-drained at all times.
4 Surfaces of embankment layers shall be kept
properly shaped and drained at all times. The Contractor
shall utilize a sufficient number of motor graders or
tractors to level and maintain the surface of each layer of
embankment during all placing and compacting
operations.
5 Whenever feasible, trucks, scrapers, tractors, loaders
and other heavy hauling equipment shall be routed over
the embankment in such a manner as will contribute
effectively to compaction of the fill material.
6 Where an embankment is to be constructed over an
area previously occupied by a building basement, cellar,
irrigation canal, well, any previous excavation, or adjacent
to structures, and where the proper use of normal
compaction equipment is not practicable, the
embankment shall be constructed and compacted in
accordance with the backfilling requirements of Sub-
section 2.7 – ‘Excavation and Backfilling for Structures’
until the use of normal compaction equipment is
practicable. Layers shall not exceed 200 mm thickness
(before compaction) and shall be compacted to the degree
of compaction specified for the embankment. The
embankment construction under this item shall be
measured and paid under the requirements of Clause
2.7.4.8:’“Unclassified Structural Excavation’
7 Each embankment layer shall be tested and approved
prior to placing the following layer in accordance with
Clause 2.5.4 ‘Testing’.
8 The Engineer may at any time order suspension of
delivery of materials to the embankment sites until
previously delivered materials have been properly placed
and preceding layers are leveled and uniformly compacted
to the specified density.
9 Unacceptable material placed in any embankment
shall be removed and disposed of by the Contractor at his
own expense, immediately after receiving the Engineer’s
instructions in this regard. Any expected delay with the
removal of such material shall be coordinated and agreed
with the Engineer.
10 The Contractor shall be responsible for the stability
of all embankments and shall replace all embankment
sections which, in the opinion of the Engineer, have been
damaged or displaced due to carelessness or neglect on
the part of the Contractor, or due to normally occurring
natural causes, such as storms, and not attributable to the
unavoidable movement of the natural ground upon which
the embankment is constructed.
11 All embankment side slopes shall be neatly finished
true to the lines and not steeper than the slope angles as
shown on the Drawings. The bottom (toe) of side slopes
shall be graded to a well rounded, smooth profile to blend
in with the adjacent terrain.
12 Where directed by the Engineer, the side slopes of
rockfill embankments shall be thoroughly blanketed with
A-1, A-2-4 material, and compacted to the satisfaction of
the Engineer
13 The Engineer may permit the Contractor to utilize
suitable surplus material at his own expense to widen
embankments or flatten slopes, etc within the right-of-way.
Surplus material used in such manner shall be compacted
to 90 per cent of maximum density. When widening
embankments, the Contractor shall bear the cost of
modifying the culverts and any protection work necessary.
14 Rockfill shall not be used within 5m of a structural
element (next to bridge abutments footings, etc). In some
specific cases, rock fragments not exceeding 75mm
particle size may be used next to structural elements, but
only after obtaining the Engineer’s approval on the
location and extent of the work.
15 Rockfill shall not be used within 600 mm of top and
bottom of box and pipe culverts. Subgrade material shall
be used in these areas up to width excavated for
structures.
16 Potable or sea water can be used for all embankment
construction works, except that only potable water shall
be used for compaction of fill material within 1m from all
surfaces of structures.
2.5.3.2 Trial Embankments Sections
1 If shown on the Drawings, or if required by the
Engineer, a trial embankment shall be constructed. The
trial section shall be at least 2 lanes wide by 100 m long at
approved locations at or adjacent to the Site. Compaction
and other equipment used shall be as specified in Section
19 ‘Plant and Equipment’.
2 The initial sections of rock embankment shall serve
as the trial sections for rock fill, in order to establish the
optimum degrees of consolidation for the different layer
thickness. This shall be obtained by compaction trials
correlating number of passes of the roller with settlement
of the layer, or by different approved methods. The
maximum permitted layer thickness shall be related to the
unit weight of the vibratory roller and for compaction, as
given in Table 2.5.3.1 and shall not exceed 800 mm loose
thickness.
♦ 2-9 ♦
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 Maximum Thickness of
Minimum Roller Mass*
Layer
(Kg/m Width)
(Loose Thickness)
400 mm 2300 - 2900
500 mm 2900 - 3600
600 mm 3600 - 4300
700 mm 4300 - 5000
800 mm > 5000
* For multiple rollers, this shall be assumed as
the high axle load.
Table 2.5.3.1: Maximum Layer Thickness / Minimum Roller
Mass Requirements
2.5.3.3 Foundation Preparation
1 If the original surface upon which embankment is to
be placed is an existing pavement, the surface shall be
ploughed, scarified, or otherwise broken up regardless of
the height of the embankment to be placed thereon.
2 Clearing and grubbing, and removal of tree stumps,
shall be undertaken. The degree of compaction for the
area to be cleared shall then be determined. The top 150
mm of the surface on which the embankment is to be
placed shall be scarified, brought to a uniform moisture
content within the specified range, and compacted to the
density specified for the embankment. Hard and smooth
surfaces are to be roughened before filling is placed.
3 Where embankment is to be placed over topsoil
containing unsuitable organic material which does not
meet the requirements of Table 2.5.2.1, the ground shall
be stripped off to a depth of 200mm and the cleared
surface shall be scarified to a minimum depth of 200mm
or as directed by the Engineer, brought to a uniform
moisture content within the specified range, and
compacted to the density specified for the embankment.
4 Where embankment is to be placed and compacted
on hillsides or where new embankment is to be
compacted against existing embankments or where
embankment is built part width at a time, the slopes
steeper than 3:1 (H:V) when measured at right angles to
the road centerline shall be continuously benched as the
embankment is brought up in layers. Benching shall be of
sufficient width to permit operation of spreading and
compaction equipment, and in any case not less than 2 m
wide except where insufficient width is available between
existing and new embankments. Each horizontal cut shall
begin at the intersection of the original ground and the
vertical sides of the previous cuts. The vertical face of
each bench shall not be less than 1 m in height and not
exceed 2 m. Approved benching shall be measured as
unclassified excavation.
5 Where embankment is to be placed and compacted
on wadi slopes, the entire slope area shall be graded and
trimmed to remove any vertical faces and overhangs. The
final graded slope shall not be steeper than 1.5H:1V. The
slope shall then be continuously benched as the
embankment is brought up in layers, all as described
above for embankment on hillsides.
♦ 2-10 ♦
6 Rockfill shall not be placed on any slopes steeper
than 1:1. All slopes steeper than 1:1 shall therefore be re-
graded to a slope of 1:1 or milder and all vertical faces and
overhangs removed.
2.5.3.4 Embankment Construction
1 Roadway embankment consisting of soil or granular
material shall be placed in horizontal layers not exceeding
200 mm compacted thickness, compacted as specified and
approved prior to placing the next layer. The thickness of
the first layer over areas of Class A-3 dune sand may
exceed 250 mm in order to bridge these areas.
Approximately uniform thickness of each layer shall be
achieved prior to compaction. As the compaction of each
layer progresses, continuous leveling and working of the
material shall be carried out to ensure uniform density.
The correct moisture content shall be maintained at all
times.
2 Where embankments are to be constructed to a
height in excess of 1.5 m above top of original ground
level, the Engineer may approve layers up to 250 mm
compacted thickness if these layers are located at depths
greater than 1.5m from the final elevation of embankment
and if the Contractor's equipment and the nature of the
material result in the required density throughout the layer
thickness.
3 When the moisture content of the embankment
material does not fall within the required moisture range,
(optimum moisture ± 2%) water shall be added and
thoroughly mixed into the soil by approved methods or
the material shall be aerated, whichever is necessary to
adjust the material to the required moisture content.
4 When water is added to embankment material, the
amount added shall be sufficient to provide a moisture
content within the required range plus a reasonable
additional amount to compensate for evaporation and
other unavoidable losses. Water added in excess of this
amount shall be removed by aeration or other approved
means at the Contractor's expense. Satisfactory methods
and sufficient equipment shall be used for the furnishing
and handling of the water in a manner that will minimize
loss due to evaporation or waste.
5 Embankments that consist of rock-soil material with
sufficient soil to make rolling feasible shall be placed and
compacted in an approved manner and to the required
degree of compaction. Water shall be added as and when
directed to assist in the compaction of such materials.
6 In the case of embankments which are to be formed
of approved rock-soil material containing an appreciable
quantity of rock fragments (normally not exceeding 30%
greater than 80mm) and which cannot be placed in layers
of the thickness prescribed without crushing, pulverizing,
or otherwise breaking down the fragments, the
embankment may be constructed in layers not exceeding
in thickness twice the average size of the largest rock
fragments and in any case not exceeding 600 mm (before
compaction).
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7 Rockfill materials shall be placed in such a manner
that the larger rocks are well distributed and the voids are
filled to the maximum practical extent by smaller particles
of rocks, gravel or approved granular materials. Each layer
shall be bladed into a neat and homogeneous mass prior
to compaction. Any rocks found protruding from the
leveled surface shall be removed and replaced by smaller
particles. Initial breakdown compaction shall be
performed with heavy bulldozers. The top level of each
layer must be surveyed before and after compaction and
approved by the Engineer before the next layer is placed.
Oversize rock pieces (i.e. exceeding the maximum particle
size defined in Table 2.5.2.2 by not more than 10%) may
be used in high rockfill embankments to a level 3 meters
below sub-grade.
2.5.4 Testing
2.5.4.1 General
1 For verification of material, moisture content,
compaction, thickness and other properties of the
materials or workmanship the Engineer shall at all times
have access to all parts of the Works and Site. All
sampling and testing of material and work shall be carried
out as specified to the satisfaction the Engineer.
2 Materials shall be tested in accordance with BS 930,
AASHTO T96, AASHTO T204, AASHTO T205, AASHTO
T104, AASHTO T176, BS 1377, AASHTO M145, ASTM
D1556 and other applicable and relevant standards.
3 The Engineer shall test the compaction of
embankment materials in accordance with the
Specification to ensure that adequate compaction or
consolidation has been achieved. All such tests shall be
fully documented by the Contractor, in an approved
manner.
4 In the case of cohesionless, free draining rock-soil
materials, where maximum density tests fail to produce a
well defined moisture/density relationship, the relative
density test shall be used. Alternatively an electronic
compaction meter or any other approved test equipment
shall be provided by the Contractor and used to determine
the degree of compaction achieved.
5 To determine the degree of compaction for
embankment consisting of rock fill, average differential
settlement values shall also be determined from surveys
of an adequate number of grid point elevations as directed
by the Engineer at the commencement of, during and after
embankment construction. (Refer to Item 6 of Paragraph
2.5.4.3 below).
6 For rockfill embankments, the modulus of soil
reaction shall be determined by the plate bearing test;
using the method given in AASHTO T222.
2.5.4.2 Standards of Compaction for Soil and Granular
Materials
1 The following compaction standards shall apply to
embankment materials other than predominantly rock
materials. The ‘maximum density’ of soil type materials
shall be the modified maximum density determined in
accordance with AASHTO T 180 (Method D). The ‘relative
density’ shall be the relative density determined in
accordance with ASTM D 4254, which identifies the state
of compactness of the material with respect to its loosest
and densest state. The relative density shall be the
standard to which the field density is referred for
comparison in the case of cohesionless, free draining
granular materials.
2 Soil type materials shall be compacted to at least
90% modified maximum density for the full depth of
embankment; except for the 600 mm of embankment
material immediately below the sub-grade layer that shall
be compacted to at least 95% modified maximum density.
Moisture content shall be within plus or minus 2% of
optimum at the time of compaction.
3 Cohesionless, free draining granular materials (of 75
mm maximum size, with not more than 15% passing 0.075
mm (No. 200) sieve and a plasticity index (PI) not
exceeding 20%) shall be compacted to at least 70% of
relative density for the full depth of embankment. The 600
mm depth of such material immediately below the sub-
grade layer shall be compacted to at least 75% of relative
density.
4 Minimum soil tests required during the construction
of sub-grade and/or embankment are:
- One sample for CBR, classification (AASHTO
M145), and laboratory (Moisture - density) or
relative density compaction from each source
prior to use. Each sample shall represent not
more than 5,000 cubic meters.
- One sample for classification representing not
more than 3,000 cubic meters of the material in
use.
- For every completed layer, one field density
shall be determined for each 1500 square
meters or 100 linear meters, whichever is less.
Testing shall be in accordance with ASTM D
1556 or ASTM D 2167 or BS 1377 Part 9.
2.5.4.3 Degree of Compaction for Rock Fill Materials
1 To ensure proper compaction of rockfill
embankments, the Contractor shall conduct compaction
tests such as the plate load bearing test or other approved
equivalent tests using equipment and materials available
in order to determine the best compaction control criteria.
2 A rockfill test section shall be placed on a firm
surface approved by the Engineer, and the material and
layer thickness shall conform to the requirements of these
specifications.
3 The test section shall be of sufficient dimensions to
permit the establishment of at least twenty leveling points
on a 5 meter (5m) square grid, and no fewer than 3 points
on any one line and no point less than three meters from
the edge of the layer. The arrangement of the leveling
points shall be approved by the Engineer.
♦ 2-11 ♦
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4 Compaction shall then commence with a minimum
of three passes of a vibratory roller, as shown in Table
2.5.3.1. Leveling points shall then established, short
lengths of painted steel bars hammered flush with the
surface of the rockfill are suitable for this purpose. A level
reading shall be taken at each leveling point on top of a
moveable 300 mm square flat steel plate with a hole
drilled in the center of the plate to enable a visual check to
be made that the plate is located centrally over the bar.
5 Further readings shall be taken at the leveling points
after two additional passes with the roller. If the average
settlement is less than half of one per cent (0.5%) of the
average compacted layer thickness, or as determined by
the Engineer, the rockfill compaction test is deemed
complete.
6 If the average settlement is more than half of one
percent (0.5%), two additional passes of the roller are
required and the leveling procedure shall be repeated. If
the average settlement is then less than half of one
percent (0.5%), of the average compacted layer thickness
the test is deemed complete. If not, this step shall be
repeated.
7 The total number of passes of the rolling equipment
necessary to obtain the required result will establish the
minimum number of passes to be used on the rock
embankments. However, in no case shall the number of
passes be less than five (5).
8 This verification procedure shall be conducted for
each change of material and at least once each week
during the initial stages of construction until a reliable
rolling pattern is established. The frequency verification
procedure can then be reduced as approved by the
Engineer.
9 Documentation of the rockfill compaction tests shall
be maintained by the Contractor in the project records and
shall be copied to the Engineer.
2.5.4.4 Monitoring Settlement of Rockfill
1 On completion of the embankment, the Contractor
shall carry out precise leveling of the crest of the
embankment. This shall consist of leveling transverse
sections (a minimum of five points) at a maximum spacing
of 30 m along the embankment. These shall be referenced
to a stable approved datum. Leveling shall be carried out
at suitable time intervals until the average rate of
settlement over a period of one month does not exceed
0.1 mm per day. No permanent pavement construction
will be permitted until the specified criteria are achieved.
Adequate time shall be allowed in the construction
program for the settlement survey.
2.5.5 Method of Measurement
1 No separate items are included in the Bill of
Quantities for embankments. The cost is deemed to be
included in the items for excavation and borrow
excavation stated in Sub-sections 2.3 and 2.4..
♦ 2-12 ♦
2 The volume of embankment displaced by pipe
culverts, box culverts and associated end walls shall be
deducted from the measured volume of embankment. No
deduction shall be made for pipes less than 500 mm in
diameter and associated end walls.
3 Surplus materials utilized at the Contractor's option
within the ROW but, beyond the cross sections shown on
the Drawings, are not measured as part of the
embankment.
4 Benching described under Item 4 of Paragraph 2.5.3.3
is measured as Unclassified Excavation, under Clause
2.3.4.
5 No adjustments or allowances are made in respect of
expansion or shrinkage of earthwork volumes which may
occur during excavation and compaction..
6 Embankment foundation treatment such as stripping,
scarifying and re-compaction of topsoil containing
unsuitable organic material, as detailed in Item 3 of
Paragraph 2.5.3.3 is not measured but shall be considered
as subsidiary work the costs of which are deemed to be
included in the rates for excavation and borrow excavation
in Sub-sections 2.3 and 2.4
7 Scarifying old pavement beds, construction of the
trial embankment section if it is outside the pavement,
foundation, preparation, testing, including furnishing and
using an approved type electronic compaction meter and
grid pattern consolidation surveys, and all other ancillary
embankment work are not measured, but shall be
considered as subsidiary work the costs of which are
deemed to be included in the rates for excavation and
borrow excavation in Sub-sections 2.3 and 2.4
2.5.6 Basis of Payment
1 No separate payment will be made for any work in
this Sub-section 2.5. The cost of all work for embankments
is deemed to be included under Sub-sections2.3 and 2.4.
2.5.7 Items in the Bill of Quantities
1 No items are included in the Bill of Quantities. All
items under Sub-section 2.5 are subsidiary to other items.
2.6 Sub-grade Construction
2.6.1 Description
1 This Subsection describes construction of the sub-
grade layer and preparing the sub-grade surface ready to
receive the pavement structure including shoulders, all as
shown on the Drawings.
2 The sub-grade layer is the 200 mm minimum depth
of selected material immediately below the sub-grade
surface, or as defined in the Drawings or directed by the
Engineer.
3 Wherever shallow ground water is expected under
the roadway and wherever damage to the pavement
layers is potential due to water impact, a suitable
subsurface drainage blanket shall be installed under the
copy 249
sub-grade of the roadway. Drainage blanket is a course of 5 The layer directly underneath the drainage blanket
washed granular material placed to cut off upward and the one directly above it shall satisfy the following
capillary flow of pore water under paved areas, where and filter criteria:
as shown on the Drawings.
i. The 15% size of filter (D15 Filter) shall not be
2.6.2 Materials greater than 4 times the 85% size of the
1 Sub-grade material shall consist of suitable materials surrounding material (D85 Surrounding
of Classes A-1, A-2-4 or A-2-5 having a 4-day soaked CBR material):
of not less than 25% when tested in accordance with D15 Filter < 4 D85 Surrounding material.
AASHTO T 193 when compacted at 100% of modified ii. The 15% size of filter (D15 Filter) shall not be
proctor AASHTO (T-180-D) and having a maximum P.I. of less than 4 times the 15% size of the
12% and Gypsum Content not exceeding 3%. The surrounding material (D15 Surrounding
Maximum Dry Density of Sub-grade material shall be material):
equal or greater than 1.9 t/cu.m. Sub-grade gradation shall D15 Filter > 4 D15 Surrounding material.
be reasonably smooth without gap grading. All material iii. The 50% size of filter (D50 Filter) shall not
shall pass 75 mm sieve. The percent of material passing exceed 25 times the 50% size of the
the 0.075 mm (No. 200) sieve shall not exceed 18% and surrounding material (D50 Surrounding
shall not be less than 5%. Where directed by the Engineer, material):
the Contractor shall screen the sub-grade material at his
D50 Filter < 25 D50 Surrounding material.
own expense. The top 200mm sub-grade material shall
iv. The plasticity index of the portion of all filter
not contain more than 0.2% total Sulphate content and
materials passing sieve # 40 shall not exceed
0.05% total Chloride content.
6%.
2 If a drainage blanket is shown on the Drawings to be
The filter materials shall not contain more than
installed directly underneath the sub-grade, the sub-grade
5% material passing through sieve # 200.
material shall respect the filter criteria specified under
Item 5 of this Clause 2.6.2.
2.6.3 Construction Requirements
3 Aggregate material for use in drainage blanket shall
be rapid draining crushed stone, or crushed or uncrushed 2.6.3.1 Sub-grade in Cut
gravel conforming to the properties stated in Table 2.6.2.1
1 Where the sub-grade is located in rock, the sub-grade,
below:
unless shown otherwise on the Drawings, shall be
Property Range undercut to a depth of 200 mm by drilling or blasting as
Permeability in m/day – ASTM D2434 300 - 1500 directed. No rock shall project more than 50 mm above
the undercut surface elevation. The sub-grade layer shall
Effective Porosity 0.25
then be constructed using approved sub-grade material.
% Fractured Faces – (COE Method) Min. 75%
Cu (D60/D10) > 3.5 2 Where the sub-grade is on in-situ soil which is of a
L.A. Abrasion – AASHTO T96 < 40 quality and CBR value at least equal to those specified for
California Bearing Ratio (CBR) – sub-grade, the 200 mm depth of such material
> 30% immediately below top of sub-grade shall be scarified and
AASHTO T193
Table 2.6.2.1: Properties of Rapid Draining Materials for all roots, sod, vegetable and other undesirable matter and
stones larger than 75 mm in any dimension shall be
use in Drainage Blanket
removed. The material shall then be brought to uniform
4 The gradation of the rapid draining material for use moisture content within the specified range and
in drainage blanket shall be as provided in Table 2.6.2.2 compacted to 100% AASHTO T 180 (Method D) maximum
below: density.
3 Where the sub-grade is on in-situ soil which is
Sieve Designation (mm) Percent Passing unsuitable for retention as the sub-grade layer, such
38.0 (1-1/2 in.) 100 material immediately below the top of sub-grade layer
25.0 (1 in.) 70 – 100 shall be sub-excavated to a depth of 200 mm, hauled away
19.0 (3/4 in.) 55 – 100 and disposed of unless approved for use as embankment
fill. The sub-grade layer shall then be constructed using
12.5 (1/2 in.) 40 – 80
approved sub-grade material, as specified for sub-grade in
9.5 (3/8 in.) 30 – 65 embankment. If the material below sub-grade does not
4.75 (No. 4) 10 – 50 consist of suitable materials satisfying the requirements of
2.4 (No. 8) 0 – 25 top 600mm embankment, it shall be excavated for further
1.2 (No. 16) 0–5 200mm and replaced by suitable material to satisfy the
requirements of the top 600mm of the embankment.
Table 2.6.2.2: Gradation of Rapid Draining Materials for
use in Drainage Blanket

♦ 2-13 ♦
copy 249
4 The underlying natural material shall be scarified, ii. Place drainage blanket in layers not exceeding
leveled and rolled. The surface of the natural soil shall be 150mm compacted thickness each, with no
approved by the Engineer before placement of suitable layer less than 75 mm thick when compacted.
material.
2.6.3.6 Preparation of Sub-grade Construction on
2.6.3.2 Sub-grade in Embankment Sabkha and Gypsum Rich Soils
1 The 200 mm minimum depth of embankment 1 Where the road sub-grade passes over sabkha areas
immediately below top of sub-grade shall consist of or gypsum-rich soils with a high water table the
selected, approved sub-grade material. The material shall Contractor shall take the special precautions mentioned
be spread in one layer over the full width of the top of below if the sabkha or the gypsum-rich soils are
embankment, brought to a uniform moisture content encountered within the top 1m below the sub-grade level.
within the specified range and compacted to 100%
2 These precautions shall include but shall not be
AASHTO T 180 (Method D) maximum density.
limited to the construction of suitable temporary haul
2.6.3.3 Surface Tolerances roads for all construction plant operating in the area. Such
haul roads shall be constructed, at the Contractor’s
1 All finished levels, lines and grades shall be in expense. using rock fill and geotextiles as necessary to
accordance with the details shown on the Drawings. Each ensure a safe stable surface,
cross section shall be checked at maximum intervals of 20
3 If directed by the Engineer the Contractor shall
m, at each change in cross slope and elsewhere as
construct sub-grade and embankment (where applicable)
directed.
over sabkha areas or gypsum-rich soils with a surcharge
2 The tolerances on levels of finished sub-grade, top of of excess material that shall remain in place till all
embankment under the sub-grade layer and sub- appreciable settlement has stopped. The Contractor shall
excavated (undercut) surface shall be as given in Table provide a means of monitoring the settlement. The
2.6.3.1. Engineer shall decide when appreciable settlement has
stopped.
Surface Tolerances
4 Unless a specific treatment for using geotextiles,
Finished Sub-grade Soil +10 or -30 mm geogrids or geosynthetics is described elsewhere in the
contract, work over sabkha or gypsum-rich soils shall
Rock (if approved) +50 or -50 mm
consist of initially stabilizing the existing weak soil by
Top of Embankment or Sub- laying and rolling rock fill layer type 1 according to Table
+10 or -30mm
excavated Surface Soil 2.6.3.2 below. This operation should be continued by
Table 2.6.3.1: Tolerances on Elevations of Finished Sub- adding and rolling type 1 rock fill layer with steel vibratory
grade roller till the layer is completely stabilised.
5 A layer of geotextile fabric shall be laid over the
3 If instructed by the Engineer, when the finished sub-
compacted type 1 pervious material. A layer of 50mm
grade surface is tested with a 4 m long straightedge
pervious backfill type 2 according to Table 2.6.3-2 shall be
placed parallel to, or at right angles to the centerline, the
laid over the stabilised layer to protect the geotextile fabric.
maximum depression of the surface from the straight
edge shall be 30 mm.
US Standard Percentage Passing
2.6.3.4 Maintenance of Finished Sub-grade Sieve Size Type 1 Type 2
6 inch 100 -
1 The finished and approved sub-grade shall be
5 inch 85 - 100 -
continuously maintained in a smooth, well compacted and
4 inch 75 - 90 -
properly drained condition until the sub-base (or base)
2 inch 45 - 65 -
course is constructed. Reapproval of the sub-grade will be
required if the overlying course is not constructed within 1 1/2 inch 35 - 55 -
14 days of sub-grade completion or if the sub-grade layer 3/4 inch 20 - 35 100
is damaged by traffic or any other causes prior to the 1/2 inch 10 - 25 95 - 100
placement of the sub-base layer. 3/8 inch 5 - 20 70 - 100
No.4 - 0 - 55
2.6.3.5 Drainage Blanket No.8 - 0 - 10
1 Wherever and as shown on the drawings, place No. 16 - -
drainage blanket under roadway pavements on prepared No. 200 - 0-3
sub-grade as follows: Table 2.6.3.2: Definition of Type 1 and Type 2 Rockfill
i. Compact drainage blanket to required cross Materials for Sabkha Treatment
sections and thickness to not less than 95
percent of maximum dry density according to
ASTM D 1557.

♦ 2-14 ♦
copy 249
6 A layer of 200mm thick capillary break rock fill type 1 2.6.5 Basis of Payment
shall be laid over type 2 pervious backfill to receive the
1 The amount of completed and accepted work,
required road layers after the above operation.
measured as provided for above, will be paid for at the
unit rates for the relevant items in the Bill of Quantities ,
2.6.3.7 Preparation of Subgrade Construction on top of which rate shall be full compensation for supplying
Dune Sand materials, transporting, hauling and placing, for labor,
equipment, tools and other items necessary for the proper
1 Dune sand roadbed shall be compacted only after
completion of the work.
being confined by special means and methods that shall
be approved by the Engineer. These methods may include
the construction of an edge dyke of various materials on
2.6.6 Items in the Bill of Quantities
both sides of the road to provide the necessary i. Sub-grade preparation in cut (sq.m.)
confinement. ii. Drainage blanket (cu.m.)
2 Dune sand material will be allowed to receive dry iii. Preparation of sub-grade
compaction only if the material is tested and proven to be construction on sabkha or
A-3 type and only in case where the Proctor test showed a gypsum-rich soils (sq.m.)
maximum dry density at 0 % moisture. Otherwise, the iv. Preparation of sub-grade construction on top of
material shall be brought to uniform moisture content dune sand (sq.m.)
within the specified range and shall be compacted to 100%
AASHTO T 180 (Method D) maximum density. 2.7 Excavation and Backfilling for
Structures
2.6.4 Method of Measurement
1 Sub-grade layer in embankment is not measured 2.7.1 Description
separately but is included as part of the computation for
1 This Sub-section describes excavation in any
the volume of embankment.
material for buildings and pump houses; bridges, culverts,
2 Sub-grade preparation in cut is be measured by sq.m. pipe culverts, under-drains; drainage and utility
of top width of sub-grade layer computed from cross structures; flood areas cut-off-walls; retaining walls of all
sections shown on the Drawings. The rate shall include for types; and for other major and minor structures; including
all excavation below top of sub-grade, scarifying removing all necessary clearing and grubbing; bailing; drainage;
undesirable matter and compacting of replaced matter pumping; dewatering; sheeting; temporary shoring and
where necessary. cribbing; construction of temporary cofferdams or cribs;
3 Drainage blanket shall be measured by cubic meters backfilling with suitable approved material to the level of
of aggregate materials, furnished, screened, washed, original ground or to the top level of any adjacent
placed, spread, compacted, completed and accepted. embankment; and disposal of all surplus or unsuitable
Measurement shall be of volumes computed from the excavated material, all as shown on the Drawings, or as
cross sections shown on the Drawings and of the field directed by the Engineer.
measurements of area and compacted depth of each trial 2 The work also includes removal of those portions of
section. No allowance shall be made in the measurement existing structures below ground which would in any way
for overdepth and/or overwidth construction, regardless of obstruct or interfere with construction of new structures.
the Engineer’s permission for it to remain in place.
3 The Contractor will be deemed to have satisfied
4 Sub-grade construction on sabkha or gypsum-rich himself, at the time of tendering, as to the type and nature
soils shall be measured by sq.m. of top width of sub-grade of soils and rock that will be encountered in structural
layer computed from the cross sections shown on the excavations.
Drawings The rates shall include for all excavation below
top of sub-grade, scarifying, removing undesirable matter, 2.7.2 Excavation
construction of temporary haul roads, any rockfill,
geotextile or geo-synthetics used, surcharge materials, 2.7.2.1 General
compaction and completion and any accessories all as
1 The Contractor shall notify the Engineer a sufficient
specified in Paragraph 2.6.3.6 and as shown on the
time in advance of the beginning of any excavation for
relevant drawings,.
structures so that the Engineer may, where necessary,
5 Sub-grade construction on top of dune sand shall be survey and record the cross sectional or longitudinal
measured by sq.m. of top width of sub-grade layer elevations and measurements of the existing ground and
computed from cross sections shown on the Drawings. existing structures affected by the proposed structure.
The rates shall include for all excavation below top of sub- Any materials removed or excavated before these
grade, scarifying removing undesirable matter, installation measurements have been taken and approved by the
and dismantling of the confinement structure or side Engineer will not be paid for.
embankment and compacting the soil layers as specified

♦ 2-15 ♦
copy 249
2 The Contractor shall be responsible for the safety of
all foundation and trench excavations whether supported
or not. Approval of the Contractor's support system or
omission of a support system for any excavations will not
absolve the Contractor from his sole responsibility in this
regard.
3 The Contractor shall take all necessary precautions,
including shoring or other means, to protect employees
and others in the excavation and on the ground above.
4 The sides of all foundation pits and trenches
shallower than 1.5m shall be vertical and adequately
supported unless otherwise shown on the Drawings. Sides
more than 1.5 m in depth shall be sloped at a stable slope
or supported in an approved manner unless the material
through which the pit or trench is cut is deemed to be
sufficiently self-supporting and not requiring support.
5 Pits and trenches shall be kept free from water until
footing concrete has been placed or pipes have been
installed. The Contractor shall minimize, as far as
practicable, the length of time excavated areas are open.
The Contractor shall be responsible for repair of damage
due to weather, equipment, and other causes during
periods when the excavations are left open.
6 The Contractor shall plan the Works so that no
excavation is left in an exposed condition for a period
greater than 30 days unless otherwise approved.
7 Where excavation is adjacent to public highways and
walkways, warning lights, barriers and barricades shall be
provided to the Engineer’s satisfaction. No excavation
shall be left in an exposed condition for more than 7 days
unless otherwise approved.
8 For excavation in material sensitive to moisture (stiff
clays, marls, etc.) the excavation shall be cleaned and a
concrete blinding layer cast immediately on completion of
the excavation.
9 The Contractor shall notify the Engineer of any sign
of failure or cracks within or around the excavation
immediately when such signs are noticed.
2.7.2.2 Temporary Support System
1 When a temporary support system is required to
protect adjacent property or to protect the public during
construction, the Contractor's design for such support
system shall be submitted for approval prior to
commencing its construction.
2 All temporary support systems shall be designed
with adequate factors of safety to serve with minimal
maintenance, for the duration of its intended use, and
shall include adequate safety provisions to protect the
public from construction activities.
3 Notwithstanding any approval of temporary support
systems, the Contractor shall be solely responsible for the
adequacy of their design and construction and for
maintenance and all necessary safety precautions
associated therewith.
♦ 2-16 ♦
2.7.2.3 Excavation for Major Structures and Bridges
1 Foundations for buildings, pump houses and other
major structures and bridges, shall be excavated in
accordance with the dimensions as shown on the
Drawings and shall be of sufficient size to permit placing
of the full width and lengths of the footings.
2 Excavation shall be carried down to the levels shown
on the Drawings or as established by the Engineer based
on previous investigations. No concrete shall be placed
prior to approval of the excavation pit.
3 Unless shown otherwise on the Drawings, the
bottom of all excavations shall be covered with a 75mm
minimum depth of lean (blinding) concrete Class 15 to
serve as a working platform.
4 Foundation pits or trenches shall be of sufficient size
and provide minimum sufficient working space to permit
construction of structures or structure footings of the full
width and length shown on the Drawings.
5 Where footings are constructed using formwork, the
excavations shall generally not extend more than 500 mm
beyond the maximum dimension on each side of the
proposed footing unless additional working space is
clearly required and approved by the Engineer. Any
unauthorized overwidth of excavation beyond the lateral
limits or depths shown on the drawings or approved by
the Engineer shall be backfilled with selected fill or lean
concrete as directed by the Engineer at the Contractor’s
expense.
6 Where footings are located, in or adjacent to firm,
original ground and where formwork is not required or
ordered, any unauthorized overdepth excavation below
the approved elevation of base of footing shall be
backfilled with blinding concrete.
7 Where excavation to rock foundation is required, the
excavation shall proceed in such a manner as to allow the
solid rock to be exposed and prepared in horizontal beds
or properly serrated for receiving the concrete. All loose
and disintegrated rock and thin strata shall be removed.
8 When unstable material or other unsuitable material
is encountered below foundation elevation, the Contractor
shall excavate such material and replace it with suitable
backfill material or concrete to the depth as directed by the
Engineer.
9 If temporary works are required for maintaining the
excavation dry, the Contractor shall be responsible for the
design and execution of the works. The proposed design
shall be submitted to the Engineer for approval but, such
approval shall not relieve the Contractor of his sole
responsibility in this regard.
2.7.2.4 Excavation for Box Culverts, Pipe Culverts and
Miscellaneous Structures
1 Excavation shall be carried out to the limits required
for construction and to the depth required for bedding
material or removal of unsuitable material. All trench
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excavation shall proceed upgrade, commencing at the
downstream end.
2 Foundation material supporting the bedding or
structure shall be AASHTO M 145 Class A-1-a, A-1-b or A-
2-4 compacted to 95% AASHTO T 180 maximum density.
If the natural material does not meet the classification
requirements, it shall be sub-excavated to a depth of at
least 200mm and replaced with material meeting the
specified requirements. Any rock or hard material within
200 mm of the bottom of the pipes shall be similarly sub-
excavated and replaced with material meeting the
specified requirements.
3 If no special bedding material is required, the
foundation for precast and prefabricated culverts shall be
formed to the shape of the culvert, including all
protrusions. The shaping shall extend to 25% of the
height of culvert.
4 Where rock is encountered in the toe wall excavation
for concrete box culverts or concrete cut-off-walls for
floodway, embankment protection and pipe culverts and
the rock is of such quality as will prevent erosion, part of
the toe wall may be eliminated in the rock strata as
directed and the toe wall shall be keyed into the rock strata
in a satisfactory manner. The minimum thickness of the
key shall be as shown on Drawings or as instructed by the
Engineer.
5 Precast concrete pipes and metal pipes shall be
installed in trenches cut into previously constructed and
compacted embankment or from top of sub-grade. Unless
otherwise shown on the Drawings, trench width shall not
be greater than the external diameter of the pipe plus 500
mm on each side.
6 In the case of metal pipes, the bottom of the trench
shall be shaped to a template so that at least 10% of the
overall height of pipe or arch will be in contact with the
bottom of the trench as excavated. Recesses shall be
excavated to receive any parts of the pipe which extend
below the outside perimeter. Where rock, hardpan or
other unyielding material is encountered it shall be
removed below design grade or as ordered by the
Engineer for a depth of at least 200 mm and backfilled as
specified.
7 Trenches for cast in-situ pipes shall be cut into
previously constructed and compacted embankment from
top of sub-grade or embankment height or twice the
nominal span of the pipe whichever is less. Trench width
shall not be greater than the external diameter or span of
pipe plus 500 mm on each side when external forms are
used, or the external span of pipe including protection
plus 100 mm on each side when external forms are not
used.
8 When excavation is required for installation of ducts,
the Contractor shall notify the Engineer upon completion
of the excavation. No duct shall be laid until the depth
and cross section of the excavation has been approved.
9 Over-width or over-depth excavation for precast
concrete pipes shall be made good at the Contractor's
expense by provision of an in situ concrete cradle or
increased thickness of concrete bedding as directed, or by
the use of other approved suitable materials.
10 Over width excavation for in situ concrete pipes shall
be made good at the Contractor's expense by concrete
bedding brought up to the external haunch of the pipe or
by the use of other approved suitable materials.
11 Over depth excavation for metal pipes shall be made
well by furnishing and backfilling an approved, fine
granular material containing not more than 0.5% of
combined chlorides and sulfates.
2.7.3 Backfilling
2.7.3.1 General
1 The Contractor shall obtain approval for his proposed
method and rate of placing of backfill before work
commences.
2 Backfill materials shall be uniformly graded granular
material, capable of being compacted to required
compaction, and having adequate permeability to permit
free drainage through it. Backfill material shall also
conform to the requirements listed in Table 2.7.3.1 below:
Surface Requirements
Minimum D10 value 1 mm
Maximum Plasticity Index 10 per cent
Requirements for bridges, culverts etc. shall be as
specified in subsequent sections
Table 2.7.3.1: Requirements for Backfill Materials
3 Backfill material shall not be placed against any
structure until approval is given. Unless otherwise shown
on the Drawings structures shall be backfilled to the same
requirements as specified for the adjacent embankment.
4 Backfill shall be placed in level layers for the full
width of the excavated area until the elevation of the
original ground or surrounding embankment is reached.
Backfill next to walls, between columns or in other
confined areas, shall be compacted by approved hand or
portable equipment.
5 Each successive layer of backfill shall contain only
sufficient material to ensure proper compaction and in no
case shall any layer be greater than 150 mm thickness
(after compaction). The moisture content of the backfill
material shall be uniform and within the moisture range
designated. Backfill material shall be compacted to 95% of
the maximum density as determined by AASHTO T 180
(Method D).
6 Jetting of fills or other hydraulic methods involving
or likely to involve liquid or semi-liquid pressure will not
be permitted.
7 Water shall be drained from the areas to be backfilled
wherever practicable. In cases where, in the opinion of
the Engineer, it is not practicable to drain the areas to be
backfilled, the initial backfill material shall consist of
♦ 2-17 ♦
copy 249
crushed, open graded material conforming to
gradation given in Table 2.7.3.2 below:
ASTM Sieve Percentage Passing Size
3/8" 100
No. 4 < 85
No. 30 < 45
<5
No. 200
Table 2.7.3.2: Requirements for Open Graded Backfill -
Gradation
Such material may be deposited below the standing water
level without compaction. Above the water level normal
laying and compaction will be considered.
8 Additional water to be added during placement of
backfill material to achieve required compaction shall be
fresh water or brackish water approved by the Engineer.
9 Minimum tests required during backfilling operations
to verify material are:
- One Proctor test for each structure.
- One gradation of materials when materials
changed.
- One plasticity index and field density for 50%
of the layers and for each footing and
abutment as instructed by the Engineer.
2.7.3.2 Backfilling for Box Culverts, Pipe Culverts,
Bridge and Building Foundations, Walls,
Abutments and Miscellaneous Structures
1 Structures shall not be subject to the pressures of
backfilling or to live loads until the 28-day strength of the
concrete has been reached, unless a shorter period is
approved in special circumstances where the load is
sufficiently small as not to constitute a risk of any damage
to the structure in the opinion of the Engineer. This period
may be extended if subnormal curing conditions exist.
2 Backfill placed around culverts shall be deposited on
both sides to approximately the same level at the same
time. Special care shall be taken to prevent any wedging
action against the structure and slopes bounding the
excavation shall be stepped, where necessary, to prevent
such wedge action occurring.
3 All backfill intended to support false work loads,
including temporary fills shall be selected to support the
required load. As a minimum, such material shall be
AASHTO M 145, Class A-1-a, A-1-b or A-2-4, compacted to
90% of the maximum density as determined by AASHTO T
180 (Method D).
4 Backfill around bridge and building foundations,
abutment walls and retaining walls shall be completed to
the level of the original ground line and to such heights
above original ground line or to the levels as shown on
the Drawings. Care shall be exercised to prevent forward
movement of the wall.
♦ 2-18 ♦
the 5 Unless shown otherwise on the Drawings, when
special permeable backfill (sheathing) is to be placed
against the back faces of retaining walls or wing walls, it
shall consist of a continuous covering of approved type
proprietary filter cloth protected by a continuous wall of
200mm minimum thickness precast, porous (no-fines)
concrete blocks laid with dry joints. Prior to construction
of the block wall, ensure that all underdrains or perforated
pipes are laid along the base of the wall under the
sheathing, as shown on the Drawings.
6 Backfill material for culverts, pipe culverts and
miscellaneous structures within 300 mm of any part of the
structure shall be Class A-1-a, A-1-b or A-2-4. The 200 mm
minimum thickness of sub-grade layer shall consist of
approved sub-grade material placed and compacted to
100% maximum density as specified under Sub-section
2.6 – ‘Sub-grade Construction’. The backfill shall be
completed to the level of the original ground or to the top
elevation of any adjacent embankment.
7 Backfilling around and over pipe culverts shall not
commence until headwalls and wingwalls have been
constructed and attained the specified 28-day strength.
8 Water used for compaction of backfill around metal
pipes and reinforced concrete structures shall be from an
approved source and shall not contain more than 0.5%
combined chlorides and sulphates nor contain other
potentially harmful minerals.
9 When pipes or other structures temporarily extend
above the grade of the partially constructed embankment,
the Contractor shall construct the fill over the structure of
sufficient depth to protect the structure from any damage
resulting from construction or other traffic.
10 The Contractor shall complete the backfill around box
culverts to the level of the original ground line and to the
full width of excavation area. If the top of culvert extends
above the original ground line the Contractor shall
continue the backfill to the top of culvert and for a width of
3 m on each side of the culvert for the full width of
roadway embankment. If the embankment is in place at
the time of backfilling, the Contractor shall backfill around
the culvert to the top of embankment.
11 Backfill around pipe culverts shall be completed to
the level of original ground line and to the full width of
excavation area. If the top of the culvert extends above
the original ground line the Contractor shall continue the
backfill to the top of culvert for a width of 1.5 times the
maximum external width of the culvert on each side of the
culvert centerline to the full width of the roadway
embankment. If the embankment is in place at the time of
backfilling, the Contractor shall backfill around the culvert
to the top of culvert or as shown on the Drawings.
12 Any existing roadway pavement cut through,
damaged or removed during excavation for pipe culvert
installation shall be reinstated, after pipe installation and
trench backfilling, using approved base and surfacing
course materials at least equivalent to those in the original
pavement. Materials and construction shall conform to the
copy 249
relevant requirements Sections 3 and 4 of this
specification.
13 Miscellaneous structures other than pipe culverts
shall be backfilled in accordance with the methods
specified. Compaction of backfill when structures are
outside the roadway right-of-way or in approach roads,
minor roads or similar areas, shall be to 90% of maximum
density as determined by AASHTO T 180 (Method D).
2.7.4 Method of Measurement
1 All structural excavation, of whatever type, shall be
measured as ‘unclassified’ which shall be deemed to
include all materials encountered of any nature, including
silts, clays, sand, gravel and granular materials and
fractured, jointed and solid rock.
2 Structural excavation is measured by cubic meter of
material excavated for the major structures hauled away
and disposed of as directed, or stockpiled. Measurement
of structural excavation shall be from original ground
levels or ground levels after removal of all unclassified
highway excavation. Limits shall not be greater than
vertical planes 500 mm from the maximum dimension, on
each side of the footing or other controlling portion of the
structure. Where structures are constructed against
natural ground or rock, excavation limits shall be the
dimensions of the structure as shown on the Drawings.
Bottom limits shall be the ordered foundation levels. Only
material excavated from its original position shall be
measured for payment. No measurements shall be made
of structural excavation in embankments previously
constructed by the Contractor.
3 Additional excavation in unstable material or other
unsuitable material encountered below foundation level
shall be measured as part of the unclassified structural
excavation.
4 Structural Excavation under Water shall be measured
by cu.m. of material excavated for the major structures,
hauled away and disposed of as directed, or stockpiled on
or in the vicinity of the Works, and the excavated areas
backfilled, completed and accepted.
5 Unauthorized overdepth and overwidth excavation in
soil and rock and the backfill material including blinding
concrete required in such cases, shall not be measured for
direct payment, but shall be considered as subsidiary work
the costs of which will be deemed to be included in the
rates for structural excavation
6 Structural excavation in any material or under water
for box culverts less than one sq.m. in external cross
section, and structural excavation for pipe culverts,
underdrains (subsoil drains), pits, catchbasins, manholes,
inlets, energy dissipaters, slope protection, fence posts,
guardrail posts, lighting columns, sign posts, signal
supports and all other minor structures, shall not be
measured for direct payment, but shall be considered as
subsidiary work the costs of which will be deemed to be
included in the rates and prices for the relevant items..
7 Unless specified otherwise in the special
specifications, temporary cofferdams, temporary support
system, bailing, drainage, dewatering, pumping, sheeting,
concrete blinding layers and all other Temporary Works
shall not be measured for direct payment, but shall be
considered as subsidiary work the costs of which will be
deemed to be included in the rates for structural
excavation.
8 Backfilling to structural excavation shall not be
measured separately but is considered as subsidiary work
the cost of which are deemed to be included in the rates
for structural excavation
9 Any blinding concrete used at the bottom of
excavations, as shown on the Drawings or as instructed by
the Engineer shall be measured and paid for in accordance
with the relevant method of measurement under Clause
5.1.5 of Section 5 ‘Concrete and Concrete Structures’.
2.7.5 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities ,
which rate shall be full compensation for equipment, tools,
labor, materials, transporting, hauling, placing, and for
other items necessary for the proper completion of the
work.
2.7.6 Items in the Bill of Quantities
i. Unclassified structural excavation
(depth 0 to 2m) (cu.m.)
ii. Unclassified structural excavation
(2m < depth < 4m) (cu.m.)
iii. Unclassified structural excavation
(depth > 4m) (cu.m.)
iv. Structural Excavation under Water (cu.m.)
2.8 EARTHWORK FOR PIPE
TRENCHES
2.8.1 Description
1 This Sub-section describes requirements for
excavation of trenches in any material for water supply,
sewage, stormwater drainage and irrigation pipes, and all
other associated works, including all necessary clearing
and grubbing, bailing, draining, shoring, planking,
strutting and supporting the sides of excavation. The work
includes backfilling with suitable approved material and
disposal of the excess material to designated and
approved tip locations.
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2.8.2 Materials i. For pipes not exceeding 65 mm diameter:
Nominal diameter plus 300 mm.
2.8.2.1 Backfill Material ii. For pipes over 65 mm and not exceeding 600
1 Initial backfill (up to 300 mm above the top of the mm diameter: Nominal diameter + 600 mm.
pipe) shall be selected fill, sand or other approved material iii. For pipes over 600 mm diameter: Nominal
and shall conform to the following: diameter + 1000 mm.
7 Where the above specified trench widths are
Standard Percent by Weight Percent by exceeded; the Contractor shall provide additional pipe
Sieve Size Passing for Pipes Weight Passing
protection or pipes of increased strength if the Engineer
(mm) other than uPVC for uPVC Pipes
calls for such measures, all at his own expense.
19 100 -
8 Excavation of trenches with battered sides will not be
4.76 25 – 100 100 permitted within 4m of any building or other structure.
9 When the pipes are to be laid in embankments or
1.19 10 – 75 25 – 75
other fill areas, the embankment or fill area shall first be
0.354 5 – 30 10 – 30 filled and compacted as specified to the proposed finished
grade or to a height of at least 300 mm above the top of
0.177 3 – 10 3 – 10
pipe whichever is lower. The trench shall then be
0.074 0–5 0–5 excavated as in undisturbed material.
10 When pipes are to be laid under existing pavements,
Table 2.8.2-1: Requirements for Initial Backfill - Gradation
trenches shall be excavated carefully and to minimum
2 For GRP pipes, graded crushed stone 2.83-8 mm shall widths. Methods that will give straight and vertical face
be used for initial backfilling. shall be used. The pavement shall be kept at its original
level and condition.
3 The remainder of the trench shall be backfilled with
suitable material either from material removed in the 11 In combined trenches where one pipe is at a lower
course of excavating the trench, or imported from level than an adjacent pipe the following shall be applied:
approved borrow pit. In either case the backfill material i. The whole trench shall have a depth related to
shall be non-plastic. The percentage by weight passing a the lower pipe and the thickness of the bedding
No. 200 (0.075 mm) sieve shall not exceed 15%. The shall be increased to the upper pipe as
percentage passing a 63 mm sieve shall be 100. necessary.
ii. The lower pipe shall be backfilled with
2.8.3 Construction thoroughly compacted granular material up to
a level of 0.30 meters above the higher pipe.
2.8.3.1 Excavation for Pipe Trenches
12 Final excavation to the correct grade level for trench
1 The Contractor shall not commence excavation of beds shall be carried out immediately before laying beds
any section of work until a full supply of pipes and fittings or pipes. Unstable material, rock projections, boulders and
is available for that section. hard spots shall be removed and replaced with approved
2 During excavation, material suitable for backfilling filling material, that will be compacted as instructed. Local
shall be piled at sufficient distance from the sides of the soft spots shall be compacted by tamping in bedding
trench as to avoid overloading and prevent cave in. All material.
excavated material not required, or unsuitable for 13 The bottoms of trenches shall be accurately graded
backfilling shall be removed and carted away to an to provide uniform bearing and support for the bottom
approved dumping area. quadrant of each section of the pipe. Bell holes shall be
3 Trenches shall be excavated to such depths as will excavated to the necessary size at each joint or coupling to
permit the pipes to be laid at elevations, slopes or depths eliminate point bearing. Any material that may cause point
of cover indicated on the drawings, and at uniform slopes bearing shall be removed.
between indicated elevations. 14 The Contractor shall report to the Engineer any
4 Where excavation depth exceeds the level indicated unsuitable or weak ground material that may be found
on the drawings and is not authorized in writing by the below the indicated excavation levels before executing
Engineer, the Contractor shall place backfill or concrete to any trimming of the excavation, pipe laying, concreting, or
the required bottom level, as instructed by the Engineer, other work. Where, in the judgment of the Engineer the
all at his own expense. bottom of the trench is unsuitable, such material shall be
removed to the width and depth ordered by the Engineer.
5 Trenches shall be excavated with vertical sides
The trench shall then be made up by backfilling with
between the bottom level and 300 mm above the top of
approved material.
the pipe.
15 Where rock is encountered, the trench shall be
6 Trench width up to 300 mm above the crown of the
excavated to 150 mm below bed level and replaced with
pipe shall not exceed the following:
granular material, concrete, or blinding grade as directed.

♦ 2-20 ♦
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2.8.3.2 Backfilling
1 Trenches shall not be backfilled at joints until after
that section of the pipeline has successfully passed the
specified tests.
2 Initial backfill or surround up to a level of 300 mm
above top of the pipe, shall be placed and hand
compacted in 150 mm layers. The backfill shall be brought
up evenly on both sides of the pipe for the full length of
the pipe. Care shall be taken to ensure thorough
compaction of the fill under the haunches of the pipe.
3 Suitable backfill shall be placed and well compacted
in layers not exceeding 150 mm thick after compaction.
Heavy compactors shall not be used until there is 600 mm
cover over pipes.
4 Unless otherwise specified each layer shall be
compacted to at least 95% maximum density for
cohesionless soils and 90% maximum density for cohesive
soils.
5 Backfilling trenches for pipes with concrete beds and
or surrounds shall not start before 24 hours after placing
concrete. Heavy compactors shall not be used and traffic
shall not be allowed before the elapse of 72 hours after
placing the concrete.
6 When the backfill material is too wet from rain or
excessive application of water, no compaction shall be
done. In this case the work shall be suspended until the
previously placed and new materials have dried
sufficiently to permit proper compaction. Other measures
shall be taken if necessary to obtain proper compaction.
7 Temporary crossing are to be provided over trenches
to prevent construction traffic damaging pipes after
backfilling.
2.8.3.3 Restoration of Surfaces
1 Restoration of asphalt, concrete, gravel pavements
and the likes shall be of materials and thickness to match
the existing pavement. Materials and workmanship shall
be in accordance with local authority requirements and as
directed by the Engineer.
2 Restoration of pavement shall be done according to
the existing pavement quality and level to ensure that new
pavement matches the existing to provide uniform surface
with the existing profile.
3 Grassed areas shall be restored by spreading
approved fertile soil over affected area after backfilling.
Seeding, fertilizers and water shall be applied until grass is
restored to its former condition.
4 Surface grading shall be carried out to restore all un-
surfaced areas and any adjoining areas disturbed to
provide a level, smooth surface.
5 The Contractor shall proceed with restoration of
surfaces as soon after completion of other work as is
practicable, but in no case more than 10 days after
backfilling of trenches and other excavated areas.
Restoration shall be completed within 20 days from the
start of restoration.
2.8.4 Method of Measurement
1 Trench excavation and backfill shall be paid for per
cu.m. measured in horizontal layers for the different depth
categories shown in the Bill of Quantities. Trench length
shall be measured between outer surfaces of manholes or
chambers. Trench width shall be as specified or shown on
Drawings. Depth of excavation shall be the depth of every
horizontal layer. Excavation for bedding is included as
trench excavation.
2 Rates for trench excavation and backfill shall include
for:
i. Excavating in any material encountered
including rock.
ii. Blasting, barring, wedging or other quarrying
methods for rock excavation.
iii. Excavation at any level.
iv. Excavating curved on plan.
v. Allowance for working space.
vi. Increase in bulk for excavating.
vii. Excavating below water table and dewatering
as necessary.
viii. Keeping excavations free from water.
ix. Leveling, compacting, trimming and grading
bottoms and trimming sides and bottoms of
excavation.
x. Supporting the sides of excavation.
xi. Filling with material as specified and
compacting around pipes and beds multiple
handling of excavated material and excavation
from borrows and transporting about the Site.
xii. Segregation of the various classes of excavated
spoil and stock piling as may be directed by the
Engineer.
xiii. Disposal of surplus excavated material
including depositing and consolidating where
directed on Site or removing from Site and
depositing at a tip to be provided and paid for
by the Contractor.
xiv. Pipe bedding, initial backfill or gravel, and final
backfill.
xv. Filling over-excavation with material as
specified
xvi. Consolidation of primary backfill (initial
backfill) material using water or hand tamping.
xvii. Compaction of secondary backfill (main
backfill) material.
xviii. Reinstatement of unpaved surfaces.
(Reinstatement of paved surfaces shall be
made and paid for according to Sections 4 or
12 as appropriate)
2.8.5 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities,
which rate shall be full compensation for equipment, tools,
labor, materials, transporting, hauling, placing, and for
♦ 2-21 ♦
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other items necessary for the proper completion of the
work.

2.8.6 Items in the Bill of Quantities

i. Trench excavation and backfilling (Depth up to 2m)
ii Trench excavation and backfilling (Depth > 2m < 3m)
iii Trench excavation and backfilling (Depth > 3m < 4m)
iv Trench excavation and backfilling (Depth > 4m)

♦ 2-22 ♦
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Ref. Title Page No. Ref. Title Page No.
3.1 Materials for Sub-Base 3.3.3.8 Maintenance of Completed Base 3-7
and Base Courses 3-1 3.3.3.9 Testing 3-7
3.3.4 Method of Measurement 3-8
3.1.1 Description 3-1
3.3.5 Basis of Payment 3-8
3.1.2 Materials 3-1
3.3.6 Items in the Bill of Quantities 3-8
3.1.3 General Requirements for Materials 3-1
3.1.3.1 Sources and Production 3-1 3.4 Stabilized Base Courses 3-8
3.1.3.2 Stockpiling 3-1
3.4.1 Description 3-8
3.1.3.3 Sampling and Testing 3-1
3.4.2 Materials 3-8
3.2 Granular Sub-Base Course 3-2 3.4.2.1 Soil for Cement Stabilisation 3-8
3.4.2.2 Cement as Stabilising Agent 3-8
3.2.1 Description 3-2
3.4.2.3 Bitumen as Stabilising Agent 3-9
3.2.2 Materials 3-2
3.4.2.4 Lime as Stabilising Agent 3-9
3.2.3 Construction Requirements 3-2
3.4.2.5 Water 3-9
3.2.3.1 Subgrade Surface Preparation 3-2
3.4.2.6 Mix Design 3-9
3.2.3.2 Equipment 3-3
3.4.3 Construction Requirements 3-9
3.2.3.3 Construction of Trial Sections 3-3
3.4.3.1 Surface Preparation 3-9
3.2.3.4 Stockpiling of Granular Material 3-3
3.4.3.2 Construction of Trial Section 3-9
3.2.3.5 Mixing and Spreading 3-3
3.4.3.3 Cement Stabilisation Procedures –
3.2.3.6 Compaction 3-3
Plant Mixing 3-10
3.2.3.7 Tolerances 3-4
3.4.3.4 Cement Stabilisation Procedures -
3.2.3.8 Maintenance of Completed Sub-base 3-4
Batch Mixing 3-10
3.2.3.9 Testing 3-4
3.4.3.5 Cement Stabilisation Procedures -
3.2.4 Method of Measurement 3-4
Continuous Mixing 3-10
3.2.5 Basis of Payment 3-4
3.4.3.6 Cement Stabilisation Procedures -
3.2.6 Items in the Bill of Quantities 3-4
Mixed in Place Procedures 3-10
3.3 Aggregate Base Course 3-5 3.4.3.7 Cement Stabilisation Procedures -
Placing of Stationary Plant Mixes 3-11
3.3.1 Description 3-5
3.4.3.8 Cement Stabilisation Procedures -
3.3.2 Materials 3-5
Compaction and Finishing 3-11
3.3.2.1 Crushed Stone Aggregate 3-5
3.4.3.9 Curing of Cement Stabilised Courses 3-12
3.3.3 Construction Requirements 3-6
3.4.3.10 Testing of Cement Stabilised Courses 3-12
3.3.3.1 Surface Preparation 3-6
3.4.3.11 Bitumen Stabilisation Procedures -
3.3.3.2 Equipment 3-6
Mix Design 3-12
3.3.3.3 Construction of Trial Sections 3-6
3.4.3.12 Bitumen Stabilisation Procedures -
3.3.3.4 Stockpiling of Aggregate Materials 3-6
Stationary Plant Mixing 3-12
3.3.3.5 Mixing and Spreading 3-6
3.4.3.13 Bitumen Stabilisation Procedures -
3.3.3.6 Compaction 3-6
Mixed in Place Procedures 3-12
3.3.3.7 Tolerances 3-7

♦ 3-0 ♦
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Ref. Title Page No.
3.4.3.14 Bitumen Stabilisation Procedures -
Placing and Spreading Stationary
Plant Mixes 3-12
3.4.3.15 Bitumen Stabilisation Procedures -
Compaction and Finishing 3-12
3.4.3.16 Bitumen Stabilisation Procedures -
Tolerances and Replacement
of Unsatisfactory Areas 3-12
3.4.3.17 Bitumen Stabilisation Procedures -
Testing of Bitumen Stabilised Courses 3-13
3.4.3.18 Lime Stabilisation Procedures -
Mix Design 3-13
3.4.3.19 Lime Stabilisation Procedures - Safety
Precautions 3-13
3.4.3.20 Lime Stabilisation Procedures -
Stationary Plant Mixing 3-13
3.4.3.21 Lime Stabilisation Procedures - Mixed
in Place Procedures 3-13
3.4.3.22 Lime Stabilisation Procedures - Placing
and Spreading Stationary Plant Mixes 3-13
3.4.3.23 Lime Stabilisation Procedures -
Compaction and Finishing 3-13
3.4.3.24 Lime Stabilisation Procedures –
Tolerances and Replacement
of Unsatisfactory Areas 3-13
3.4.3.25 Testing of Lime Stabilised Courses 3-14
3.4.4 Method of Measurement 3-14
3.4.5 Basis of Payment 3-14
3.4.6 Items in the Bill of Quantities 3-14

♦ 3-0 ♦
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3.1 Materials for Sub-Base and Base
Courses
3.1.1 Description
1 This Sub-section describes general requirements for
materials for construction of granular sub-base, aggregate
base and stabilised base courses, all as and where shown
on the drawings.
3.1.2 Materials
1 Materials for use in the construction of the sub-base
and base courses for flexible and rigid pavements may
include any or all of the following:
i. Screened or partially crushed granular material,
consisting of well graded gravel including sand
and silt, or crushed stone or crushed gravel for
sub-base course construction.
ii. Crushed stone for base course construction.
2 All material sources and the quality of materials shall
be approved prior to procuring or processing material
from such sources. Inspection, sampling, testing and
retesting as necessary, shall be as specified hereunder for
specific materials.
3 Storage and handling of all materials shall conform
to the relevant requirements of this specification and as
approved by the Engineer. Materials shall be stored on
hard, clean surfaces or as directed by the Engineer.
3.1.3 General Requirements for Materials
3.1.3.1 Sources and Production
1 The Contractor shall be responsible for locating
sources and manufacturers of materials in accordance
with the requirements of this Specification in the
quantities and rates of production needed to complete the
work on time.
2 The Contractor shall satisfy himself as to the location,
suitability and quantity of materials available; extent of
work necessary to obtain the materials, and to crush,
screen and wash them; and the length of haul to the Site.
3 Prior to starting quarry or borrow pit operations; the
Contractor shall obtain written permission from the
authorities or owners concerned.
4 Screening plants or crushing and screening plants
shall not be put into operation until approved by the
Engineer. If, after any plant is put into operation, it fails to
perform as intended, the Contractor shall either rectify the
defects in the existing plant to the satisfaction of the
Engineer, or shall provide alternative approved plant.
5 Approval of the crushing and screening plants and
other equipment shall in no way relieve the Contractor of
his responsibilities in respect of producing granular
materials and aggregates which conform to this
Specification and in the quantities required for the
completion of the work on time.
3.1.3.2 Stockpiling
1 Stockpile areas shall be surveyed prior to stockpiling
to establish control points and to obtain a record of
existing cross sections for future use in determining
stockpile quantities. The areas shall be adequately drained
at all times.
2 Stockpiling procedures shall not result in noticeable
degradation or segregation of the stockpiled material, or
introduction of foreign materials into the stockpile, or
coning. Heights of granular material and aggregate
stockpiles shall not exceed 3 m berms.
3.1.3.3 Sampling and Testing
1 The Contractor shall submit to the Engineer, 10 days
prior to the scheduled beginning of crushing and
screening operations, a statement of origin indicating the
aggregate source and the quarry location and
qualifications, as well as the types and composition of all
stone and/or gravel aggregates and granular materials
proposed for use in the work.
2 Samples for testing shall be taken by the Contractor,
in the presence of the Engineer. Duplicate samples shall
be submitted to the Engineer for future reference, if
instructed. Sampling shall be in accordance with AASHTO
T2. The Contractor shall conduct the tests in the site
laboratory, or have the tests carried out at an approved
external laboratory.
3 In order to ascertain the properties of granular and
aggregate materials, the Contractor shall submit for
testing representative samples of all materials intended
for incorporation in the work, prior to starting quarry or
borrow pit operations. The representative samples shall
be taken by the Contractor in the presence of the Engineer.
4 Tests performed by the Contractor shall be utilized in
assessing the locations, extent of deposits and quantities
of materials which, when properly processed, will conform
to this Specification, and shall in no way obviate the need
for further testing by the Engineer. Approval of specific
sources of materials shall not be construed as final
approval and acceptance of materials from such sources.
5 Processed materials shall be tested and approved
before being stockpiled on Site or incorporated in the
work and may be inspected and tested at any time during
their preparation, storage and use. Materials awaiting
testing and approval shall not be unloaded and mixed
with materials previously approved. If the grading and
quality of any materials delivered to the Site do not
conform to the grading and quality of the established
control samples, the Engineer will reject such materials.
6 The Contractor shall permit the Engineer to inspect
any and all materials used or to be used, at any time
during or after their preparation, or while being used..
Unsatisfactory materials, whether in place or not, shall be
removed promptly from the Site. The Contractor shall
furnish all necessary labor, transport, tools and equipment
required by the Engineer for such inspections.
♦ 3-1 ♦
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3.2 Granular Sub-Base Course accordance with AASHTO T 96 (Los Angeles Abrasion
Test).

3.2.1 Description 6 The granular material shall have a 4-day soaked CBR
of not less than 60% when compacted at 100% of modified
1 This Sub-section specifies standards for granular proctor AASHTO (T 180-D) and tested in accordance with
sub-base material, mixing, spreading on prepared AASHTO T 193.
subgrade, compacting and finishing.
7 When tested for soundness in accordance with
AASHTO T 104, the material shall not show signs of
3.2.2 Materials
disintegration, and the percentage loss in weight after 5
1 Granular material for use in sub-base courses shall cycles shall not exceed 12% in the case of the sodium
be naturally occurring gravel, blended as necessary with sulfate test and 18% in the case of the magnesium sulfate
fine or coarse material and screened to produce the test.
specified gradation. Crushing of natural granular material 8 The portion of granular material, including any
shall not normally be required, unless for the purpose of blended material, passing the 0.425 mm (No. 40) mesh
meeting the gradation requirements, or, when shown on sieve shall have a liquid limit (L.L.) of not more than 25
the Drawings, to produce a higher quality sub-base with and a plasticity index (P.I.) not greater than 6 when tested
improved mechanical stability. in accordance with AASHTO T 89 and T 90.
2 Gravel shall consist of hard, durable and sound 9 If additional fine material is required to correct the
stones, free from dirt, organic matter, shale or other gradation of the granular material, or for adjusting the L.L.
deleterious substances. or P.I. of the fraction passing 0.425 mm (No 40) sieve, it
3 Granular materials shall meet the requirements of shall be uniformly blended and mixed with the granular
Class A, B or C shown in Table 3.2.2.1, and as specified on material. Additional fine material for these purposes shall
the Drawings, when tested in accordance with AASHTO T- be obtained from the crushing of stone, gravel, or slag.
27 after dry mixing and just before spreading and 10 The granular material shall not contain more than
compacting. The class of granular material shall be as 3 % gypsum and shall be free from organic content.
shown on the Drawings or otherwise as selected by the
11 The granular material shall have a minimum sand
Engineer based upon the test results of the materials
equivalent value of 28, when tested in accordance with
survey, and projected traffic. The actual gradation shall, in
ASTM D2419.
all cases, be continuous and smooth within the specified
limits for each class. 12 The maximum permitted swell for the granular
material used in the sub-base courses shall be 1.0%, when
Percent by weight passing tested in accordance with ASTM D4829.
Sieve Designation
(square openings) 13 The Granular Sub-base Course material shall have
Class A Class B Class C
chloride content of less than 3.5 percent and sulphate
content of less than 2.0 percent when tested in accordance
63 mm 100 - -
with BS 812.
50 mm 90 - 100 100 - 14 Only potable water shall be used for mixing granular
sub-base material.
37.5 mm - 70 - 100 -

25 mm - 55 - 85 100 3.2.3 Construction Requirements

19 mm - 50 - 80 - 3.2.3.1 Sub-grade Surface Preparation

1 Prior to subgrade surface preparation, the sub-grade

9.5 mm - 40 - 70 50 - 85
shall be constructed in accordance with the requirements
4.75 mm 35 - 70 30 - 60 35 - 65 of Sub-section 2.6 and properly maintained and kept well
2.00 mm - 20 - 50 25 - 50 drained thereafter.

0.425 mm - 10 - 30 15 - 30 2 At all special grade control points, such as at bridge

0.075 mm 0 - 10 5 - 15 5 - 15
Table 3.2.2.1: Gradation of Granular Sub-Base Material by
Class
4 The material shall not contain more than 5% clay
content at any stage of construction when tested in the
Hydrometer Test in accordance with AASHTO T88.
5 The loss in weight of granular material shall not
exceed 40% after 500 revolutions, when tested in
structures, existing pavements, etc the sub-grade shall be
lowered to a depth sufficient to permit construction of the
sub-base course to the specified elevations and thickness.
Transitions shall be of sufficient length to avoid abrupt
changes of grade and shall be within plus or minus 3% of
the final design grade unless otherwise directed. Surplus
material shall be removed and disposed of.
3 The sub-grade shall be inspected and approved
immediately prior to commencement of sub-base
construction. Any soft, yielding material shall be removed

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and replaced by approved topping material. Holes,
depressions and other irregularities shall be made good as
directed and the subgrade re-compacted as necessary and
finished ready to receive the sub-base course.
3.2.3.2 Equipment
1 Equipment used to handle, place, spread, water,
compact and finish sub-base shall conform with the
requirements of Section 19 of these Specifications and
with the Contractor's approved equipment list.
3.2.3.3 Construction of Trial Sections
1 If directed by the Engineer, before commencement of
sub-base construction, the Contractor shall lay and
compact trial sections of varying thickness of sub-base.
Each trial section shall be 2 lanes wide by 50 m long, at
approved locations on or close to the Site. Each trial
section shall be laid using the same materials, mix
proportions, mixing, spreading and compaction
equipment, and construction procedures, proposed for
use in the work.
2 The objectives of these trials shall be to determine
the adequacy of the Contractor's equipment and the loose
depth measurements that will result in the specified
compacted layer depths, to verify the field moisture
content, and to identify the relationship between the
number of compaction passes and the resulting density of
the sub-base material.
3.2.3.4 Stockpiling of Granular Material
1 Stockpiling procedures shall conform to the
requirements of Sub-section 3.1.
2 Methods used for stockpiling granular material and
removing it from stockpiles shall not result in significant
degradation or segregation or the introduction of
significant amounts of foreign materials or extraneous
matter.
3 Granular material adversely affected, in the opinion
of the Engineer, by stockpiling or handling procedures,
shall not be incorporated in the work regardless of
previous approval of such material, until the deficiencies
have been rectified in an acceptable manner.
3.2.3.5 Mixing and Spreading
1 Mixing shall generally be performed in batching
plants. Mixing in stockpiles shall be done only if approved
by the Engineer and under his supervision. The amount of
water added, as approved by the Engineer, shall be such
that the material will be uniform and within the specified
moisture content range at the time of compaction.
Wetting of granular material in trucks before or during
delivery to the Site will not be permitted. However, water
shall be added to the material, if necessary, during placing
and compaction of sub-base material.
2 The sub-base material shall be placed on the
subgrade in a uniform layer or layers not exceeding 200
mm thickness (after compaction) with the necessary
control guide wire requirements. Where the required
thickness is greater than 200 mm but less than 400 mm,
the material shall be placed in layers of equal thickness.
3 If approved by the Engineer, when heavy duty
vibratory compaction equipment is used the maximum
layer thickness may be increased up to 300 mm (after
compaction) provided compaction tests with appropriate
testing equipment based on successful Site trials indicate
that the specified compaction standard will be attained
and will be uniform through the thickness.
4 The sub-base material shall be placed to the required
width using an approved paver/finisher or grader if
approved by the Engineer. However, any pavers or
graders used for placing the sub-base material shall be
equipped with calibrated sensors to maintain the design
levels and thicknesses. Water shall be applied by
approved spraying equipment and thoroughly mixed with
the sub-base material.
5 The material shall not be handled in such a way as to
cause segregation. If the spreading equipment causes
segregation in the material, or leaves ridges or other
objectionable marks on the surface which cannot be
readily eliminated or prevented by adjustment of the
equipment, the use of such equipment shall be
discontinued and it shall be replaced by a spreader or
grader capable of spreading the material in a proper
manner.
6 All segregated material shall be removed and
replaced with well-graded material. ‘Skin’ patching will
not be permitted. Only minor surface manipulation and
watering to achieve the required surface tolerances will be
permitted during the compaction process.
7 Neither hauling nor placement of material will be
permitted when, in the judgment of the Engineer, the
weather or surface conditions are such that hauling
operations will cause cutting or rutting of the subgrade or
cause contamination of the sub-base material.
3.2.3.6 Compaction
1 The Contractor shall plan the sequence of operations
so that the least amount of water will be lost by
evaporation from uncompleted surfaces. If the
uncompleted surface material loses water due to
evaporation, the Contractor shall apply additional water as
required to prevent raveling or excessive drying.
2 The sub-base material shall be compacted by means
of approved compaction equipment, progressing
gradually from the outside towards the center, with each
succeeding pass uniformly overlapping the previous pass.
3 Rolling shall continue until the entire thickness of
each sub-base layer is thoroughly and uniformly
compacted to 100% AASHTO T 180 (Method D) maximum
density. Final rolling of the completed course shall be by
means of an approved self-propelled roller. Rolling shall
be accompanied by sufficient blading, to insure a smooth
surface, free from ruts or ridges and having the proper
♦ 3-3 ♦
copy 249
shape. When additional water is required, it shall be
applied in an approved manner.
4 Any areas inaccessible to normal compaction
equipment shall be compacted by use of portable
mechanical tampers until the required standard of
compaction is achieved.
5 Each layer shall be completely compacted and
approved prior to delivery of materials for the subsequent
layer.
6 Prior to placing a subsequent layer, the existing
surface shall be made sufficiently moist as directed, to
ensure proper bond between the layers.
7 The edges and edge slopes of the sub-base course
shall be bladed or otherwise dressed to conform to the
lines and dimensions shown on the Drawings and to
present straight, neat lines and slopes as free of loose
material as practicable.
8 Material which has dried out prior to final
compaction, or which has dried and de-compacted
subsequent to final compaction, shall be watered and re-
compacted using approved equipment and procedures. If
the Contractor is unable to return the material to its
original or specified condition with respect to compaction,
thickness and surface tolerances, the Contractor shall
remove the material and reconstruct the sub-base course
on a re-approved subgrade.
9 The water shall be clean and free from deleterious
substances. Water from doubtful sources shall not be used
until tested in accordance with AASHTO T26 and approved.
10 Sea, brackish or saline water shall not be used in the
mixing, spreading and compacting operations for
aggregate sub-base course.
3.2.3.7 Tolerances
1 The fully compacted and completed sub-base course
shall conform to the lines, grades and cross sections as
shown on the Drawings.
2 The elevations of the finished sub-base course shall
be checked by the Contractor in the presence of the
Engineer at maximum intervals of 20 m and at
intermediate points as directed.
3 The tolerances on elevations of finished surface shall
be plus 10 mm to minus 20 mm. Minus tolerance shall be
compensated by the subsequent layer.
4 When the finished surface is tested with a 3 m long
straightedge, placed parallel to, or at right angles to the
centerline, the maximum deviation of the surface from the
testing edge between any 2 contact points shall not
exceed 10 mm.
5 All areas which exceed the specified tolerances shall
be corrected by removing the defective sections of sub-
base and reconstructing them or, if approved, by
scarifying, adding new material, or removing extra
material, mixing and re-compacting and finishing to the
specified standard.
♦ 3-4 ♦
3.2.3.8 Maintenance of Completed Sub-base
1 Following completion and acceptance of the sub-
base course, it shall be maintained in good condition prior
to laying the base course.. The sub-base shall be bladed,
broomed and otherwise maintained, keeping it free from
raveling and other defects until such time as the base
course is placed. Water shall be applied at such times and
in such quantities as directed by the Engineer.
3.2.3.9 Testing
1 Every 1000 cu.m. of sub-base material, or whenever
there is a change in the material source, shall be subject to
a full set of tests as listed in Table 3.3.3.1 after placing and,
if found satisfactory, shall be approved for compaction.
This approval shall not be deemed to constitute
acceptance of the sub-base course.
2 Sampling and testing shall conform with the relevant
requirements of this specification and to the satisfaction of
the Engineer.
3 Compaction shall be tested in accordance with
AASHTO T 191 or AASHTO T 205. If there is a delay
between the construction of any layer and the following
layer, if necessary and required by the Engineer the
compaction of the lower layer may be re-verified to ensure
that it has not loosened due to traffic, passage of
construction equipment, adverse weather conditions or
otherwise.
3.2.4 Method of Measurement
1 Granular sub-base course is measured by cu.m. of
compacted sub-base. Measurement shall be of volumes
computed from the cross sections shown on the Drawings
and shall be calculated from the top surface area of each
layer, excluding the tapered edges..
2 No measurement shall be made for direct payment of
overdepth construction, regardless of the Engineer's
permission for it to remain in place.
3.2.5 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities,
which rate shall be full compensation for equipment, tools,
labor, locating sources of supply, supplying materials,
sampling and testing, screening, crushing, transporting,
stockpiling, laying, mixing and compacting and for extra
material in tapered edges, and other items necessary for
the proper completion of the work.
3.2.6 Items in the Bill of Quantities
i. Granular Sub-Base Course (Class A) cu.m
ii. Granular Sub-Base Course (Class B) cu.m
iii. Granular Sub-Base Course (Class C) cu.m
copy 249
3.3 Aggregate Base Course 9 The crushed aggregate base course material shall
have a 4-day soaked CBR of not less than 80% when
3.3.1 Description compacted at 100% of modified proctor AASHTO (T180-D)
and tested in accordance with AASHTO T 193.
1 This Sub-section specifies standards for crushed
aggregate base course material, mixing, spreading on
prepared sub-base course or sub-grade, compacting and Per cent by weight passing
Sieve Designation
finishing. (square openings) Class A Class B Class C
3.3.2 Materials
63 mm 100 - -
3.3.2.1 Crushed Stone Aggregate
50 mm 90 - 100 - -
1 Aggregate for use in base course construction shall
be either crushed stone or crushed gravel. The fine 37.5 mm 60 - 90 100 -
aggregate shall consist of screenings obtained from 25 mm 42 - 77 60 - 100 100
crushed stone, gravel, or sand. Aggregate may be washed,
if directed, to remove excessive quantities of clay, silty 19 mm 35 - 70 55 - 85 80 - 100
clay or salts.
12.5 mm 25 - 60 - -
2 Crushed stone shall consist of hard, durable particles
or fragments of stone, free from dirt or other objectionable 4.75 mm 15 - 40 35 - 60 30 - 60
matter, and shall contain no more than 8% of flat, 2.00 mm 10 - 25 25 - 50 20 - 45
elongated particles when tested according to ASTM D4791
0.425 mm 5 - 15 15 - 30 -
and, soft, or disintegrated pieces when tested according to
ASTM C235 and C123. 0.075 mm 2-9 8 - 15 3 - 10
3 Crushed gravel shall consist of hard durable stones, Table 3.3.2.1: Gradation by Class of Aggregate Base
rocks, and boulders crushed to specified sizes and shall be Course
free from excess flat, elongated, soft or disintegrated
pieces, dirt, or other objectionable matter 10 When tested for soundness in accordance with
AASHTO T 104, the material shall not show signs of
4 The method used in production of crushed gravel
disintegration and the loss by weight shall not exceed 12%
shall be such that the finished product shall be as uniform
in the case of the sodium sulfate test and 18% in the case
as practicable. The crushing of the gravel shall result in a
of the magnesium sulfate test.
product, which shall have at least 90% by weight of
particles with at least one fractured face. All stones, rocks, 11 The aggregate material shall not contain more than
and boulders of inferior quality occurring in the pit shall 2% gypsum and shall be free from organic content.
be wasted. 12 The aggregate material shall have a minimum sand
5 Any material passing 4.75 mm (No. 4) sieve and equivalent value of 50, when tested in accordance with
produced in the crushing process shall be incorporated in ASTM D2419.
the base material up to the gradation limits required for 13 The maximum permitted swell for the aggregate
the base course aggregate. material used in the base courses shall be 0.5%, when
6 Crushed aggregate for base course delivered to road tested in accordance with ASTM D4829.
site shall meet the requirements of Class A, B or C 14 The portion of aggregate, including any blended
gradations as shown in Table 3.3.2.1 when tested in material, passing the 0.425 mm (No. 40) mesh sieve shall
accordance with AASHTO T 27 after mixing with water have a liquid limit (L.L.) of not more than 25 and plasticity
and just before spreading and prior to compacting. The index (P.I) of not more than 6 when tested in accordance
class of aggregate shall be as shown on the Drawings. The with AASHTO T 89 and T 90.
actual gradation shall, in all cases, be continuous and 15 If additional fine material is required to correct the
smooth within the specified limits for each class. Gap aggregate gradation, or for adjusting the L.L. or P.I. of the
graded aggregate will not be accepted. If gradation is fraction passing the 0.425 mm (No. 40) sieve, it shall be
tested after compaction a tolerance of 3% is allowed in uniformly blended and mixed with the aggregate material
upper limit for percentage of material passing sieve 200. plant at the crushing plant or by an approved plant.
7 The amount of the fraction of material passing the Reworking of the material in situ to obtain the specified
0.075mm (No. 200) mesh sieve shall not exceed one half gradation will not be permitted. Additional fine material
the fraction passing the 0.425mm (No. 40) mesh sieve. for these purposes shall be obtained from the crushing of
stone, gravel, or slag.
8 The loss in weight shall not exceed 40% after 500
revolutions, when tested in accordance with AASHTO T 96 16 The Aggregate Base Course material shall have
(Los Angeles Abrasion Test). chloride content of less than 3.5 percent and sulphate
content of less than 2.0 percent when tested in accordance
with BS 812.

♦ 3-5 ♦
copy 249
17 Only potable water shall be used for mixing
aggregate base material.
3.3.3 Construction Requirements
3.3.3.1 Surface Preparation
1 The sub-base course shall be in accordance with the
requirements of Sub-section 3.2 and properly maintained
and kept well drained thereafter.
2 The sub-base surface shall be inspected and
approved prior to commencement of base construction.
Holes, depressions and other irregularities shall be made
good as directed and the sub-base re-compacted as
necessary and finished ready to receive the base course.
3 Where no sub-base course is required or shown on
the Drawings, and the aggregate base course is placed
directly on completed sub-grade, preparation of the
subgrade surface shall be as specified in Paragraph 3.2.3.1.
3.3.3.2 Equipment
1 Equipment used to handle, place, spread, water,
compact and finish base course shall conform with the
requirements of Section 19 and with the Contractor's
approved equipment list.
3.3.3.3 Construction of Trial Sections
1 If directed by the Engineer, the Contractor shall lay
and compact trial sections of varying thickness of base.
Each trial section shall be 2 lanes wide by 50 m long, at
approved locations on or close to the Site. Each trial
section shall be laid using the same materials, mix
proportions, mixing, spreading and compaction
equipment, and construction procedures, proposed for
use in the Works.
2 The objectives of these trials shall be to determine
the adequacy of the Contractor's equipment and the loose
depth measurements that will result in the specified
compacted layer depths, to verify the field moisture
content for compaction, and to identify the relationship
between the number of compaction passes and the
resulting density of the base course material.
3.3.3.4 Stockpiling of Aggregate Materials
1 Stockpiling procedures shall conform to the relevant
requirements of Sub-section 3.1.
2 Methods used for stockpiling aggregate materials
and removing them from stockpiles shall not result in
significant degradation or introduction of significant
amounts of foreign materials or extraneous matter.
3 Aggregate materials adversely affected, in the
opinion of the Engineer, by stockpiling or handling
procedures, shall not be incorporated in the work
regardless of previous approval of such material, until the
deficiencies have been rectified in an acceptable manner.
♦ 3-6 ♦
3.3.3.5 Mixing and Spreading
1 All components of base course material shall be
premixed with water in a pugmill mixing plant. The
amount of water added, as determined, shall be such that
the material will be uniform and within the specified
moisture content range at the time of compaction. Other
methods of mixing will be allowed only if directed by the
Engineer, provided such method(s) do not reduce the
quality of work. The Contractor shall demonstrate, in the
presence of the Engineer, his ability to attain the
requirement given in this Specification.
2 The premixed material shall be placed on the sub-
base in a uniform layer or layers not exceeding 200 mm in
thickness (after compaction) with the necessary control
guide wire requirements. Where the required thickness is
greater than 220 mm but less than 400 mm, the material
shall be placed in layers of equal thickness.
3 If approved by the Engineer when heavy duty
vibratory compaction equipment is used, the maximum
layer thickness may be increased up to 300 mm (after
compaction) provided compaction tests with appropriate
testing equipment based on successful Site trials indicate
that the specified compaction standard will be attained
and will be uniform through the thickness.
4 The base course material shall be placed to the
required width using an approved paver/finisher. However,
any pavers or finishers used for placing the base material
shall be equipped with calibrated sensors to maintain the
design levels and thicknesses. The material shall be
delivered such that it is ready for compaction without
further shaping.
5 The material shall not be handled in such a way as to
cause segregation. If the spreader causes segregation in
the material, or leaves ridges or other objectionable marks
on the surface which cannot be readily eliminated or
prevented by adjustment of the spreader operation, the
use of such spreader shall be discontinued and it shall be
replaced by a spreader capable of spreading the material
in a proper manner.
6 All segregated material shall be removed and
replaced with well-graded material. ‘Skin’ patching will
not be permitted. Only minor surface manipulation and
watering to achieve the required surface tolerances will be
permitted during the compaction process.
7 Hauling or placement of material will not be
permitted when, in the judgment of the Engineer, the
weather or surface conditions are such that hauling
operations will cause cutting or rutting of the sub-base or
subgrade or cause contamination of the base course
material.
3.3.3.6 Compaction
1 The Contractor shall plan the sequence of operations
so that the least amount of water will be lost by
evaporation from uncompleted surfaces. If the
uncompleted surface loses water due to evaporation, the
copy 249
Contractor shall apply additional water as required to 5 The tolerances on layer thickness, after being
prevent raveling or excessive drying.. compacted and finished, shall not exceed +10mm and -
2 The base course material shall be compacted by 5mm.
means of approved compaction equipment, progressing 6 The thickness of the finished base course shall be
gradually from the outside towards the center, with each checked at 20m intervals along the road by taking levels
succeeding pass uniformly overlapping the previous pass. on the centerline and both shoulders.
3 Rolling shall continue until the entire thickness of 7 All areas which exceed the specified tolerances shall
each base layer is thoroughly and uniformly compacted to be corrected by removing the defective sections of base
100% AASHTO T 180 (Method D) maximum density. Final course and reconstructing them or if approved, by
rolling of the completed course shall be by means of an scarifying and adding new material, or removing extra
approved self-propelled roller. Rolling shall be material, and re-compacting and finishing to the specified
accompanied by sufficient blading, to ensure a smooth standard.
surface, free from ruts or ridges and having the proper
shape. When additional water is required, it shall be 3.3.3.8 Maintenance of Completed Base Course
applied in an approved manner. 1 Following completion and acceptance of the base
4 Any areas inaccessible to normal compaction course, it shall be maintained by the Contractor until the
equipment shall be compacted by use of portable subsequent pavement layers are laid.. The surface shall be
mechanical tampers until the required standard of broomed, rolled and otherwise maintained, keeping it free
compaction is achieved, or to the satisfaction of the from raveling and other defects until such time as the
Engineer. following course is placed. Water shall be applied at such
5 Each layer shall be completely compacted and times and in such quantities as directed.
approved prior to delivery of materials for the following
3.3.3.9 Testing
layer.
6 Prior to placing a following layer, the surface shall be 1 Every 1000 cu.m. of base course material, or
made sufficiently moist as directed, to ensure proper bond whenever there is a change in the material source, shall be
between the layers. subject to a full set of tests as listed in Table 3.3.3.1 after
placing and if satisfactory shall be approved for
7 The edges and edge slopes of the base course shall
compaction and use. This approval shall not be deemed
be bladed or otherwise dressed to conform to the lines
to constitute acceptance of the base course for full
and dimensions shown on the Drawings and to present
payment purposes.
straight, neat lines and slopes as free of loose material as
practicable.
8 Material which has dried out prior to final Source of Materials Control on Site (The Road)
compaction, or which has dried and de-compacted Repetition
Repetition
subsequent to final compaction, shall be watered and re- Required Required Required
Required for
compacted using approved equipment and procedures. If Tests for all Tests
all Tests in
the Contractor is unable to return the material to its (A) Tests in (B)
(B)
(A)
original or specified condition with respect to compaction,
1.Gradation Minimum 1. Proctor Minimum
thickness and surface tolerances, for the final layer only of Materials one test AASHTO one test for
the Contractor shall scarify the material and reconstruct AASHTO for each T180-D every 1000
the base course on a re-approved sub-base surface or to T27 source cu.m. of
the satisfaction of the Engineer. every layer,
2.Plasticity or
3.3.3.7 Tolerances Index whenever
AASHTO " Materials
1 The fully compacted and completed base course T89 & T90 changed,
shall conform to the lines, grades and cross sections as whichever is
shown on the Drawings. less
3.Abrasion 2.
2 The elevations of the finished base course shall be AASHTO Gradation
checked by the Contractor in the presence of the Engineer T96 " of Materials
at intervals of 20m on straight lines and of 10 m on curves, AASHTO "
and at intermediate points as directed. T27
4. C.B.R.
3 The tolerances (for final layer only) on elevations of
AASHTO
finished surface shall not exceed +5mm or -10mm. T193 " 3. Plasticity
4 When the finished surface is tested with a 4 m long Index
straightedge, placed parallel to, or at right angles to the AASHTO "
centerline, the maximum deviation of the surface from the 5.Sand T89 & T90
equivalent
testing edge between any 2 contact points shall not "
ASTM
exceed 10mm.

♦ 3-7 ♦
copy 249
 Source of Materials Control on Site (The Road) 3.3.5 Basis of Payment
Repetition 1 The amount of completed and accepted work,
Repetition
Required Required Required measured as provided for above, will be paid for at the
Required for
Tests for all Tests unit rates for the various items in the Bill of Quantities,
all Tests in
(A) Tests in (B) which rate shall be full compensation for equipment, tools,
(B)
(A)
labor, locating sources of supply, supplying materials,
D2419 4. C.B.R.
sampling and testing, screening, crushing, transporting,
AASHTO "
T193 stockpiling, laying, mixing and compacting and for extra
6.Percentag material in tapered edges, and other items necessary for
e of the proper completion of the work.
fractured 5. Abrasion
Grains AASHTO 3.3.6 Items in the Bill of Quantities
T96 "
i. Aggregate Base Course (Class A) cu.m
7.Thin and
elongated 6. Sand ii. Aggregate Base Course (Class B) cu.m
pieces equivalent
ASTM ASTM " iii. Aggregate Base Course (Class C) cu.m
D4791 D2419
3.4 Stabilized Base Courses
7. Clay
lumps & 3.4.1 Description
friable
1 This Sub-section specifies stabilized base courses
particles "
ASTM C235 composed of sand, sandy gravel, sandy clay soil or similar,
and C123 stabilized with cement or bitumen or lime as appropriate
and as shown on the Drawings.
8. Field
Density " 3.4.2 Materials
3.4.2.1 Soil for Stabilization
9. Test for every
Thickness 2000 sq.m. 1 Sand and gravel soils shall have the following
and for every particle size distribution given in Table 3.4.2.1.
layer
Table 3.3.3.1: Required Tests and Minimum Repetition for AASHTO Sieve % passing (by mass)
50 mm 100
Base and Sub-Base Course Materials
4.75 mm 50 - 100
2 Sampling and testing shall conform to the 1.80 mm 37 - 80
requirements of this specification. 425 μm 15 - 50
3 Compaction shall be tested in accordance with 75 μm 0 - 20
AASHTO T 191, AASHTO T 205 or any acceptable method. 2 μm 0-3
If there is a significant delay between the construction of Table 3.4.2.1: Soil for Stabilization
any layer and the following layer, the Engineer may
require the compaction of the lower layer to be re-verified 2 The mix-in-place method of construction shall be
to ensure that it has not loosened due to traffic, passage of used only on sites with naturally occurring sand and
construction equipment, adverse weather conditions or gravel mixture. For the central plant method of
otherwise. construction, the materials shall be selected by the
Contractor from other sources complying with the
3.3.4 Method of Measurement requirements of this Clause and shall be subject to the
1 Aggregate base course shall be measured by cu.m. approval of the Engineer.
of compacted base course. Measurements shall be of 3.4.2.2 Cement as Stabilizing Agent
volumes computed from the cross sections shown on the
Drawings and shall be calculated from the top surface area 1 Cement for stabilization shall be ordinary Portland
of each layer, excluding the tapered edges.. cement or sulfate resisting cement, as shown on the
2 No measurement shall be made for direct payment of Drawings, or as instructed by the Engineer. Portland
overdepth construction, regardless of the Engineer's cement shall conform to the requirements of BS12 Part 2
permission for it to remain in place. or AASHTO M85 Type I for ordinary and rapid hardening
types, and BS4027 Part 2 or AASHTO M85 Type V for
sulfate resisting cement.

♦ 3-8 ♦
copy 249
2 At least two silos shall be used for cement storage.
Before recharging a silo it shall be emptied completely
and cleaned out. During the time of charging a silo shall
not be used for batching.
3 The stored cement shall be free-flowing and free of
lumps. Cement shall not be stored for longer than 4
months. Cement that has remained in store for a period
greater than 4 months, or of which there is doubt as to
quality shall be re-tested by standard mortar tests to
determine whether it still meets the requirements of the
standards.
4 Curing seal shall consist of approved proprietary
curing compound, or MC-70 cutback bitumen to prime
coat standard as specified in Section 4.
3.4.2.3 Bitumen as Stabilizing Agent
1 Bitumen may include straight run (penetration grade)
bitumen; RC cutback bitumen, MC cutback bitumen, or
cationic emulsified bitumen, Type SS. Penetration grade,
cutback bitumen and emulsified bitumen shall conform to
all relevant requirements herein.
2 The selection of suitable bitumen will depend on the
properties of the material to be stabilized and shall be
subject to laboratory and field trials by the Contractor,
under the supervision of the Engineer.
3 When the material moisture content is high, the
material must be dried before the use of penetration grade
bitumen or viscous cutback bitumen and plant mixing of
materials as appropriate.
4 When the natural moisture content of the material is
low, use cutback bitumens or emulsified bitumens as
appropriate.
3.4.2.4 Lime as Stabilizing Agent
1 Hydrated lime (calcium hydroxide) and quicklime
(calcium oxide) shall conform to AASHTO M216. Mixing of
different brands of lime or use of lime from different mills
will not be permitted.
2 Lime slurry shall be a homogeneous pumpable
mixture of lime and water. Slurry shall be a premixed
material in which the lime solids content shall be not less
than 30% by weight.
3.4.2.5 Water
1 The water shall be clean and free from impurities, oil,
acid, salts, alkali, organic matter, and other potentially
deleterious substances. Water from doubtful sources shall
not be used until tested in accordance with AASHTO T26
and approved.
3.4.2.6 Mix Design for Cement Stabilized Base
1 Before starting the work of stabilization, soil-cement
trial mixes shall be carried out. The proposed mix design
shall be submitted by the Contractor for approval by the
Engineer. It shall show the percentage of cement and
water to be used with the naturally occurring soil so as to
obtain a stabilized mixture with the following properties:
i. The minimum cube compressive strength shall
be 5.0 N/mm2 after molding and storage at a
minimum humidity of 95% for a period of 7
days. The molding shall be in accordance with
AASHTO T134 and the strength testing shall be
in accordance with BS 1881. The cement
content of trial mixes shall be adjusted until
this strength is achieved.
ii. The maximum volume change (swelling) shall
be 2% and the maximum loss in weight shall
be not more than 8%, when cylinders are
molded and tested in accordance with AASHTO
T 135, Method B.
iii. Cement content and water content of the mix
on the Site shall each be within - 0.2% to +2%
of the approved mix design.
iv. The total salt content of the cement stabilized
base course mixture shall meet the following
requirements: The total chloride content (sum
of both acid soluble and water soluble
chlorides) expressed as chloride ion, when
tested in accordance with BS 1881, shall not
exceed 0.10 percent by weight of dry cement.
The total sulfate content expressed as SO3,
when tested in accordance with BS 1881, shall
not exceed 3 percent by weight of dry cement.
3.4.3 Construction Requirements
3.4.3.1 Surface Preparation
1 Prior to placing of stabilized base on sub-base or
subgrade, the subgrade shall have been properly
completed and approved as specified in Sub-section 2.6
and the sub-base shall have been properly completed and
approved as specified in Sub-section 3.2.
3.4.3.2 Construction of Trial Section
1 If instructed by the Engineer before commencement
of stabilization work and after completion of laboratory
mix design, the Contractor shall lay a trial section of
stabilized material 2 lanes wide by 50m long, at an
approved location on or near to the Site.
2 This trial section shall be laid using the same
materials, mix proportions, mixing, spreading and
compaction equipment, and construction procedures that
are proposed for use in the work.
3 The trial section shall serve as a field verification of
the laboratory mix design. The results of the dry density
and moisture content measurements made in the trial
section will be used in association with the laboratory
tests to establish the moisture content and minimum per
cent compaction to be attained in the stabilization work.
4 The trial section shall also demonstrate the adequacy
of mixing, spreading and compaction equipment and the
suitability of the methods and organization proposed.
♦ 3-9 ♦
copy 249
3.4.3.3 Cement Stabilization Procedures - Plant Mixing
1 When cement and granular or crushed material are
to be mixed in a stationary plant, the plant shall be an
approved type pugmill mixing plant of either the batch
mix type with revolving blade or rotary drum, or the
continuous mixing type. Proportioning of materials and of
water may be by either weight or volume.
2 Cement shall be added in such a manner that it is
uniformly distributed during the mixing operation. Safe,
convenient facilities shall be provided for sampling
cement in the supply line to the weigh hopper or pugmill.
3 Means shall be provided whereby the Engineer may
verify the amount of water per batch or the rate of flow for
continuous mixing. The time of the addition of water and
the points at which it is introduced into the mixer shall be
as approved.
4 The charge in a batch mixer, or the rate of feed to a
continuous mixer, shall not exceed that which will permit
complete mixing of all of the material. Dead areas in the
mixer, in which the material does not move or is not
sufficiently agitated, shall be corrected.
5 The moisture content of the completed mixture shall
be not more than one per cent below optimum moisture
content at the point of delivery to the work area.
3.4.3.4 Cement Stabilization Procedures - Batch Mixing
1 Batch mixing plants shall be equipped with a
sufficient number of paddles of a type and arrangement to
produce a uniformly mixed batch.
2 The mixer platform shall be of ample size to provide
safe and convenient access to the mixer and other
equipment.
3 The mixer shall be equipped with a timing device
which will indicate by a definite audible or visual signal
the expiration of the mixing period. The device shall be
accurate to within 2 seconds.
4 The time of mixing a batch shall begin after all
ingredients are in the mixer and shall end when the mixer
is half emptied. Mixing shall continue until a
homogeneous mixture of uniformly distributed and
properly coated materials of uniform appearance is
produced. The time of mixing shall not be less than 30
seconds. When blending of different sizes is required, the
materials shall be blended as they enter the mixer.
5 Cement for each batch shall be weighed on scales
separate from the aggregate batching scales. Each
cement scale graduation shall be approximately 0.001
times the total capacity of the scales. The total capacity
shall not be greater than twice the amount of cement
required when the plant is operated at full capacity. No
scale shall be used with a capacity less than 500 kg.
3.4.3.5 Cement Stabilization Procedures - Continuous
Mixing
1 Continuous mixing plants shall be designed such that
granular materials are drawn from the storage facility by
♦ 3-10 ♦
feeders which continuously supply the correct amount of
granular material in proportion to the cement and so
arranged that the proportion of each size of granular
material can be separately adjusted if more than one size
is used. Storage facilities containing fine material shall be
equipped with vibrating units which shall vibrate the side
walls of the feeder to prevent any hang-up of materials
while the plant is operating.
2 A control system shall be provided that will
automatically close down the plant when the material in
any storage facility approaches the strike-off capacity of
the feed gate. The plant will not be permitted to operate
unless the control system is in proper working order.
3 The feeder for the granular material shall be
mechanically or electrically driven. Mechanically driven
feeders shall be directly connected with the drive on the
cement feeder. The drive shaft on the feeder shall be
equipped with a revolution counter reading to 0.1 of a
revolution. Electrically driven feeders shall be actuated
from the same circuit that services the motor driving the
cement feeder.
4 The cement feeder and the granular material feeders
shall be equipped with devices by which the rate of feed
can be determined while the plant is in full operation.
3.4.3.6 Cement Stabilization Procedures - Mixed in
Place Procedures
1 Mixed in place procedures will normally be permitted
when the granular material to be stabilised is in-situ site
material.
2 Plant and equipment for pulverizing (if required) and
for mixing all materials will be approved on the basis of
preliminary trials to establish that such plant and
equipment are capable of producing the specified degree
of mixing and uniformity of stabilized material for the full
thickness of each layer. Single pass or multi-pass
equipment may be used.
3 The mixing equipment shall be equipped with a
device for controlling the depth of processing and the
mixing blades shall be maintained or reset periodically so
that the correct depth of mixing is obtained at all times.
Cement shall be spread ahead of the mixer by means of a
cement spreader, fitted with a device to ensure a uniform
and controllable rate of spread of cement transversely and
longitudinally.
4 If multi-pass equipment is utilized, the fine cohesive
fraction (if any) of the material shall first be pulverized to
the required depth with successive passes and the
moisture content adjusted if it is more than 3% below the
value required for compaction. Cement shall then be
spread and mixing continued with successive passes until
the required depth and uniformity have been achieved.
5 If it is necessary to adjust the moisture content of the
material to the optimum for compaction, water shall be
added during the mixing operation using a water sprayer
of such design that the water is added in a uniform and
controllable manner both transversely and longitudinally.
copy 249
6 Te mixing equipment shall be set so that it cuts
slightly into the edge of any adjoining completed lane so
as to ensure that all material forming the layer has been
properly processed. The Engineer may approve the use of
scarifiers or preparizers ahead of the mixing equipment.
The output of the mixing equipment shall be such that a
minimum rate of 20 lin.m./h measured longitudinally of
completed stabilized layer can be maintained in order to
permit satisfactory compaction of the mix.
3.4.3.7 Cement Stabilization Procedures - Placing of
Stationary Plant Mixes
1 Immediately prior to depositing the mix, the surface
area to be covered shall be moistened and kept moist.
2 The cement stabilized mix shall be protected against
moisture loss during transporting, by use of suitable
covers. The mix shall be deposited on the roadbed at a
prescribed quantity which shall provide the compacted
thickness for the width being spread without resort to
spotting, picking up, or otherwise shifting the mixture.
Segregation shall be prevented and the mix shall be free
from pockets of coarse or fine materials.
3 The mix shall be spread in widths of not less than 2
lanes, insofar as the width of surface permits.
Longitudinal construction joints shall fall within 300 mm of
lane lines. The mix shall be spread by one or more
spreaders operating in a staggered position across the
surface. If traffic conditions require that less than 2 lanes
be spread, not more than 2 hours shall elapse between the
times of placing the material in adjacent lanes.
4 The compacted thickness of any one layer shall not
exceed 200 mm and shall be not less than 80 mm. When
more than one layer is placed, the surface of the lower
layer of compacted mix shall, until covered with the next
layer, be kept moist with water or a curing seal as
specified.
5 In the case of areas inaccessible to mechanical
spreading equipment, the mix may be spread in one layer
by approved methods only. After spreading, the material
shall be thoroughly compacted to the required lines,
grades, and cross section by means of pneumatic tampers,
or other approved compacting equipment.
6 Use of motor graders will not be permitted during
spreading or compacting operations. Motor graders may
be used only to trim the edges and surface after
compaction in order to finish within the specified
tolerances.
7 A motor grader may be classified as a self-propelled
mechanical spreader if it has been equipped with end
wings on the blade, has the blade locked in a position
perpendicular to the direction of travel, and is equipped
with cross slope and automatic grade controls that meet
the requirements for the specified type of spreading.
8 Each layer of the mix shall be spread in one
operation with an approved type self-propelled
mechanical spreader such that the layer is made ready for
compaction without further shaping. The spreader shall
be provided with a fully automatic and adjustable screed
that strikes off and distributes the material to the full width
being spread and to the surface tolerances specified.
9 The spreader shall be equipped with grade sensing
controls to automatically control the longitudinal grade
and transverse slopes of the screed. Screed action
includes any cutting, crowding, or otherwise that produces
a finished surface texture of uniform appearance.
3.4.3.8 Cement Stabilization Procedures - Compaction
and Finishing
1 Immediately upon completion of spreading or
spreading and mixing in place operations, and completion
of shaping, the mix shall be initially compacted by one
complete pass using approved type rollers.
2 If the finished surface after initial compaction is
outside the specified tolerance, all high spots shall be
trimmed off to within the specified tolerance. Filling of
low areas by drifting or hauling of trimmed material will
not be permitted.
3 Following trimming, the finished surface shall be
finally compacted to not less than 100% of the laboratory
density of the approved job mix specimens as determined
by AASHTO T 134. Final compaction shall be
accomplished in such a manner that no loose material
remains on the surface and all tear marks are eliminated.
4 The surface tolerances shall conform with the
tolerance requirements for Aggregate Base Course.
Where any areas are lower than the allowable tolerance,
the stabilised layer shall be removed and fresh stabilised
mix placed and properly compacted and finished, unless
filling of the low areas with bituminous concrete or
cement concrete is approved.
5 If the superimposed course will be cement concrete,
the low areas may, if approved, be filled with concrete at
the time and during the same operation that the concrete
pavement is placed.
6 When the superimposed course will be bituminous
concrete, the low areas may, if approved, be filled with
bituminous concrete to the same standard. This filling
shall be carried out as a separate operation prior to
placing the bituminous concrete course (unless the
thickness to be placed is too small to make this
practicable).
7 Not more than 2 hours shall elapse between the time
water is added to the mixed materials and the time of
completion of initial compaction. Final compaction shall
be completed within 30 minutes of initial compaction.
8 At the end of each day's work and when operations
are delayed or stopped for more than 2 hours, a vertical
construction joint shall be made in the fully compacted
layer, perpendicular to the centerline. Additional mix shall
not be placed until the construction joint has been
approved.
9 One hour after the stabilized mix has been finally
compacted; vertical longitudinal joints shall be
constructed by cutting into the existing edge to a depth of
♦ 3-11 ♦
copy 249
approximately 100 mm. The mix cut away shall be
discarded. The face of the cut joints shall be moistened in
advance of placing the adjacent lane.
3.4.3.9 Curing of Cement Stabilized Courses
1 Curing seal as specified shall be applied uniformly to
the completed surface at a rate of between 0.5 and 1.2
kg./sq.m., or as determined by the Engineer. The curing
seal shall be applied on the same day that final
compaction is performed and as soon as practicable
thereafter. The surface shall be kept moist until the seal is
applied.
2 Damage to the curing seal or stabilized surface shall
be promptly repaired by an approved manner.
3.4.3.10 Testing of Cement Stabilised Courses
1 For every 5,000 sq.m. of each stabilised layer or for
each day's completed area (whichever is smaller) the
following sampling and testing shall be carried out:
- In situ density of a minimum of 3 samples
(taken immediately after final compaction)
determined in accordance with AASHTO T 191
or T 205 and which shall be not less than 100%
of the density of the approved laboratory mix.
- Cement content in accordance with AASHTO T
211.
- Gradation of mix in accordance with AASHTO
T 27.
- Moisture - density relationship for mix sampled
fresh from the Site, in accordance with
AASHTO T 134 if the source of the material is
changed.
- Compressive strength of a set of 3 test
specimens molded and cured in accordance
with AASHTO T 134 and T 126, and tested in
accordance with AASHTO T 22.
3.4.3.11 Bitumen Stabilization Procedures - Mix Design
1 The material to be stabilized shall be a sand, sandy
gravel or silty or clayey gravel and sand material with a P.I.
not exceeding 12% and L.L. not exceeding 25% and with
not more than 30% passing a 0.075 mm (No. 200) sieve.
2 Bitumen-soil mix proportions shall be established by
field laboratory trial mixes, carried out in the presence of
the Engineer. The compressive strength shall be
determined in accordance with AASHTO T 167 and in such
a way as to ensure that the optimum composition of the
mix is established.
3 The laboratory trial mixes, after being air cured for a
period of 7 days and tested in accordance with AASHTO T
167, shall have a minimum compressive strength at 25
degrees C, of 2 MN/sq.m. (20 kg/sq.cm.) and a Marshall
stability at 60 degrees C, of 2,000 N (204 kg). The Index of
Retained Strength when tested using a Marshall mould
shall be not less than 70%.
♦ 3-12 ♦
3.4.3.12 Bitumen Stabilization Procedures - Stationary
Plant Mixing
1 When approval is given to utilize stationary plant for
mixing, whether batch mixing plant or continuous type
mixing plant, the plant and equipment and handling and
mixing procedures shall conform with the relevant
requirements of Section 4 - "Bituminous Pavement" and
with the appropriate requirements specified herein for
plant mixing of cement stabilized materials.
3.4.3.13 Bitumen Stabilization Procedures - Mixed in
Place Procedures
1 Approved type multi-pass or approved type purpose-
built, single-pass equipment shall be utilized for on Site
mixing and placing. Operators shall be trained and fully
experienced in the operation of such equipment.
2 Multi-pass equipment may consist of suitable
bitumen distributor and motor graders or as otherwise
approved.
3 The process of pulverizing the fine grained cohesive
fraction (if any) of the granular material shall be as
specified for cement stabilized courses. Bitumen, of the
type and grade selected by the Engineer, shall then be
applied to the surface using approved type heating and
pressure distribution equipment. Emulsified bitumen shall
not normally require heating.
4 Spreading and mixing of the bitumen and granular or
other material shall be carried out as specified for cement
stabilized courses.
3.4.3.14 Bitumen Stabilization Procedures – Placing and
Spreading Stationary Plant Mixes.
1 The placing and spreading of stationary plant mixes
shall be as specified for cement stabilized courses.
3.4.3.15 Bitumen Stabilization Procedures - Compaction
and Finishing
1 Compaction of bitumen stabilized courses to 100% of
laboratory density of approved job mix specimens,
finishing, and provision of longitudinal joints, shall be as
specified for cement stabilized courses.
3.4.3.16 Bitumen Stabilization Procedures - Tolerances
and Replacement of Unsatisfactory Areas
1 Finished surface tolerances and the rectification
procedures for any areas which fail to meet such
tolerances, shall be as specified for cement stabilized
courses.
2 Where high spots require trimming after initial
compaction, raking or similar procedures may be required.
If the area is unduly damaged or pitted, the stabilized mix
shall be removed and replaced with fresh stabilized mix
spread and properly compacted and finished.
copy 249
3.4.3.17 Bitumen Stabilization Procedures - Testing of
Bitumen Stabilized Courses
1 For every 5,000 sq.m. of each stabilized layer or for
each day's completed area (whichever is the smaller) the
following sampling and testing shall be carried out:
i. In situ density of a minimum of 3 samples
(taken immediately after completion of final
compaction) determined in accordance with
AASHTO T 191 or T 205 and which shall be not
less than 100% of the density of the approved
laboratory mix.
ii. Composition of the mix by extraction in
accordance with AASHTO T 164. The variation
from the approved job-mix, based on results of
4 tests, shall not exceed the following:
- Aggregates passing
No. 200 (0.075 mm) +1 percent
- Asphalt content +0.2 percent
iii. Compressive strength in accordance with
AASHTO T 167, of samples before compaction.
The minimum compressive strength value shall
be not less than the value specified under Item
3 of Paragraph 3.4.3.11.
iv. Marshall stability in accordance with AASHTO
T245, of samples before compaction. The
minimum Marshall stability value shall be not
less than the value specified under Item 3 of
Paragraph 3.4.3.11.
3.4.3.18 Lime Stabilization Procedures - Mix Design
1 The material to be stabilized shall be a clayey gravel,
clayey sand or lean clay soil with not more than 50%
passing 0.425 mm (No. 40) sieve and plasticity index
greater than 10%.
2 The lime content and optimum moisture content
shall be determined in the field laboratory and in the
presence of the Engineer. Cylinders molded in accordance
with AASHTO T 220 shall be cured and tested at 7 days
and 28 days. Load rate of application shall be in
accordance with AASHTO T 22. The minimum
compressive strength at 7 days after molding shall be one
MN/sq.m. (10 kg./sq.cm.).
3 Lime content and water content of the mix shall each
be within -0.2% to +2.5% of the approved mix design
percentages.
3.4.3.19 Lime Stabilization Procedures - Safety
Precautions
1 Special precautions shall be taken when handling
quicklime as it will rapidly corrode equipment and can
inflict severe skin burns to personnel coming in contact
with it.
2 Suitable methods for handling quicklime shall be
adopted, including fully mechanized or bottom dump
handling equipment and protective clothing worn by the
operators. Working operations should take into account
the wind direction to minimize the dust problem and
consequent eye or skin irritation to any personnel in the
vicinity.
3 When hydrated lime is used, precautions shall also
be taken against the effects of prolonged exposure to the
skin.
3.4.3.20 Lime Stabilization Procedures - Stationary Plant
Mixing
1 When approval is given to utilize stationary plant for
mixing, whether batch mixing plant or continuous type
mixing plant, the plant and equipment and handling and
mixing procedures shall be as specified for cement
stabilization and as specified herein for plant mixing of
lime stabilized materials.
3.4.3.21 Lime Stabilization Procedures - Mixed in Place
Procedures
1 Mixed in place procedures will normally be permitted
when the soil to be stabilized is in-situ site material.
2 Spreading and mixing of the lime and soil material
shall be carried out as specified for cement stabilized
courses.
3.4.3.22 Lime Stabilization Procedures - Placing and
Spreading Stationary Plant Mixes
1 Placing and spreading of stationary plant mixes shall
be as specified for cement stabilized courses.
3.4.3.23 Lime Stabilization Procedures - Compaction
and Finishing
1 Compaction of lime stabilized courses to 100% of
laboratory density of approved job mix specimens,
finishing and provision of longitudinal joints, shall be as
specified for cement stabilized courses with the following
modifications:
i. When quick lime is used, the layer shall not be
compacted immediately after spreading the lime,
as hydration of the lime will cause damage to the
compacted layer. The time within which the
compaction shall be completed will be as
estimated in the laboratory.
ii. Compaction shall not take place after lime
hydration. Any lime stabilized material that has
been mixed or deposited after lime hydration,
shall be removed and replaced with fresh
material, mixed and treated as specified.
3.4.3.24 Lime Stabilization Procedures - Tolerances and
Replacement of Unsatisfactory Areas
1 Finished surface tolerances and the rectification
procedures for any areas which fail to meet such
tolerances shall be as specified for cement stabilized
courses.
♦ 3-13 ♦
copy 249
3.4.3.25 Testing of Lime Stabilized Courses

1 For every 5,000 sq.m. of each stabilized layer or for

each day's completed area (whichever is the smaller) the
following sampling and testing shall be carried out:
i. In situ density of a minimum of 3 samples
(taken immediately after completion of final
compaction) determined in accordance with
AASHTO T 191 or T 205 and which shall be not
less than 100% of the density of the approved
laboratory mix.
ii. Lime content in accordance with AASHTO T
232.
iii. Gradation of mix in accordance with AASHTO
T 27.
iv. If the source of materials changes, the moisture
- density relationship in accordance with
AASHTO T 134 and gradation of the new mix in
accordance with AASHTO T27.
v. Compressive strength of a set of 3 test
specimens molded and cured in accordance
with AASHTO T 134 and T 126, and tested in
accordance with AASHTO T 22.

3.4.4 Method of Measurement

1 Cement stabilized course, bitumen stabilized course
and lime stabilized course shall each be measured by cu.m.
of compacted stabilized course. Measurements shall be of
the area and thickness dimensions shown on the
Drawings.
2 Curing seal shall be measured by sq.m. of areas
computed from the length and width of the completed
sections shown on the Drawings.

3.4.5 Basis of Payment

1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities,
which rate shall be full compensation for equipment, tools,
labor, locating sources of supply, supplying materials,
sampling and testing, screening, crushing, transporting,
stockpiling, laying, mixing and compacting and for extra
material in tapered edges, and other items necessary for
the proper completion of the work.

3.4.6 Items in the Bill of Quantities

i. Cement Stabilized Base Course
(thickness) cu.m

ii. Bitumen Stabilized Base Course

(thickness) cu.m

iii. Lime Stabilized Base Course

(thickness). cu.m

iv. Curing Seal sq.m

♦ 3-14 ♦
copy 249
Ref. Title Page No. Ref. Title Page No.
4.1  Materials for Bituminous 4.2.5.2  Prime Coat Application 4-11 
Construction 4-1 4.2.5.3  Tack Coat Application 4-12 
4.2.5.4  Polymer Modified Tack Coat 4-12 
4.1.1  Description 4-1 
4.2.6 Method of Measurement 4-12
4.1.2  Aggregate Materials Generally 4-1 
4.2.7 Basis of Payment 4-12
4.1.2.1  Sources and Production 4-1 
4.2.8 Items in the Bill of Quantities 4-12
4.1.2.2  Stockpiling 4-1 
4.1.2.3  Sampling and Testing 4-1  4.3 Bituminous Courses 4-12
4.1.3 Aggregates for Bituminous Paving Mixes 4-1
4.3.1 Description 4-12
4.1.4 Aggregates for Seal Coats 4-3
4.3.2 Materials 4-13
4.1.5 Bitumen Generally 4-3
4.3.3 Job Mixes and Project Mixes 4-13
4.1.5.1  Type and Grade 4-3 
4.3.4 Equipment 4-14
4.1.5.2  Transporting Bitumen 4-4 
4.3.4.1  General 4-14 
4.1.5.3  Storage of Bitumen 4-4 
4.3.4.2  Mixing Plant 4-14 
4.1.5.4  Heating of Bitumen 4-4 
4.3.4.3  Spreading and Finishing Equipment 4-14 
4.1.5.5  Sampling and Testing 4-4 
4.3.5 Construction of Trial Sections 4-15
4.1.6 Bitumen Products 4-4
4.3.6 Mixing Procedures 4-15
4.1.6.1  Penetration Graded Bitumen 4-4 
4.3.7 Surface Preparation 4-15
4.1.6.2  Bitumen Modifier and Modified
4.3.8 Delivery, Spreading and Finishing 4-16
Bituminous Material 4-5 
4.3.8.1  Delivery of Mix to Site 4-16 
4.1.6.3  Rapid-Curing (RC) Cutback Bitumen 4-7 
4.3.8.2  Setting Out and Reference Lines 4-16 
4.1.6.4  Medium-Curing (MC) Cutback Bitumen 4-7 
4.3.8.3  Spreading and Finishing 4-16 
4.1.6.5  Slow-Curing (SC) Cutback Bitumen 4-7 
4.3.8.4  Joints and Edges 4-17 
4.1.6.6  Emulsified Bitumens Generally 4-7 
4.3.8.5  Compaction 4-17 
4.1.6.7  Anionic Emulsified Bitumen 4-8 
4.3.9 Sampling and Testing 4-18
4.1.6.8  Cationic Emulsified Bitumen 4-10 
4.3.10 Surface Tolerances 4-20
4.1.7 Method of Measurement and Basis
4.3.11 Determination of Thickness of Courses 4-20
of Payment 4-10
4.3.12 Method of Measurement 4-20
4.2 Prime and Tack coats 4-10 4.3.13 Basis of Payment 4-21

4.2.1 Description 4-10 4.4 Bituminous Base Course 4-21

4.2.2 Materials 4-10
4.4.1 Description 4-21
4.2.2.1  Medium Curing Cutback Bitumen 4-10 
4.4.2 Materials 4-21
4.2.2.2  Rapid-Curing Cutback Bitumen 4-10 
4.4.3 Job Mix and Project Mix 4-21
4.2.2.3  Slow-Curing Emulsified Bitumen 4-10 
4.4.4 Equipment 4-21
4.2.3 Equipment 4-11
4.4.5 Construction of Trial Sections 4-21
4.2.4 Construction of Trial Sections 4-11
4.4.6 Mixing Procedures 4-21
4.2.5 Application Procedures 4-11
4.4.7 Surface Preparation 4-22
4.2.5.1  Medium Curing Cutback Bitumen 4-11

♦ 4-0 ♦
copy 249
Ref. Title Page No. Ref. Title Page No.
4.4.8 Delivery, Spreading and Finishing 4-22 4.6.6.3  Heating of Bitumen 4-26
4.4.8.1  General 4-22  4.6.6.4  Spreading Slurry Seal 4-26 
4.4.8.2  Rollers 4-22  4.6.6.5  Spraying of Bitumen 4-26 
4.4.8.3  Standard of Compaction 4-22  4.6.6.6  Application of Aggregate 4-26 
4.4.9 Sampling and Testing 4-22 4.6.6.7  Rolling and Brooming 4-27 
4.4.10 Surface Tolerances 4-22 4.6.6.8  Maintenance and Protection of Sealed
4.4.11 Determination of Thickness 4-22 Surfaces 4-27 
4.4.12 Method of Measurement 4-22 4.6.7 Tolerances and Records 4-27
4.4.13 Basis of Payment 4-22 4.6.8 Method of Measurement 4-28
4.4.14 Items in the Bill of Quantities 4-23 4.6.9 Basis of Payment 4-28
4.6.10 Items in the Bill of Quantities 4-28
4.5 Bituminous Binder and Wearing
Courses 4-23 4.7 Bituminous Leveling Course and
Patching Work 4-28
4.5.1 Description 4-23
4.5.2 Materials 4-23 4.7.1 Description 4-28
4.5.3 Job Mix and Project Mix 4-23 4.7.2 Materials 4-28
4.5.4 Equipment 4-23 4.7.3 Job Mix and Project Mix 4-28
4.5.5 Construction of Trial Sections 4-23 4.7.4 Equipment 4-28
4.5.6 Mixing Procedures 4-23 4.7.5 Construction of Trial Sections 4-28
4.5.7 Surface preparation 4-23 4.7.6 Mixing Procedures 4-28
4.5.8 Delivery, Spreading and Finishing 4-23 4.7.7 Surface Preparation 4-28
4.5.8.1  General 4-23  4.7.8 Delivery, Spreading and Finishing 4-29
4.5.8.2  Rollers 4-23  4.7.9 Sampling and Testing 4-29
4.5.8.3  Standard of Compaction 4-24  4.7.10 Surface Tolerances 4-29
4.5.8.4  Skid Resistance and Surface Texture 4-24  4.7.11 Determination of Thickness 4-29
4.5.9 Sampling and Testing 4-24 4.7.12 Method of Measurement 4-29
4.5.10 Surface Tolerances 4-24 4.7.13 Basis of Payment 4-29
4.5.11 Determination of Thickness 4-24 4.7.14 Items in the Bill of Quantities 4-29
4.5.12 Method of Measurement 4-24
4.8 Bituminous Cold Mix Courses 4-29
4.5.13 Basis of Payment 4-24
4.5.14 Items in the Bill of Quantities 4-24 4.8.1 Description 4-29
4.8.2 Materials 4-29
4.6 Bituminous Seal Coats – Surface
4.8.3 Job Mix and Project Mix 4-29
Dressings 4-25
4.8.4 Equipment 4-29
4.6.1 Description 4-25 4.8.5 Construction of Trial Sections 4-29
4.6.2 Materials 4-25 4.8.6 Mixing Procedures 4-30
4.6.2.1  Bitumen 4-25  4.8.7 Surface Preparation 4-30
4.6.2.2  Aggregates 4-25  4.8.8 Delivery, Spreading and Finishing 4-30
4.6.3 Equipment 4-25 4.8.9 Sampling and Testing 4-30
4.6.4 Construction of Trial Sections 4-25 4.8.10 Surface Tolerances 4-30
4.6.5 Rates of Application 4-25 4.8.11 Determination of Thickness 4-30
4.6.6 Construction Requirements 4-25 4.8.12 Method of Measurement 4-30
4.6.6.1  General 4-25 4.8.13 Basis of Payment 4-30
4.6.6.2  Surface Preparation 4-26 4.8.14 Items in the Bill of Quantities 4-30

♦ 4-0 ♦
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Ref. Title Page No. Ref. Title Page No.
4.9 Pavement Repairs and 4.12.2 Reference Documents for Profiler
Reinstatement 4-30 Rideability Testing 4-34
4.12.3 Terminology 4-34
4.9.1 Description 4-30
4.12.4 Testing Equipment 4-34
4.9.2 Materials 4-30
4.12.5 Testing Procedure 4-34
4.9.3 Equipment 4-30
4.12.6 Submittals 4-35
4.9.4 Preparation of Pavement 4-30
4.12.7 Required Rideability 4-35
4.9.5 Placing and Finishing Repair Materials 4-31
4.12.8 Method of Measurement 4-35
4.9.6 Sampling and Testing 4-31
4.12.9 Basis of Payment 4-35
4.9.7 Surface Tolerances 4-31
4.12.10 Items in the Bill of Quantities 4-35
4.9.8 Method of Measurement 4-31
4.9.9 Basis of Payment 4-31
4.9.10 Items in the Bill of Quantities 4-32

4.10 Bituminous Pavement Widening 4-32

4.10.1 Description 4-32
4.10.2 Materials 4-32
4.10.3 Construction Requirements 4-32
4.10.3.1 Construction 4-32
4.10.3.2 Traffic Control 4-32
4.10.4 Method of Measurement 4-32
4.10.5 Basis of Payment 4-32
4.10.6 Items in the Bill of Quantities 4-32

4.11 Recycled Bituminous Mixes 4-32

4.11.1 Description 4-32
4.11.2 Materials 4-33
4.11.3 Job Mix and Project Mix 4-33
4.11.4 Equipment 4-33
4.11.5 Construction of Trial Sections 4-33
4.11.6 Mixing Procedures 4-33
4.11.7 Surface Preparation 4-33
4.11.8 Delivery, Spreading and Finishing 4-33
4.11.9 Sampling and Testing 4-33
4.11.10 Surface Tolerances 4-33
4.11.11 Determination of Thickness 4-33
4.11.12 Method of Measurement 4-34
4.11.13 Basis of Payment 4-34
4.11.14 Items in the Bill of Quantities 4-34

4.12 Surface Rideability

Measurement 4-34
4.12.1 Description 4-34

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♦ 4-0 ♦
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4.1 Materials for Bituminous
Construction
4.1.1 Description
1 This Sub-section includes specifications for materials
for use in the construction of the various bituminous
pavement courses including the following:
i. Coarse and fine mineral aggregates and filler.
ii. Bitumen products including penetration graded
bitumens, cutback bitumens, emulsified
bitumens, modified bitumens, and rejuvenating
agents for use in bituminous courses and surface
treatments.
iii. Polymers for bitumen modification, Elastomers
such as Styrene-Butadiene-Styrene (SBS)
copolymers or Plastomers such as Polyethylene
(PE) polymer, as shown on the drawings.
2 All materials sources and the quality of materials
proposed for use in the work shall be approved prior to
procuring or processing material from such sources.
Inspection, sampling, testing and retesting as necessary,
shall be at the Contractor's expense.
3 Storage and handling of all materials shall conform
to the relevant requirements of these specifications.
Materials shall be stored on hard, clean surfaces.
4.1.2 Aggregate Materials Generally
4.1.2.1 Sources and Production
1 The Contractor shall satisfy himself as to the location
of the sources of aggregate materials, the length of haul to
the site, the suitability and quantity of materials available;
extent of work necessary to obtain the material available;
the work required to open the quarry and to crush, screen
and wash (if necessary) the materials to meet the specified
gradation.
2 Prior to starting quarry operations, the Contractor
shall obtain written permission from the authorities or
owners concerned.
3 Crushing and screening plants shall not be put into
operation prior to their approval. If, after any plant is put
into operation, it fails to perform as intended, the
Contractor shall either rectify the defects in the existing
plant to the satisfaction of the Engineer, or shall provide
alternative approved plant.
4 Approval of the crushing and screening plants and
other equipment shall in no way relieve the Contractor of
his responsibilities in respect of producing aggregates
which conform to the Specifications and in the quantities
required for the completion of the work.
4.1.2.2 Stockpiling
1 Stockpile areas shall be surveyed prior to stockpiling
to establish control points and to obtain a record of
existing cross sections for future use in determining
stockpile quantities. The areas shall be adequately drained
at all times.
2 Stockpiling procedures shall not result in degradation
or segregation of the stockpiled material, or introduction
of foreign materials into the stockpile. Heights of
aggregate stockpiles shall not exceed 5 m.
4.1.2.3 Sampling and Testing
1 Sampling and testing procedures shall conform to
the relevant requirements of this Specification.
2 The Contractor shall submit to the Engineer, 30 days
prior to the scheduled start of crushing and screening
operations, a statement of origin and composition of all
aggregates proposed for use in the work.
3 In order to ascertain the properties of aggregate
materials, the Contractor shall submit for testing,
representative samples of all materials intended for
incorporation in the work, prior to starting quarry
operations. The representative samples shall be taken by
the Contractor in the presence of the Engineer. Tests shall
be performed by the Contractor at his laboratory or at an
approved outside laboratory
4 Test results shall be utilized by the Contractor in
assessing the locations, extent of deposits and quantities
of materials which will conform to the Specification when
properly processed. Any special tests that may be required
by the Engineer shall be carried out by the Contractor, in
his own laboratory, or an outside laboratory, approved by
the Engineer. Engineer’s approval of test results shall in
no way obviate the need for further testing if required by
the Engineer. Approval of specific sources of materials
shall not be construed as final approval and acceptance of
materials from such sources.
5 Processed materials shall be tested and approved
before being stockpiled on Site or incorporated in the
work and may be inspected and tested at any time by the
Engineer during their preparation, storage and use.
Questionable materials awaiting testing and approval,
shall not be unloaded and mixed with materials previously
approved. If the grading and quality of any materials
delivered to the Site do not conform to the grading and
quality of the established control samples, the Engineer
will reject such materials.
6 Samples shall satisfy all specified test requirements.
The Contractor shall permit the Engineer to inspect any
and all materials used or to be used, at any time during or
after their preparation, or while being used during
progress of the work. Unsatisfactory materials, whether in
place or not, shall be removed promptly from the Site.
The Contractor shall furnish all necessary materials, labor,
tools and equipment and transport required by the
Engineer for such inspections.
4.1.3 Aggregates for Bituminous Paving
Mixes
1 Aggregates for use in bituminous base course,
binder course, leveling, wearing and cold mix courses
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shall consist of crushed stone. The coarse fraction of the 11 Combined coarse and fine aggregates for bituminous
aggregates for use in bituminous wearing course shall mixes, including mineral filler, when tested in accordance
consist of 100% crushed stone from a hard, high quality with AASHTO T 27 and T11, shall conform to the
Gabbro and/or non-vesicular Basalt. gradations shown in Table 4.1.3.3. For the Gradation of
2 Coarse aggregate shall be the fraction of crushed Leveling Course, this should be provided in the Special
aggregate material retained on 4.75 mm (No. 4) sieve. Specifications depending on the particular conditions of
Fine aggregate shall be the fraction of crushed aggregate the Project.
material passing 4.75 mm (No. 4) sieve. Mineral filler shall
Percent passing
be added when the combined grading of coarse and fine Sieve
aggregates is deficient in material passing 0.075 mm (No. Size Base course Wearing course
Binder
200) sieve. (mm) Class Class course Class Class
3 The material from hot bins passing the number 40 A B A B
sieve (0.425mm) when tested in accordance with AASHTO 25 100 100 100 - -
T 90 shall be non plastic. In addition the material from cold 90-
19 60-90 65-100 100 100
bins should not have PI greater than 4. 100
90-
4 Aggregates shall be free of gypsum and the coarse 12.5 - - - -
100
fraction of the aggregate shall not contain more than 5%
9.5 42-67 60-80 47-72 56-80 73-93
chert when tested in accordance with AASHTO T113.
5 Aggregates shall be of uniform quality, free from 4.75 25-50 40-60 30-56 35-56 51-71
decomposed stone, organic matter and shale. 2.36 - 28-48 - - 34-54
6 The percentage by weight of friable particles, clay 2.00 15-31 - 19-36 22-36 -
lumps, and other deleterious matter shall not exceed 1%
1.18 - 20-36 - - 22-38
as determined by AASHTO T 112.
0.600 - 14-26 - - 18-30
7 Aggregate particles shall be clean, hard, durable and
sound. Crushing shall result in a product such that, for 0.425 8-20 - 8-20 8-20 -
particles retained on 4.75 mm (No. 4) sieve, at least 90% 0.300 - 8-20 - - 10-22
by weight shall have 2 or more fractured faces, when
tested in accordance with ASTM D5821. 0.150 - 7-15 - - 9-17

8 The flakiness index and the elongation index test 0.075 2-15 2-8 2-8 2-8 2-8
shall be conducted in accordance with BS 812, the Table 4.1.3.3: Gradation of Aggregates for Bituminous
following are maximum limits: Mixes
Bituminous Bituminous
12 The loss in weight of aggregate after 500 revolutions,
Index Wearing Binder & Base
Course Courses when tested in accordance with AASHTO T 96, shall not
Flakiness Index F.I 25 30 exceed 35% for binder and base courses, and 25% for
Elongation Index E.I 25 30 wearing course.

Table 4.1.3.1: Flakiness and Elongation Indices of 13 When tested for soundness in accordance with
AASHTO T 104 the coarse aggregate (retained on No.4
Aggregates for Bituminous Mixes
sieve) shall not show signs of disintegration and the loss
9 Aggregates shall be washed if directed, to remove by weight after 5 cycles shall not exceed 10% in the case
any clay lumps, organic matter, adherent dust or clay films of the sodium sulfate test and 12% in the case of the
or other extraneous or deleterious matter that may magnesium sulfate test.
prevent or detract from proper adhesion of bitumen to the 14 When tested for resistance to stripping in accordance
aggregate particles. with the AASHTO T-182 at least 95% coated particles
10 Mineral filler shall consist of finely divided mineral should be achieved. If resistance to stripping is not
matter such as limestone dust, hydrated lime; other non- achieved then anti-stripping agent should be used. For
plastic mineral filler, free from clay and organic impurities; additional stripping resistance requirements for wearing
or Portland cement, conforming to AASHTO M 17. The course layer, refer to Sub-section 4.5.
gradation of the mineral filler shall comply with the 15 Polish stone value (PSV) of coarse aggregates used
requirements of Table 4.1.3.2: in the wearing course mix when tested according to BS
812 shall be at least 60%.
Sieve Size Percent Passing by Mass
16 The sand equivalent for fine aggregates, when tested
0.600 mm (No. 30) 100
in accordance with AASHTO T45, shall be a minimum of
0.300 mm (No. 50) 95 - 100
75.
0.075 mm (No. 200) 70 - 100
Table 4.1.3.2: Gradation of Mineral Filler for Bituminous
Mixes

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4.1.4 Aggregates for Seal Coats 7 The loss in weight of aggregate after 500 revolutions,
when tested in accordance with AASHTO T 96 (Los
1 Cover aggregates for bituminous seal coats shall Angeles Test), shall not exceed 35%.
consist of screenings of crushed stone. Aggregate for
8 When tested for soundness in accordance with
slurry seals shall consist of crushed stone fines or natural
AASHTO T 104, the aggregates shall not show signs of
sand blended with not less than 50% crushed stone fines.
disintegration and the loss by weight shall not exceed 10%
For heavy-duty applications slurry aggregate shall consist
in the case of the sodium sulphate test or 12% in the case
of 100% crushed fines. Wadi gravels shall not be used for
of the magnesium sulphate test.
seal coats, suitability of suggested crushed stone fines for
use in slurry seal shall be demonstrated prior to use. 9 When tested for resistance to stripping in accordance
with AASHTO T 182, at least 95% of the aggregate surface
2 Aggregates shall be free of crystalline or amorphous
area shall remain coated with a bitumen film. If resistance
gypsum (expressed as SO3), and shall not contain more
to stripping is not achieved then anti-stripping agent
than 5% chert when tested in accordance with AASHTO
should be used.
T113.
10 Polish stone value (PSV) of coarse aggregates used
3 Aggregate particles shall be clean, hard, durable and
in the upper layer of seal coats when tested according to
sound. For particles retained on 4.75 mm (No. 4) sieve, at
BS 812 shall be at least 60%.
least 90% by weight shall have 2 or more fractured faces
and 100% by weight shall have one or more fractured 11 The sand equivalent for fine aggregates, when tested
faces, when tested in accordance with ASTM D5821. in accordance with AASHTO T45, shall be a minimum of
75.
4 Flakiness index and elongation index tested in
12 Table 4.1.4.2 below summarizes the required
accordance with BS 812 shall not exceed 25% for each of
aggregate properties listed under items 7 to 11 above:
flakiness and elongation index. The percentage by weight
of clay lumps and friable particles as determined by Standard Test Specification
Aggregate Property
AASHTO T 112 shall not exceed 3%. Light weight Method Requirements
aggregate of specific gravity of 2 or less shall not exceed Loss in weight of
3% as determined by AASHTO T 113. aggregate after 500
5 If necessary aggregates shall be washed, or revolutions AASHTO T96 Max. 35%
processed by an approved alternative method, to remove (Los Angeles
any clay lumps, organic matter, adherent dust or clay films Abrasion)
or other extraneous or deleterious matter that may
Soundness in
prevent or detract from proper adhesion of bitumen to the AASHTO T 104 Max. 10%
Sodium Sulphate
aggregate particles.
6 Cover aggregates and aggregate for slurry seals, Soundness in
when tested in accordance with AASHTO T 27 and T 11, Magnesium AASHTO T 104 Max. 12%
Sulphate
shall conform to the gradations given in Table 4.1.4.1.
Resistance to
Double Bituminous Surface AASHTO T 182 Min. 95%
Sieve stripping
Treatment Aggregate Slurry
Designation Polish Stone Value
1st 2nd Aggregat
(Square Application Application e (PSV) of coarse BS 812 Min. 60%
openings) (Grading B) (Grading C) aggregates

25 mm 100 - - Sand Equivalent for

AASHTO T175 Min. 75
Fine Aggregate
19 mm 90-100 - -
12.5 mm 20-55 100 - Table 4.1.4.2: Properties of Aggregates for Seal Coats

9.5 mm 0-15 58-100 100

4.1.5 Bitumen Generally
4.75 mm 0-5 10-30 90-100
4.1.5.1 Type and Grade
2.36 mm - 0-10 65-90
1.18 mm - 0-5 45-70 1 Bitumen shall be petroleum derivative penetration
grade 60-70 (unless otherwise shown in the Special
0.60 mm - - 30-50 Specification), conforming to the requirements of
0.30 mm - - 18-30 AASHTO M20. When more than one type or grade is
specified under any item, the Engineer will select the type
0.15 mm - - 10-20
and grade to be used in the work. If the specified grade is
0.075 mm 0-0.5 0-0.5 5-15 not locally available in the market, the Contractor shall be
Table 4.1.4.1: Gradation of Aggregates for Seal Coats deemed to have considered any additional costs
associated with the import of bitumen in his contract price.

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4.1.5.2 Transporting Bitumen
1 All transporting of bitumen shall be by conveyances
that are free from contamination. Tank cars or tank trucks
used for transporting bitumen shall be carefully inspected,
drained, and cleaned if necessary, before loading, to
prevent contamination of the bitumen from residues of
previous loads. Bitumen may also be delivered and
transported in metal drums.
2 Tank trucks or trailers used to transport bitumen shall
be equipped with an approved sampling device which
shall be built into the tank or re-circulating or discharge
line in such a manner that a sample can be drawn during
circulation or discharge.
4.1.5.3 Storage of Bitumen
1 The Contractor shall provide an adequate storage
facility for bitumen, at the site of the mixing plant. This
facility shall be clean and stable and provided with cover
and shelter from excessive temperatures.
2 No open fires or smoking shall be allowed in or
around the storage facility.
3 The storage capacity shall be sufficient to maintain a
uniform operation while allowing for delayed shipments
and time for testing. Different batches of bitumen shall be
separated, so as to allow for easy identification.
4 If the bitumen is delivered to the site in metal drums,
on arrival the drums shall be inspected for perforations,
rusting, melting or any other defects that could cause
pollution or chemical changes to the bitumen.
Depending on the severity of each case, the Engineer shall
decide whether to retain or reject the affected drums.
5 The stored bitumen products should be protected
from temperatures which may exceed the range of -5
degrees C to +50 degrees C.
temperature of bitumen, weigh buckets, spray bars, and
other containers.
3 Thermometers of approved type and adequate range
(calibrated in 2 degrees C increments) for accurately
measuring the temperature of the bitumen while heating,
shall be located so as to be readily visible and shall be
kept clean and in proper working order at all times.
4 Where storage tanks are required, their capacity shall
be sufficient for at least one day's production.
5 Bitumen materials, wasted through careless handling
or rendered unsuitable for use by overheating shall not be
used in the work.
4.1.5.5 Sampling and Testing
1 Procedures for sampling of bituminous materials
shall conform to AASHTO T 40.
2 General requirements and procedures for sampling
and testing of the various types of bitumen shall conform
to the requirements of the relevant sections of these
specifications.
3 Testing for conformity of bitumen products shall be
carried out to AASHTO Standard Methods listed in
AASHTO M 20 and other specified standards.
4.1.6 Bitumen Products
4.1.6.1 Penetration Graded Bitumen
1 The various grades of penetration graded bitumen
material shall conform generally with the requirements of
AASHTO M 20 as given in Table 4.1.6.1.
Penetration Grade
40 - 50 60 - 70 80 - 100
Requirement
Min Max Min Max Min Max

4.1.5.4 Heating of Bitumen Ductility at 25 ̊C

100 - 100 - 100 -
(cm)
1 Heating equipment shall be of an approved type. Kinematic Viscosity
280 - 240 - 200 -
Any method of agitation or heating that introduces free at 135 ̊C (cSt)
steam or moisture into the bitumen will not be approved. Penetration at 25 ̊C
40 50 60 70 85 100
(0.1mm)
During the process of its manufacture, conveyance,
storage, or construction use, bitumen of whatever type Softening Point ( ̊C) 50 58 48 56 46 48
shall not be heated to temperatures more than 10 degrees Specific Gravity at
1.01 1.06 1.01 1.06 1.0 -
C above the maximum application temperature specified 25 ̊C
Loss on heating to
for the respective type of bitumen nor above 170 degrees - 0.8 - 0.8 - 1.0
163 ̊C (% wt)
C, whichever is the lower. Materials heated in excess of
Penetration of
these temperatures will be rejected and shall not be used residue % of 58 - 54 - 50 -
in the work. original
2 Tanks for heating and storage of bitumen shall be Solubility in
capable of heating the material, under effective and Trichloroethylene 99 - 99 - 99 -
(% wt)
positive control at all times, to the specified temperature.
The system shall provide uniform heating for the entire Ash content (% wt) - 1.0 - 1.0 - 1.0
contents of the tank. The circulation system shall be of Flashpoint
adequate size to ensure proper and continuous circulation (Cleveland Open 250 - 250 - 225 -
of the bitumen during the entire operating period. Cup) ( ̊C)
Suitable means shall be provided, either by steam or oil
Table 4.1.6.1: Properties of Penetration Grade Bitumen
jacketing, or other insulation, for maintaining the required

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2 Sampling and testing shall be in accordance with the
AASHTO standard method listed in AASHTO M 20.
3 Penetration bitumen application temperature range
shall be as given in table 4.1.6.2. Actual Mixing and
Compacting Temperature of Asphalt Concrete shall be
determined from Kinematic Viscosity of Bitumen as shown
in MS-2.
Pen 40/50 60/70 80/100
Application
150-170 145-165 140-160
Temperature ( ̊C)
Table 4.1.6.2: Application Temperature by Bitumen Grade
4.1.6.2 Bitumen Modifier and Modified Bituminous
Material
1 An approved modifier shall be incorporated in all
penetration graded bituminous material immediately prior
to the time of use, unless otherwise shown on the
Drawings.
2 The types and penetration grades of the original
bituminous materials shall be submitted by the polymer
supplier/contractor for the Engineer’s approval.
3 The Contractor shall provide evidence of his
experience to prove that he is currently supplying and
using polymer modified bitumen on similar projects with
successful results and performance. The Contractor shall
submit data, which indicate that the product has a proven
record of performance regarding compatibility with
asphaltic concrete mixtures, blending of the product with
the asphalt cement and placing and compacting the
mixture.
4 The modified bitumen shall demonstrate significantly
reduced temperature susceptibility and/or improved
adhesive qualities. The workability of the modified
bitumen shall be unchanged from that of unmodified
7 The minimum requirements and tests to be
bitumen.
performed on the modified bitumen shall be as follows:
5 Unless specified otherwise under this Specification,
mixing and preparation of modified bitumen shall be
carried out in accordance with the modifier manufacturer’s
instructions, and to the approval of the Engineer.
6 The Contractor shall submit a method statement for
the preparation of polymer modified bitumen (PMB)
blending, including the type of polymer intended for use,
for the Engineer’s approval. The Contractor shall propose
the type of polymer he intends to use and shall
demonstrate through testing that the modified asphalt
meets all the specification requirements. Blending of the
asphalt cement and the modifier shall be done by the
supplier of the modifier in a mobile mixing plant adjacent
to the Contractor’s asphalt plant on Site. The Contractor
shall submit for the Engineer’s approval a comprehensive
QA/QC program to ensure that the pre-blended polymer
modified asphalt is delivered, stored in suitable conditions,
incorporated in the bitumen mix and laid in strict
accordance with the manufacturer’s instructions. The
minimum requirements for this program shall include but
shall not be limited to the following:
i. Compatibility with original bitumen: The
modified bitumen shall be tested for
compatibility with the polymer modifier to
ASTM D5892 for both softening point and
dynamic shear (DSR). The difference in deg C
between the softening points of the respective
top and bottom portions of the tube sample
shall not exceed 4 deg C. The separation ratio
based on G* shall have an average G* value
[(top + bottom) / 2] within 0.8 to 1.2 of the
initial G* value. Alternative compatibility test
according to ASTM D5841 can be carried out in
lieu of ASTM D5892, only in cases where the
Contractor and supplier can prove that the
ASTM D5892 cannot be adopted for the type of
polymer proposed.
ii. Mixing and compaction temperatures: The
mixing and compaction temperatures shall be
established in the laboratory by determining
the Brookfield viscosity of the approved
polymer modified bitumen at three different
temperatures 135 deg C, 165 deg C and 195
deg C. The established mixing and compaction
temperatures shall then be evaluated and
finalized based upon successful site trials.
iii. Proportion of modifier in the mix: Depending
upon the results of the tests specified in Table
4.1.6.3 below, the proportion of modifier to be
used and the quality control procedures during
mixing shall be determined in accordance with
the manufacturer’s recommendations to
provide the optimum characteristics of the mix
as specified below.
i. If Styrene-Butadiene-Styrene (SBS) polymer is
used, it shall have the following properties:
- Butadiene-Styrene Ratio = 70/30.
- Block Styrene = 30%.
- Hardness Shore A = 80.
- Density ASTM D792 = 0.93 – 0.95 g/cm3.
ii. If Polyethylene polymer is used, it shall be
polyolefinic, primarily low density polyethylene
and shall meet the following requirements:
Test Property Criterion Specification
Density 0.910 min ASTM D 792
0.940 max
Melt Index 1.0 – 15.0 ASTM D 1238
Melting Point 110° – 135° C
iii. The ratio of modifier to bitumen in the
completed mix shall be between 4 and 8 parts
of modifier for 100 parts of bitumen, according
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 to the manufacturer’s recommendations, which
must confirm that the modified bitumen will
meet the requirements of Table 4.1.6.3 and will
prove the optimized properties of the modified
binder at the proposed proportion of modifier.

iv. The modified bitumen properties shall comply

with the requirements of the latest revision of
AASHTO M320 specifications and to the
requirements of Table 4.1.6.3 below.

v. The Contractor shall obtain from the

manufacturer and provide to the Engineer
periodical certificates stating that the modifier
is being incorporated in the bitumen mix in
accordance with the with the approved QA/QC
program.

Frequency of
Ref Property Test Standard Requirements
Testing
to be agreed with the
1. Penetration, 25° C, 100g, 5s, dmm ASTM D5 at each batch
Manufacturer
ASTM D36,
2. Softening Point, °C Min. 65 at each batch
AASHTO T53
3. Viscosity (Brookfield) at 135° C, max °C ASTM D4402 3000 CP at each batch
4. Flash Point Temp, min °C AASHTO T48 230 °C every 500 t
Dynamic Shear before RTFOT, G*/sin ∂,
Min. 1.00 kPa, test temperature @ 10
5. AASHTO TP5 76 °C every 500 t
rad/s, °C, (Where G* = Dynamic Shear
Modulus and ∂ = phase angle)
Rolling Thin Film Oven (RTFO) Mass
6. AASHTO T240 1% at each batch
Loss, max, %
1
Elastic Recovery , 25° C, 10cm ASTM D6084,
7. 75 at each batch
elongation, % after RTFOT AASHTO T301

Dynamic Shear after Rolling Thin Film

8. Oven Test (RTFOT), G*/sin ∂, Min. 2.2 AASHTO TP5 76 °C every 500 t
kPa, test temperature @ 10 rad/s, °C
See requirements
9. Compatibility Test ASTM D5892 under Item 6 of every 500 t
Paragraph 4.1.6.2

Table 4.1.6.3: Modified Bitumen (Performance Grade)

Properties

Continued on page 4-7

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8 The elastic recovery specified under Item 7 of Table RC Cutback Spraying
4.1.6.3 above corresponds to modified bitumen with either Grade Temp °C
an elastomer or a blend of elastomer and plastomer
RC - 70 40 - 75
polymers. Should the Contractor opt to use plastomer
type polymer only, for the asphalt modification, then the RC - 250 65 - 105
elastic recovery requirement can be replaced by a set of RC - 800 90 - 115
tests that shall be carried out at the start of the project,
RC - 3000 105 - 135
with each set containing three samples, and the results
shall conform to the following Table 4.1.6.4: 4.1.6.4 Medium-Curing (MC) Cutback Bitumen

Property Test Standard Requirements 1 MC cutback shall conform to the requirements of

AASHTO M 82, which covers Grades MC-30, MC-70, MC-
Pressure Aging Vessel Residue 250, MC-800 and MC-3000 and are listed in Table 4.1.6.6.
2 Sampling and testing shall be in accordance with the
Pressure Aging AASHTO standard methods listed in AASHTO M 82.
Vessel (PAV)
AASHTO R28 110 °C 3 MC cutback bitumen spraying temperature ranges
Aging
Temperature, °C. shall be as follows:
Dynamic Shear, MC Cutback Spraying
G*sin∂,
Grade Temp °C
Maximum 5000
37 °C
kPa, AASHTO T315 MC - 30 21 - 63
Test temperature
@ 10 rad/s, °C. MC - 70 45 - 80
Physical MC - 250 70 - 110
Report
Hardening
Creep Stiffness, MC - 800 95 - 125
S, Maximum 300 MC - 3000 110 - 145
MPa m-value,
0 °C
minimum 0.300 AASHTO T313 4.1.6.5 Slow-Curing (SC) Cutback Bitumen
Test temperature
@ 60 s, °C. 1 SC cutback shall conform to the requirements of
Direct tension, ASTM D 2026 which covers Grades SC-70, SC-250, SC-800,
Failure strain, and SC-3000, and are shown in Table 4.1.6.7.
minimum 1.0%
AASHTO T314 0 °C 2 Sampling and testing shall be in accordance with the
Test temperature
appropriate ASTM standard methods.
@ 1.0 mm/min,
°C. 3 SC cutback bitumen spraying temperature ranges
Table 4.1.6.4: Additional Tests Required for Plastomer shall be as follows:
Type Polymer SC Cutback Spraying
Grade Temp °C
9 The percentage of the polymer to be mixed with the
conventional bitumen to modify the latter shall be based SC - 70 45 - 80
on tests to satisfy the job mix formula. SC - 250 70 - 110
10 The modifier shall be pre-blended into the SC - 800 95 - 125
conventional bitumen before mixing with the aggregate in
the hot mix plant. SC - 3000 110 – 145

11 Blending Equipment: The production of the modified 4.1.6.6 Slow-Setting (SS and CSS) Emulsified
bitumen shall require a specialized high shear blending Bitumens Generally
machinery to ensure complete and controlled dispersion
and chemical reaction of the modifiers with the 1 Selection and use of emulsified bitumens shall
conventional bitumen. generally be in accordance with the recommendations in
AASHTO R 5, subject to the following requirements.
4.1.6.3 Rapid-Curing (RC) Cutback Bitumen
2 The manufacturer shall furnish samples of the base
1 RC cutback shall conform to the requirements of bitumen used in the emulsion.
AASHTO M 81, which covers Grades RC-70, RC-250, RC- 3 When samples of undiluted emulsion are not readily
800, and RC-3000 and are listed in Table 4.1.6.5. available for test purposes, tests may be made on the
2 Sampling and testing shall be in accordance with the diluted emulsion and the respective specifications
AASHTO standard methods listed in AASHTO M 81. modified to reflect the changes in properties resulting
from dilution of the bitumen.
3 RC cutback bitumen spraying temperature ranges
shall be as follows:

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4 All emulsified bitumens shall adhere firmly to the
surface of the mineral aggregate or the highway surface
as appropriate. Failure of the emulsified bitumen to
perform satisfactorily on the job shall be deemed cause
for its rejection regardless of satisfactory laboratory test
results.

4.1.6.7 Anionic Slow-Setting (SS) Emulsified Bitumen

1 Anionic emulsified bitumens shall, prior to dilution,

conform to the requirements of AASHTO M 140, for Types
SS-1 and SS-1h and as listed in Table 4.11.
2 Sampling and testing shall be in accordance with
AASHTO T 59.
3 Emulsified bitumen spraying temperature range shall
be set so that appropriate viscosity for each application is
achieved, if specific viscosity curves are not available the
range values, generally considered as guidance, shall be
25 - 65 degrees C. The temperature range for pugmill
mixing for medium and slow setting types shall be 15-65
degrees C.

RC-70 RC-250 RC-800 RC-30

Parameter/Test
Min Max Min Max Min Max Min Max
Kinematic Viscosity at 60 oC
70 140 250 500 800 1600 3000 6000
centistokes
Flash Point (Tag, open-cup) oC - - 27 - 27 - 27 -
Water percent - 0.2 - 0.2 - 0.2 - 0.2
Distillation Test:
Distillate percentage by volume of total
distillate to 360 oC
To 190 oC 10 - - - - - - -
To 225 oC 50 - 35 - 15 - - -
To 260 oC 70 - 60 - 45 - 25 -
To 315 oC 85 - 80 - 75 - 70 -
Residue from distillation to 360 oC volume
55 - 65 - 75 - 80 -
percentage of sample by difference
Tests on residue from distillation:
Absolute viscosity at 600 2400 600 2400 600 2400 600 2400
60 oC poises
Ductility, 5 cm/min.
100 - 100 - 100 - 100 -
at 25 oC cm
Solubility in Trichloroethylene,
99 - 99 - 99 - 99 -
percent
Spot test with:
- Standard Naphta Negative for all grades
- Naphtha-xylene solvent,
Negative for all grades
percent xylene
- Heptane-xylene solvent,
Negative for all grades
percent xylene

Table 4.1.6.5: Properties of R.C. Cutback Bitumen

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 MC-30 MC-70 MC-250 MC-800 MC-3000
Parameter/Test
Min Max Min Max Min Max Min Max Min Max

Kinematic Viscosity at 60 °C
30 60 70 140 250 500 800 1600 3000 6000
centistokes
Flash Point (Tag, open-cup) °C 38 - 38 - 66 - 66 - 66 -
Water percent - 0.2 - 0.2 - 0.2 - 0.2 - 0.2
Distillation Test:
Distillate percentage by
volume of total distillate to
360 °C
To 225 °C - 25 0 20 0 10 - - - -
To 260 °C 40 70 20 60 15 55 0 35 0 15
To 315 °C 75 93 65 90 60 87 45 80 15 75
Residue from distillation to
360 °C volume percentage of 50 - 55 - 67 - 75 - 80 -
sample by difference
Tests on residue from
distillation:
300 1200 300 1200 300 1200 300 1200 300 1200
Absolute viscosity at 60 °C
poises
Ductility, 5 cm/min. at 25 °C
100 - 100 - 100 - 100 - 100 -
cm
Solubility in Trichloroethylene,
99 - 99 - 99 - 99 - 99 -
percent
Spot test with:
- Standard Naphtha Negative for all grades
- Naphtha-xylene solvent,
Negative for all grades
percent xylene
- Heptane-xylene solvent,
Negative for all grades
percent xylene

Table 4.1.6.6: Properties of M.C. Cutback Bitumen

SC-70 SC-250 SC-800 SC-3000

Parameter/Test
Min Max Min Max Min Max Min Max
Kinematic Viscosity at 60 °C
70 140 250 500 800 1600 3000 6000
cSt
Flash Point (Cleveland open
66 - 79 - 93 - 107 -
cup) degrees °C
Distillation Test:
10 30 4 20 2 12 - 5
total distillate to 360 °C
Volume % Solubility in
99 - 99 - 99 - 99 -
trichloroethylene %
Kinematic viscosity on
4 70 8 100 20 160 40 350
distillation residue at 60°C,St
Asphalt residue:
50 - 60 - 70 - 80 -
Residue of 100 penetration, %
Ductility of 100 penetration 100 - 100 - 100 - 100 -

residue at 25°C, cm Water, % - 0.5 - 0.5 - 0.5 - 0.5

Table 4.1.6.7: Properties of S.C. Cutback Bitumen

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 range values, generally considered as guidance shall be
25-65 degrees C. The temperature range for pugmill
Slow-Setting
mixing for medium and slow setting types shall be 15-65
SS-1 SS-1h degrees C.
Min Max Min Max
Viscosity, Saybolt 4.1.7 Method of Measurement and Basis of
20 100 20 100
Furol at 25 °C, s Payment
Storage stability
- 1 - 1 1 No separate measurement and no items are included
test, 24-h, %
in the Bill of Quantities for the materials described in this
Cement mixing test,
- 2 - 2 Sub-section. Measurement and payment provisions are
%
included in the appropriate Sub-sections of this Section 4.
Sieve test, % - 0.1 - 0.1
Residue by
57 - 57 - 4.2 Prime and Tack coats
distillation, %
Tests on residue
from distillation 4.2.1 Description
100 200 40 90
test: Penetration, 25
1 This Sub-section describes requirements for
°C,100 g, 5 s
furnishing and applying MC cutback bitumen prime coat
Ductility, 25°C, 5 to a previously constructed sub-base or aggregate base
cm/min, cm 40 - 40 - course, highway shoulders, or concrete pavement; and
furnishing and applying RC cutback bitumen or emulsified
Solubility in bitumen as a tack coat to a previously constructed
trichloroethylene % 97.5 - 97.5 - bituminous base or wearing surface to provide bond for a
superimposed bituminous course; all as and where shown
Table 4.1.6.8: Properties of Anionic Emulsified Bitumen on the Drawings.

4.1.6.8 Cationic Slow-Setting (CSS) Emulsified 4.2.2 Materials

Bitumen
4.2.2.1 Medium Curing Cutback Bitumen
1 Cationic emulsified bitumens shall, prior to dilution,
1 MC cutback bitumen (for prime coats) shall be as
conform to the requirements of AASHTO M 208, for Types
recommended by ASTM D 2399. Generally MC 70 shall be
CSS-1 and as listed in Table 4.1.6.9.
used unless otherwise specified.
Slow Setting
4.2.2.2 Rapid-Curing Cutback Bitumen
CSS-1
Min Max 1 RC cutback bitumen (for tack coats) shall be Grades
Tests on emulsions: RC-70 or RC-250 as appropriate and as specified in Sub-
Viscosity, Saybolt Furol at 20 100 section 4.1 – ‘Materials for Bituminous Construction’, or as
25°C, s required by the Engineer.
Storage stability test, 24-h,
1 - 4.2.2.3 Slow-Setting Emulsified Bitumen
%
Particle charge test Positive 1 Slow-setting emulsified bitumen (for tack coats)
Sieve test, % - 0.10 shall be slow setting Grades SS-1, SS-1h or CSS-1, as
Cement mixing test, % - 2.0 appropriate and as specified in Sub-section 4.1 –
Distillation: ‘Materials for Bituminous Construction’, or as required by
57 -
Residue, % the Engineer.
Tests on residue from
distillation test: 100 250 4.2.2.4 Polymer Modified Bituminous Tack Coat
Penetration, 25°C, 100 g, 5 s 1 The polymer modified tack coat material shall be as
Ductility, 25°C, 5 cm/min, cm 40 - specified in Sub-section 4.1, the original base binder
Solubility in (before polymer modification) shall be penetration grade
97.5 -
trichloroethylene % bitumen and the polymer modified bitumen binder shall
Table 4.1.6.9: Properties of Cationic Emulsified Bitumen be as specified under paragraph 4.1.6.2. The viscosity of
the binder used for the polymer modified tack coat
2 Sampling and testing shall be in accordance with
(Brookfield viscosity determined as per ASTM D4402) at
AASHTO T 59.
application temperature shall range between 200 and 400
3 Emulsified bitumen spraying temperature range shall
CP. The softening point and elastic recovery at 25° C (after
be set so that appropriate viscosity for each application is
RTFOT) of the polymer modified tack coat shall not be less
achieved, if specific viscosity curve is not available the
than 80° C and 90% respectively.

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4.2.3 Equipment
1 Equipment used for diluting emulsified bitumen,
heating cutback bitumen, spraying cutback and emulsified
bitumen, and for application of blotting material to prime
coats, shall conform with the relevant requirements of this
Specification and with the Contractor's approved list of
equipment.
4.2.4 Construction of Trial Sections
1 The Engineer may require trial sections to be
constructed prior to the commencement of on-site prime
or tack coat applications. The Contractor shall construct
trial sections using varying application rates of bitumen,
as selected by the Engineer. Each trial section shall be 2
lanes wide by 50 m long, at approved locations on or close
to the site.
2 Each trial section shall be constructed using the same
materials, mixing and spraying equipment, and
construction procedures, proposed for use in the Works.
3 The objectives of these trials shall be to determine
the adequacy of the Contractor's equipment and the most
suitable application rates for cutback bitumen prime and
tack coats, or emulsified bitumen tack coats.
4 The Contractor shall not proceed with any on-site
coat applications until the methods and procedures
established in the trials have been approved.
4.2.5 Application Procedures
4.2.5.1 Medium Curing Cutback Bitumen
1 All equipment used for surface cleaning, heating
bitumen (if required) and application of prime and tack
coats, shall be adequate for the purposes intended and
shall be approved before use.
2 All surfaces to receive prime or tack coats shall
conform to the specified tolerances and compaction
requirements and shall be properly cleaned using power
brooms or power blowers. The surfaces shall be
approved before applying any bitumen material.
3 Application of prime coats and tack coats shall be
performed only when the surface to be treated is
sufficiently dry for tack coat and sufficiently moist for
prime coat, and when the atmospheric temperature is
above 10ºC for the application of tack coat, 15ºC for the
application of prime coat. No application is to be
performed if there is fog, rain, strong winds, dusty
conditions, or dust storms.
4 The surfaces of all structures, curbs, gutters and
other highway appurtenances shall be protected in an
approved manner to prevent them from being splattered
or stained with bitumen or damaged during equipment
operation. The Contractor shall be responsible for making
good any such staining or damage to the satisfaction of
the Engineer.
5 Traffic shall not be permitted on surfaces after they
have been cleaned and prepared for prime or tack coat
application.
6 If there are undue delays in scheduling priming or
subsequent paving after priming, the surface tolerances
and compaction of the granular course shall be re-verified
and deficient areas corrected or replaced in an approved
manner at the Contractor's expense.
7 The Contractor shall maintain prime coats and tack
coats intact until they are covered by the subsequent
pavement course. Any area where the coats have been
damaged shall be cleaned of all loose material, any
surface defects repaired and the coat re-applied at the
Contractor's expense. Traffic control measures shall
conform to the requirements of the relevant Sections of
this Specification.
4.2.5.2 Prime Coat Application
1 If required by the Engineer, when the surface is an
untreated subgrade or a granular surface, the cleaned
surface shall be given a light application of water and
allowed to dry to the condition deemed appropriate by the
Engineer before the bituminous material is applied.
2 Heating of MC cutback bitumen and its temperature
at the time of application shall conform to the relevant
requirements of Sub-section 4.1.
3 Areas to be primed shall be as shown on the
Drawings and including 200 mm widths outside the edges
of the pavement line; top of embankment slopes to
pavement lines; and between curbs or gutter edges for
bridge checks.
4 Application rates for prime coat will be determined
by the Engineer from the trial sections, and shall be
generally within the following ranges:
Range of Application Rates for Prime Coat
Type of Surface kg./sq.m.
Untreated subgrade surfaces,
0.8 - 1.75
shoulders sub-base and base courses
Bridge wearing surfaces, asphalt
overlay on existing concrete 0.1- 0.4
pavements
as determined
Other surfaces from field tests
or trials
Table 4.2.5.1: Range of Application Rates for Prime Coat
5 The Engineer may order additional trial sections
and/or alter the previously established rates of application
during progress of the work.
6 Prime coat (MC-70) cutback, or other grade if ordered
by the Engineer, shall be applied at the rate selected by
the Engineer, using approved type pressure distributors
operated by skilled workmen. The spray nozzles and
spray bar shall be adjusted and frequently checked so that
uniform distribution is ensured. Spraying shall cease
immediately upon any clogging or interference of any
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nozzle, and corrective measures taken before spraying is
resumed.
7 Hand spraying will be approved only for priming
small patches or inaccessible areas that cannot be primed
by normal operation of the pressure distributor.
8 Application of prime at the junction of spreads shall
not be excessive. Any excess shall be removed from the
surface and any skipped areas or recognized deficiencies
shall be corrected by use of hand sprays.
9 When required by the Engineer, a light covering of
blotting material shall be applied to the prime coat 48
hours after spraying and when it has not dried sufficiently
to withstand damage by traffic. The blotting material shall
be smooth fine sand, or other approved material.
10 Prime coats shall be cured for 3 days before
construction traffic is allowed on it or before the
succeeding pavement layer is placed, or as directed by the
Engineer, depending on weather conditions.
4.2.5.3 Tack Coat Application
1 Tack coat shall be applied to the areas shown on the
Drawings on clean dry surface, and the rate shall be as
ordered by the Engineer. Emulsified bitumen shall be
diluted and thoroughly mixed with an equal amount of
water before application.
2 Heating of RC cutback bitumen and its temperature at
the time of application shall conform to the relevant
requirements of Sub-section 4.1 ‘Materials for Bituminous
Construction’. Where slow-setting emulsified bitumen (SS
or CSS Type) is used for tack coat, it shall not normally
require heating except in temperatures below 20 degrees
C.
3 The rate of application shall be approved by the
Engineer and after trial tests are carried out it shall be
between 0.1 and 0.5 kg./sq.m, depending on whether RC
cutback or emulsified bitumen is used and on the surface
condition of the bituminous course on which the tack coat
is to be sprayed. The resulting bitumen residue shall be at
least 0.35 kg./sq.m. The Engineer may alter the previously
established rates of application during progress of the
work, if he deems it necessary.
4 The tack coat shall be allowed to dry only until it is in
a suitable tacky condition to receive the superimposed
bituminous course. Tack coat application shall not
proceed so far in advance of the following course that it
dries out completely.
5 Spraying procedures shall be as specified for prime
coat application.
6 Blotting material shall not be applied to tack coats.
4.2.5.4 Polymer Modified Tack Coat
1 Polymer modified tack coat shall be hot applied over
the prepared polymer modified or unmodified bituminous
layers to receive the polymer modified bituminous layer,
as indicated on Drawings. The type of tack coat and its
rate of application shall be compatible with the polymer
modified bituminous layer that will be applied on top of it,
to the satisfaction of the Engineer. The rate of application
shall be between 0.25 and 0.5 kg./sq.m.
2 The polymer modified tack coat shall be applied at a
temperature ranging from 180° C to 190° C.
4.2.6 Method of Measurement
1 Bituminous prime coat shall be measured by the
square meter of the areas shown on the cross section at
the appropriate rate specified by the Engineer.
2 Bituminous tack coat shall be measured by the
square meter of the areas shown on the cross section at
the appropriate rate specified by the Engineer.
3 Polymer Modified Bituminous tack coat shall be
measured by the square meter of the areas shown on the
cross section at the appropriate rate specified by the
Engineer.
4 Surface preparation, protective measures to avoid
staining or damage to appurtenances, blotting of prime
coats when required, and cleaning stains and repairing
damage caused by equipment, priming or spraying tack
coat at areas outside the edge of the pavement line, etc.,
shall not be measured for direct payment, but shall be
considered as subsidiary work, the costs of which are
deemed to be included in the rates stated in the Bill of
Quantities.
4.2.7 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities ,
which rate shall be full compensation for supplying
materials, transporting and placing, labor, equipment,
tools and other items necessary for the proper completion
of the work.
4.2.8 Items in the Bill of Quantities
i. Bituminous prime coat.
ii. Bituminous tack coat.
iii. Polymer modified tack coat.
4.3 Bituminous Courses
4.3.1 Description
1 This Sub-section describes requirements for
furnishing materials, mixing at a central mixing plant, and
spreading and compacting various bituminous concrete
and other bituminous mixes, all as and where shown on
the Drawings.
2 Requirements with particular application to
bituminous base course, binder and wearing courses,
leveling course, cold mix courses or recycled bituminous
courses are specified in the respective Sub-sections
relating to such courses.

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4.3.2 Materials
1 Bituminous plant mixes shall generally be composed
of coarse mineral aggregate, fine mineral aggregate,
mineral filler or cement if required, and penetration
graded bitumen, polymer modified bitumen (for
performance graded bitumens) with mix additives if
specified, cutback bitumen or emulsified bitumen
appropriate to the type of bituminous course to be
constructed.
2 All materials shall conform to the relevant
requirements of Sub-section 4.1.
4.3.3 Job Mixes and Project Mixes
1 At least 30 days prior to the date on which the
Contractor intends to begin production at the mixing plant,
and after receiving approval of the aggregates, and
delivery to the Site of the bitumen specified, the
Contractor shall submit for approval his proposed job mix
formula.
2 The job mix formula shall stipulate a single
combined grading of all aggregate and filler materials
showing the specific percentage by weight passing each
sieve size and the specific percentage by weight of each
material to be used in the total mix.
3 The job mix formula shall be established by the
Contractor, under the supervision of the Engineer, in the
field laboratory. Mix design procedures shall conform to
the Marshall method of mix design and relevant
procedures contained in Asphalt Institute Manual MS-2.
All trial mixes shall be prepared and tested by the
Contractor in the presence of the Engineer.
4 The job mix formula shall specify a combination of
mineral aggregates, including filler and bitumen (plus
bitumen modifier if any) in such proportions as to produce
a job mix which is within the limits of the specified
gradation and bitumen content ranges and which meets
the Marshall Test requirements, as prescribed for each
particular type of bitumen course. It shall also stipulate the
mixing temperature at discharge from the mixer which,
unless otherwise directed, shall be 170 degrees C (for the
conventional unmodified asphalt).
5 The Marshall Test procedure shall be used to
determine the percentage of bitumen to be incorporated in
the mix. The job mix formula shall take into consideration
the absorption of bitumen into the aggregates. Air voids
shall be calculated in accordance with the procedure given
in the Asphalt Institute Manual, MS-2. The recommended
range of bitumen content is as follows:
i. Bituminous base and binder courses: 3% to
3.8%.
ii. Bituminous wearing course: 3.2% to 4.0%.
6 When compacting specimens in accordance with the
Marshall Test procedure, the number of blows applied
with the compaction hammer shall be 75 on each side,
unless otherwise specified.
7 In order to meet the requirements, an approved
additive such as Portland cement, hydrated lime or liquid
anti-strip agent, may be required in the job mix. Portland
cement shall meet the requirements of AASHTO M 85.
Hydrated lime shall meet the requirements of ASTM C 207,
Type N. Cement or hydrated lime will normally be
required in the approximate range of 2-3% by weight of
the aggregates and shall be added at the cold feed in dry
or slurry form as directed. Liquid anti-striping agent, if
needed, will normally be required in the approximate
range of 0.6-1.0% by weight of the bitumen, or according
to the manufacturer’s specifications.
8 Upon receipt of approval of the job mix formula, the
Contractor shall adjust his mixing plant to proportion the
individual aggregates, mineral filler and bitumen to
produce a final mix within the tolerances given in Table
4.3.3.1. The approved final mix that shall be used in the
daily production is called the ’project mix’.
Specified Tolerances
Sieve Designation
(square openings) Aggregate Aggregate
Class A Class B
9.5 mm and above + or - 5.0% + or - 5.0%
4.75 mm + or - 4.0% + or - 4.0%
2.36 mm - + or - 4.0%
2.00 mm + or - 4.0% -
0.15 mm (No. 80) - + or - 3.0%
0.075 mm (No. 200) + or - 1.0% + or - 1.0%
Bitumen Content + or - 0.2%
Temperature of Mix
+ or - 5.0%
on discharge
Table 4.3.3.1: Maximum Variations of Project Mix from
Approved Job Mix
9 Any deviation from these limits shall be made only
with the approval of the Engineer.
10 Conformance to gradation requirements will be
determined on the extracted aggregate in accordance with
AASHTO T 30. The bitumen content shall be determined
in accordance with AASHTO T 164 or AASHTO T 308.
11 The Engineer will test the project mix at least twice
daily during plant operation and, if necessary, direct the
Contractor to readjust the plant to conform to the job mix
formula. If, due to differing cold feed or hot bin
gradations, the Contractor cannot consistently produce a
project mix meeting the job mix requirements, production
shall cease, the job mix shall be redesigned and
reapproved and the plant readjusted to produce a new job
mix.
12 The participation of the Engineer in the preparation
of the job mix formula shall in no way relieve the
Contractor of responsibility for producing project mixes
meeting the specified requirements.
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4.3.4 Equipment
4.3.4.1 General
1 Plant and equipment for mixing, transporting,
spreading and compacting bituminous mixes, shall
conform with the requirements of the relevant subsections
of these specifications and to the Contractor's approved
equipment list.
4.3.4.2 Mixing Plant
1 Bituminous mixes shall be produced in an approved
batch mixing plant of adequate size with a minimum
capacity of not less than 80 ton/hr and a mixer capacity of
not less than 750 kg. batch. The plant shall conform to the
relevant requirements of AASHTO M 156.
2 A mechanical batch counter shall be installed as part
of the timing device and shall be designed to register only
completely mixed batches.
3 The mixing plant shall be fully equipped to control
the gradation of hot dry aggregates and of cold damp
aggregates. A suitable dust collection system shall be
installed, capable of returning all dust to the mixture
whenever required. Suitable filters shall be incorporated
whenever the mixing plant is in the vicinity of town, or
whenever they are required by law.
4 The cold feed system shall be of continuous belt feed
type or other approved system. It should be easily
modified to allow hydrated lime slurry to be added to the
mix prior to heating, and dry powdered lime added after
heating.
5 An approved automatic weighing, cycling and
monitoring system shall be installed as part of the
batching equipment. Facilities for easy sampling of the
aggregates from the hot bins whilst the plant is in
operation shall also be provided.
6 The Contractor shall systematically inspect and verify,
in the presence of the Engineer, on a weekly basis and
also whenever suspect the following key operational
aspects of the mixing plant:
- State of repair of the screens, and their frame
mountings.
- Proper working of cold and hot bin gates.
- Accuracy of batching scales for filler,
aggregates and bitumen.
- Proper working of the nozzles of the mixer
bitumen sprayer.
- State of repair of the paddle tips and liners of
the mixer.
7 The Contractor shall furnish, for reference and
retention by the Engineer, one complete set of the
manufacturer's instruction and operating manuals for the
mixing plant intended for use.
8 At the commencement of the contract, 2 copies each
of the latest editions of Asphalt Institute Specification SS-1
and Manuals MS-2, MS-3, MS-8 and MS-22 shall be
furnished by the Contractor for use by the Engineer's
supervisory staff and, in addition, one copy of each as
♦ 4-14 ♦
appropriate shall be issued to each of the Contractor's
senior staff involved in bituminous course work. At the
end of the Contract all the copies shall become the
property of the Employer.
4.3.4.3 Spreading and Finishing Equipment
1 Bituminous courses shall be spread and finished
using approved type, self-contained, power-propelled
pavers of sufficient capacity to be capable of laying up to
80 ton/hr. Pavers shall be provided with electronically
controlled vibratory screed or strike-off assembly with
devices for heating the screed, and shall be capable of
spreading and finishing the various courses of bituminous
plant mix to the proper thickness and in lane and shoulder
widths applicable to the typical cross sections shown on
the Drawings, and in incremental widths between 2.4 m
and 8 m. If the geometry of the cross section allows, wider
pavers will be required to cover the full width of the
pavement section in order to avoid longitudinal
construction joints.
2 The pavers shall be equipped with calibrated sensors
to control the road profile in accordance with the design
shown on the Drawings.
3 The pavers shall employ mechanical devices such as
equalizing runners, straightedge runners, evener arms or
other compensating devices, to maintain trueness of
grade and confine the edges of the mix to true lines
without the use of stationary side forms. Joint leveling
devices shall be provided for smoothing and adjusting
longitudinal joints between lanes.
4 The paver shall be equipped with a receiving hopper
having sufficient capacity for a uniform spreading
operation. The hopper shall be equipped with a
distribution system to place the mix uniformly in front of
the full length of the screed.
5 The screed or strike-off assembly and extensions
shall effectively produce a finished surface of the required
evenness and texture without tearing, shoving, or gouging
the mix.
6 The paver shall be capable of being operated at
forward speeds consistent with satisfactory laying of the
mix. Speed shall be fully adjustable between 3 m/min and
6 m/min.
7 The automatic controls shall consist of an automatic
linkage arrangement such that, through the process of
automatically adjusting the screed thickness control, the
mix can be placed and finished to a predetermined grade
and a uniform crown or cross section. Articulated
averaging beams utilized for grade control shall be at least
9 m in length.
8 If during construction, the spreading and finishing
equipment in operation leaves in the pavement surface
tracks or indented areas or other objectionable
irregularities that are not satisfactorily corrected by
scheduled operations, the use of such equipment shall be
discontinued and other satisfactory spreading and
finishing equipment shall be provided by the Contractor.
copy 249
9 The Contractor shall make available, for reference by
the Engineer, the manufacturer's instruction and operating
manuals for each paver intended for use.
4.3.5 Construction of Trial Sections
1 Immediately prior to finalization of the job mix
formula, the Contractor shall lay trial sections of the
various bituminous mixes intended for use in the work.
Each trial section shall be 2 lanes wide by 100 m long at
approved locations close to the Site. Each trial section
shall be laid using the same materials, proposed job mix,
mixing, spreading and compaction plant and spreading
and compaction procedures, proposed for use in the work.
2 Each trial section shall serve as a field verification of
the job mix design. The mix density achievable and the air
voids at that density shall be determined and, if less than
required, the job mix formula shall be adjusted
accordingly.
3 Each trial section shall also demonstrate the
adequacy of hauling, spreading and compaction
equipment and the suitability of the construction methods
and organization proposed.
4 If the trial section meets the required specification,
the job mix formula will be approved.
5 The trial section shall be carried out at the
Contractor's expense and is to be removed from Site, if
required by the Engineer.
4.3.6 Mixing Procedures
1 Each aggregate ingredient shall be heated and dried
such that the temperature recorded in the hot fines bin
after screening does not exceed 170 degrees C. If any
aggregates contain excess moisture so as to cause
foaming in the mixture or their temperature is in excess of
170 degrees C, they shall be removed from the bins and
disposed of as directed.
2 Immediately after heating, the aggregates shall be
screened into at least 3 sizes and conveyed into separate
bins ready for batching and mixing with the bitumen.
When the aggregates furnished are of such size and
grading that separating into 3 bins is impractical, the
number of required separations may, if approved, be
reduced to 2 only. Screening operations shall produce, at
plant operating capacity, gradations in each of the sizes of
heated and dried aggregates that are reasonably uniform
and will result in the production of a mix conforming to
the job mix requirements.
3 The dried and heated aggregate and (cold) mineral
filler shall be combined in the plant in the proportionate
amounts as determined by the job mix. Just prior to
bitumen entering the mixer, the anti-stripping additive, if
required, shall be thoroughly mixed with the bitumen
which shall then be introduced into the pugmill mixer in
the proportionate amount determined by the job mix.
4 The temperature of the bitumen upon entering the
pugmill shall be within 15ºC of the aggregate temperature.
Unless otherwise directed, the bitumen temperature shall
be as given in Table 4.3.6.1.
Max.
Type and Temperature °C
Grade of immediately after
Asphalt discharge from
Pugmill
80 - 100 pen. 160
60 - 70 pen. 165
40 – 50 pen. 170
Table 4.3.6.1: Bitumen Temperature
5 Any conventional (unmodified) bituminous mix
subjected to higher temperature than those shown in
Table 4.3.6.1 shall be rejected.
6 The mixing temperature for the polymer modified
bituminous mixture shall be as determined under Sub-
section 4.1, paragraph 4.1.6.2.
7 The mixing time required in order to obtain a
homogeneous mix and adequate coating of the
aggregates with bitumen shall be determined by the
Contractor in the presence of the Engineer. This time shall
be determined whenever the source of aggregate for the
mix changes.
8 In batch plants, mixing time shall begin upon entry of
bitumen into the pugmill.
9 Mixing time for mixing plants will be determined by
the following formula or other approved methods: Mixing
time (sec) = Pugmill dead capacity (kg.) divided by pugmill
output (kg./sec)
4.3.7 Surface Preparation
1 When the bituminous mix is to be placed on a
prepared subbase, or base, the surface shall be prepared
to meet the appropriate specified compaction and surface
tolerance requirements. The surface shall then be primed
as specified in Sub-section 4.2 – ‘Prime and Tack Coats’.
No bituminous mix shall be laid on a prime coat until it
has been inspected and approved.
2 When the bituminous mix is to be placed on an
existing bituminous surface, the surface shall be cleaned
of all foreign material and broomed free of dust. Any
loose, broken or shattered bituminous material along the
edges of the existing surface shall be removed and the
exposed surface, and a sufficient width of the shoulder
adjacent to the edge of the existing surface, shall be
shaped, bladed, compacted and broomed to provide a
uniform firm layer for the new surface course.
3 Broken, soft, or unstable areas of existing bituminous
surface, aggregate base or granular subbase shall be
removed and replaced. The areas shall be excavated to a
depth as directed and refilled with the specified
bituminous mix.
4 Prior to placing of the bituminous mix on an existing
bituminous surface when required, a tack coat as specified
in Sub-section 4.2 – ‘Prime and Tack Coats’ shall be
♦ 4-15 ♦
copy 249
applied to the existing surface at the rate determined by
the Engineer. No mixture shall be laid on a tack coat until
it has been inspected and approved.
4.3.8 Delivery, Spreading and Finishing
4.3.8.1 Delivery of Mix to Site
1 A sufficient number of haul vehicles shall be
provided so that adequate supplies of mix are delivered to
ensure that continuous paving will be achieved.
2 Hauling equipment for aggregates and bituminous
mixes shall consist of vehicles having dump bodies
suitable for dumping materials in a windrow or in
spreader boxes. The bodies shall be so constructed that
their volume measurement can be accurately determined.
They shall be constructed and maintained such that loss of
materials during hauling operations will not occur. Dump
controls shall be capable of operation from the driver's
seat.
3 Hauling equipment for hot bituminous mixes shall
have tight, clean, smooth metal beds which are
periodically thinly coated with a lime solution or other
approved material to prevent adherence of the mix. All
hauling units shall be equipped with a canvas or other
approved type of cover which shall be used to cover the
hot material upon loading at the mixing plant and shall
not be removed until the mix is discharged into the paver.
Hot mix material may be transported without such cover
only if permitted by the Engineer in special circumstances.
4 The dispatching of the hauling vehicles to the Site
shall be so scheduled that all material delivered is placed
at least 90 minutes before sunset to allow sufficient time
for compaction, unless the use of artificial light is
approved. Delivery of material shall be at a uniform rate
and in an amount well within the capacity of the paving
and compacting equipment.
5 The mix at delivery to the paver shall be not more
than 10ºC below discharge temperature at the mixing
plant. The minimum temperature for the commencement
of breakdown rolling is 120ºC. Mix loads of temperature
less than 120ºC shall not be accepted, and the load shall
be disposed of and another load used. If there is
consistent failure to meet the temperature requirement the
Engineer shall order paving operations to stop until
suitable measures are taken by the Contractor to ensure
that temperature requirements are met.
6 Each haul vehicle shall be weighed after each loading
at the mixing plant and accurate records shall be kept of
the gross weight and net weight of each load, for each
vehicle and dates and time of loading.
4.3.8.2 Setting Out and Reference Lines
1 The Contractor shall survey the centerline profile and
crown of the existing surface or base and determine a
reference grade line which will be submitted for approval.
A reference line of wire or suitable cord shall be installed
at a uniform grade parallel to the approved reference
♦ 4-16 ♦
grade line such that conformance with the required
geometrics, surface tolerance and minimum thickness
requirements shall be ensured. The reference line shall be
supported at 8m maximum spacing unless there is
noticeable sag in the line or the pavement surface, in
which case the maximum spacing shall be 4m.
2 The reference line shall be maintained taut and free
from sags at all times during spreading and initial
compacting operations.
3 Except where the paver is matching a previously
placed layer, a wire or cord reference line shall be installed
on both sides of the paver for the initial bituminous course
being laid. Thereafter only one reference line will
normally be required, if the paver is equipped with
adequate automatic super elevation control.
4.3.8.3 Spreading and Finishing
1 Bituminous mixes shall be laid only when the air
temperature is at least 5 degrees C or above, when the
existing surface is free from moisture, and when the
weather is not foggy, rainy, dusty or excessively windy
(particularly at low temperatures).
2 After completion of surface preparation, the
bituminous mix shall be spread and finished true to crown
and grade by approved automatically controlled
bituminous pavers. The mix may be spread and finished
by approved hand methods only where the Engineer
determines that machine methods are impracticable.
Hand methods include heated hand tampers of at least 10
kg. weight and approved type mechanical (vibratory)
tampers.
3 The paver shall spread the bituminous mix without
tearing the surface and shall strike a finish that is smooth,
true to cross section, uniform in density and texture and
free from hollows, transverse corrugations and other
irregularities.
4 The paver shall be operated at a speed which gives
the best results for the type of paver being used and which
coordinates satisfactorily with the rate of delivery of the
mix to the paver. A uniform rate of placement shall be
achieved without repeated intermittent operation of the
paver.
5 The mix shall be delivered to the paver in time to
permit completion of spreading, finishing and compaction
of the mix during daylight hours.
6 If during laying, the paver is repeatedly delayed
because of lack of mix or if the paver stands at one
location for an extended period, resulting in the (unrolled)
mat under and adjacent to the rear of the spreader falling
below the minimum temperature for breakdown rolling,
the affected portion of mat shall be cut out and discarded
and a transverse joint shall be constructed. Paving shall
not recommence until the Engineer is satisfied that paving
will proceed without interruptions.
7 Contact surfaces of curbing, gutters, manholes, and
similar structures shall be painted with a thin, uniform
coating of tack coat material. The bituminous mixture
copy 249
shall be placed uniformly high near the contact surfaces
so that after compaction it will be 10 mm above the edge
of such structure.
8 If during the paving operations the spreading and
finishing equipment in operation leaves in the pavement
surface tracks or indented areas or other objectionable
irregularities that are not satisfactorily corrected by the
scheduled operations, the use of the equipment shall be
discontinued, until faults are corrected to the approval of
the Engineer. If this is not possible, other satisfactory
spreading and finishing equipment shall be provided by
the Contractor.
9 Unless otherwise directed by the Engineer, where
successive bituminous layers are to be placed, the surface
of each existing layer shall be swept clean with a power
broom, or by other approved means and a tack coat
applied at the rate designated by the Engineer and in
accordance with the relevant requirements of Sub-section
4.2.
10 Transverse joints in succeeding layers shall be offset
by at least 2 m. Longitudinal joints shall be offset at least
150 mm.
11 Bituminous mix shall be spread in one or more
layers so that, after rolling, the nominal thickness of each
layer of the compacted bituminous material shall be
between 2 and 3 times maximum size of aggregate. This
maximum thickness may be increased slightly when such
increase is more appropriate to total pavement thickness
and provided the Engineer determines that such increased
thickness will not be detrimental to the quality of the
finished bituminous course, and the Contractor can show
that the required density is attained throughout the layer
thickness.
12 Transitions and structure approaches shall meet the
design criteria for geometrics, the surface tolerance
specifications, and shall not be visually discontinuous or
abrupt in appearance.
13 Side roads, entrances and lay-bys shall be paved in
accordance with the details shown on the Drawings.
4.3.8.4 Joints and Edges
1 All joints between old and new pavements or
between successive days' work shall be such as to ensure
thorough and continuous bond between the old and new
material.
2 Before placing fresh mix against previously laid
asphalt layers or against old pavement, the contact
surface shall be saw-cut to a near vertical face, and shall
be sprayed or painted with a thin uniform coat of tack coat
material unless otherwise directed. Longitudinal joints
shall be made by overlapping the paver screed on the
previously laid material (cut back as necessary) and
depositing a sufficient amount of fresh mix so that the
joint formed will be smooth and tight.
3 The Contractor shall schedule paving operations so
as to minimize the exposure of the leading lane of
longitudinal joints prior to the completion and compaction
of the joint. As a minimum, the leading lane shall not be
laid in advance of the adjacent trailing lane by more than
one half day of paving, and in no case shall the leading
lane be more than 0.5 km ahead of the trailing lane
without approval. In the event of failure to conform to
these requirements, the Engineer may temporarily
suspend paving on the leading lane.
4 Unsupported edges of bituminous layers shall be
rolled immediately following the rolling of the longitudinal
joint. The material along the unsupported edge may, if
approved, be raised slightly by hand methods, to ensure
that the full weight of the roller will bear fully on the edge
material.
5 On completion, the longitudinal edges of bituminous
pavement shall be true to the width and alignment as
shown on the Drawings. The edges shall be cut back if
necessary prior to rolling, additional mix placed manually
in a longitudinal strip adjoining each pavement edge, and
the edge rolled down to a neat 3:1 (horizontal:vertical)
slope or as shown on drawings.
6 Transverse joints shall be carefully constructed and
thoroughly compacted to provide a smooth riding surface.
Joints shall be straight-edged and string-lined to assure
smoothness and true alignment. If the joint is formed with
a bulkhead, such as a board, to provide a straight line and
vertical face, it shall be checked with a straight edge
before fresh material is placed against it to complete the
joint. If a bulkhead is not used to form the joint and the
roller is permitted to roll over the end of the new material,
the line shall be located back of the rounded edge a
sufficient distance to provide a true surface and cross-
section. If the joint has been distorted by traffic or by
other means, it shall be trimmed to line. In either case, the
joint face shall be painted with a thin coating of
bituminous material before the fresh material is placed
against it.
4.3.8.5 Compaction
1 Rollers shall be operated by competent and
experienced operators in accordance with the
manufacturer's instructions, copies of which shall be
submitted to the Engineer. Rollers shall be kept in
operation continuously if necessary, so that all parts of the
pavement receive substantially equal compaction at the
time desired.
2 After spreading and strike-off, and as soon as the mix
conditions permit the rolling to be performed without
excessive shoving or tearing, the mixture shall be
thoroughly and uniformly compacted, using approved
types, sizes and numbers of rollers. Rolling shall not be
prolonged to the point where cracks appear or shoving or
displacement occurs.
♦ 4-17 ♦
copy 249
3 Rollers shall be of self-propelled 2-axle tandem or
three wheel steel-tired, pneumatic-tired and vibratory steel
wheel types, in proper operating condition, capable of
reversing without backlash or tearing of the surface, and
shall be operated at speeds slow enough to avoid
displacement of the bituminous mix.
4 Initial breakdown rolling shall be carried out by use
of 2 dual-drum vibrating steel-wheeled vibratory rollers
each of minimum weight 7,000 kg. and with vibrating
frequency of 2,000-3,000 cycles/min. These rollers shall be
purpose made for compaction of hot bituminous courses.
5 Intermediate rolling shall be carried out by use of at
least 2 self-propelled, tandem pneumatic smooth-tired
rollers each capable of exerting contact pressures of up to
690 KN./sq.m. (100 psi) and ballast - adjustable to ensure
uniform wheel loadings.
6 Final rolling shall be carried out by use of two, 2-axle
tandem steel-tired static rollers each of minimum weight
10,000 kg., capable of exerting contact pressures of up to
65 kg./cm2 (350 lb/in.).
7 Prior to use on Site of pneumatic-tired rollers, the
Contractor shall furnish, for reference and retention by the
Engineer, manufacturers' charts or tabulations showing
the contact areas and contact pressures for the full range
of tire inflation pressures and for the full range of tire
loadings for each type and size of compactor tire to be
used. The Contractor shall ensure that tire pressures are
maintained at all times in conformity with such charts or
tabulations. The maximum allowable tolerances shall be
plus or minus 35 KN./sq.m. (5 psi).
8 Rollers shall move at a slow but uniform speed,
generally with the drive roll or wheels nearest to the paver.
Recommended speeds are shown in Table 4.3.8.1 (km/h.).
Speed of Rollers (Km./hr.)
Roller Type Breakdown Intermediate Finish
Rolling Rolling Rolling
Steel Tired
3 5 5
Static Rollers
Pneumatic
5 5 9
Tired Rollers
Vibratory
4.5 4.5 -
Rollers
Table 4.3.8.1: Recommended Speeds of Rollers
9 If vibratory rollers are used, when it is required to
change direction the vibration shall be turned off before
the roller is stopped, and turned on after motion in the
new direction begins.
10 Rolling shall begin as soon as the mixture will bear
the roller weight without undue displacement. The
minimum temperature of the mat at which rolling shall be
allowed to start is 120ºC.
11 Breakdown rolling shall consist of 3 complete
coverages of each of the 2 rollers specified in Item 4 above
unless otherwise directed. Rolling shall be longitudinal,
beginning at the low side of the spread of material and
proceeding towards the high side, overlapping on
♦ 4-18 ♦
successive trips by at least one half the width of the rear
wheels. Alternate trips of the rollers shall be of slightly
differing lengths.
12 The speed of the rollers, rolling pattern and, in the
case of vibratory rollers, the frequency and amplitude of
vibration, shall be approved by the Engineer. To prevent
adhesion of the mix to the rollers, the wheels shall be kept
properly and lightly moistened with water. An excessive
use of water will not be permitted.
13 The rolling pattern, type and number of rollers shall
be established by a site trial so as to achieve the required
compaction. The approved rolling pattern shall be
followed.
14 The initial or breakdown rolling shall be followed by
intermediate rolling involving 3 coverages with
pneumatic-tired rollers unless otherwise specified.
15 Finishing rolling shall then be carried out by means
of 2-axle tandem power steel rollers unless otherwise
designated. If, the specified density is not achieved,
changes shall be made in size and number of rollers being
used to ensure the compaction requirements are met.
16 The average compacted density for all bituminous
courses shall be equal to or greater than 98% of the
average Marshall bulk specific gravity for each day's
production unless otherwise directed by the Engineer. It is
also required that 90% of the results shall be greater than
the minimum specification tolerance limit of 96.3%.
17 Any mix that becomes loose, broken, mixed with
foreign material, or which is in any way defective in finish
or density, or which does not conform in all other respects
with the specified requirements shall be removed,
replaced with suitable material and properly finished.
4.3.9 Sampling and Testing
1 Sampling and testing shall conform to the
requirements of the relevant Sub-sections of the
Specification and Table 4.3.9.1.
2 The Marshall bulk specific gravity shall be
determined in accordance with AASHTO T 166. The
Marshall specimens shall be prepared from the same
material used in construction, taken from samples of fresh
bituminous mix at the mixing plant or from trucks
delivering mix to the Site. Oven heating for up to 30
minutes to maintain the heat of the sample is permissible.
3 The bulk specific gravity of the mix as placed and
compacted in situ shall be determined from 100 mm
nominal diameter core samples, or slab samples cut from
each compacted layer on the road at locations designated
by the Engineer who may require additional tests to
determine limits of areas deficient in density, or for
recheck.
4 Samples for in-situ bulk specific gravity
determinations shall be taken in sets of 2 from each
pavement location. Minimum frequency of sampling for
each bituminous layer shall be one set/lane/500 m, with a
minimum of one set per day of placing bituminous layers.
copy 249
 Frequency of Tests Required
(A) (B)
Work item Tests at source of Frequency for all tests Tests at road site Frequency for all
material mentioned under (A) tests mentioned
under (B)
4-1
Materials used in 1. Specific gravity
bituminous mix (at & water absorption
- Test for each
batching plant)
Source
2. Abrasion Test - Test for each 1,000
cu.m of asphalt
3. Chert content
produced
4. Clay lumps & - When materials
friable materials quality changes
5. Flaky and elongated - As requested
particles
6. Soundness
4-2
Materials used in
1. Gradation
bituminous mix (from
hot bins)
2. Specific gravity - Test for each source
and water - When materials
absorption quality changes
3. Plasticity index - As requested

4. Sand equivalent
5. Stripping with
asphalt
4-3 1. Complete mix - For each project
Bituminous mix design in accordance -When results are not
design for each with American Asphalt consistent with the mix
course (from hot bins) Institute (MS2) design results.
2. Loss of stability -As requested
4-4
Bituminous Mix
At batching plant
Marshall stability for
each layer
1. Stability - Test for each day’s 1. Stability
2. Flow production 2. Flow
- Test each 3
3. Extraction (binder - Test for every 200 3. Extraction (binder working days
content & gradation) cu.m of asphalt content & gradation) - Test for each
4. Air voids produced per day 4. Air voids batching plant
- Test for each
5. Voids in mineral 5. Voids in mineral - As requested
batching plant
aggregates aggregates
- As requested
6. Daily Marshall 6. Daily Marshall
density density
-Test each 200
7. Compaction
lin.m., per lane
density
7. Loss of stability - Once a week and for batch
& thickness (after
layer
final compaction)
- As requested
- Test each 3
8. Loss of stability working days
- As requested
Table 4.3.9-1 Frequency of Testing for Bituminous 6 The Contractor shall, when necessary, furnish and
Pavement apply cold water, ice, or other cooling substance to the
surface of the pavement to prevent the sampling from
5 The Contractor shall cut the samples with an
shattering or disintegrating. The Contractor shall fill and
approved core drill in the presence of the Engineer. The
compact all test holes at his own expense.
equipment shall be capable of cutting the mixture without
shattering the edges or otherwise disturbing the density of
the specimen.

♦ 4-19 ♦
copy 249
4.3.10 Surface Tolerances
1 The fully compacted and completed bituminous
course shall conform to the lines, grades and cross
sections as shown on the Drawings.
2 The elevations of the finished course shall be
checked by the Contractor in the presence of the Engineer
at maximum intervals of 10m and at intermediate points
as directed.
3 The finished surface is tested with a 3 m long
straightedge, placed parallel to, or at right angles to the
centerline, the maximum deviation of the surface from the
testing edge between any 2 contact points shall not
exceed the tolerances specified for each type of
bituminous course laid, as shown under Paragraphs
4.4.10.1 and 4.5.10.1 for the bituminous base and wearing
courses, respectively. All areas which exceed the specified
tolerances shown under Paragraphs 4.4.10.1 and 4.5.10.1
shall be corrected by removing the defective sections of
bituminous course and reconstructing them, or if
approved by the Engineer, by increasing the thickness of
the succeeding course(s).
4 The finished surface shall also be tested using the
rolling straight edge, and the areas which exceed the
specified tolerances shown under Paragraphs 4.4.10.2 and
4.5.10.2 shall be corrected by removing the defective
sections of bituminous course and reconstructing them, or
if approved by the Engineer, by increasing the thickness of
the succeeding course(s).
5 The tolerances specified for evenness of finished
surfaces for all types of bituminous courses, shall not
invalidate the tolerances specified for construction
thickness and elevations of such courses.
4.3.11 Determination of Thickness of
Courses
1 The Contractor shall compensate for minor
deficiencies in the thickness of any bituminous course in
the pavement structure by increasing the thickness of the
subsequent bituminous course. After completion of the
final (wearing) course any deficiencies in the thickness of
any course which have not been compensated for by
increasing the thickness of a subsequent course, will be
considered deficiencies in the final (wearing) course.
2 Cylinder core samples shall be taken as specified for
in- situ bulk specified gravity core samples.
3 Thickness of bituminous courses shall be determined
by average caliper measurement of cores, rounded
upwards to the nearest mm.
4 Paved sections to be measured separately shall
consist of each 300 lin.m. section in each traffic lane. The
last section in each traffic lane shall be 300 m plus the
fractional part of 300 m remaining. Other areas such as
intersections, entrances, crossovers, ramps, etc. shall be
measured as one section and the thickness of each shall
be determined separately. Small irregular unit areas may
be included as part of another section.
♦ 4-20 ♦
5 One core shall be taken from each section by the
Contractor at approved locations and in the presence of
the Engineer. When the measurement of the core from
any paved section is not deficient by more than 5 mm
from the specified thickness, the core will be deemed to be
of the specified thickness as shown on the Drawings.
6 When the measurement of the core from any paved
section is deficient by more than 5 mm but not more than
20 mm, 2 additional cores spaced at not less than 100 m
shall be taken and used together with the first core to
determine the average thickness of such section.
7 When the measurement of the core from any paved
section is less than the specified thickness by more than
20 mm, the average thickness of such section shall be
determined by taking additional cores at not less than 5 m
intervals parallel to the centerline in each direction from
the affected location until, in each direction, a core is taken
which is not deficient by more than 20 mm. Exploratory
cores for deficient thickness will not be used in average
thickness determinations.
8 Any deficiencies in the total thickness of bituminous
courses shall be subject to a proportional reduction in the
volume of final (surface) course measured for payment, or
complete removal and replacement, as shown in Table
4.3.11.1 below. Alternatively, the Contractor shall
construct at his own expense, a surface course overlay, if
practicable in the judgment of the Engineer. Any such
overlay shall be a minimum of 40 mm compacted
thickness and to the specified standard of the course it is
overlaying.
9 If the deficiency in total thickness of the asphalt
layers is from 0 to 3mm, full payment will be made, on
condition that deficiencies are not found in more than 10%
of the total project. Deficiencies between 3mm and 10mm,
80% of the full payment for the bituminous courses will be
made.
Deficiency in the
Deficiency in the
Thickness of
Thickness of Total Action
Individual Asphalt
Asphalt Layers
Layers
≤ 5mm ≤ 3mm Full payment
5 – 20mm 3 – 10mm 80% payment
> 20mm (or 25% > 10mm (or 15%
Remove and
of design of design
replace
thickness) thickness)
Table 4.3.11-1: Tolerances in bituminous concrete layer
thicknesses
4.3.12 Method of Measurement
1 Conventional and polymer modified bituminous
courses are measured in the respective Sub-sections for
each type of bituminous course transported, furnished,
spread, compacted, completed and accepted.
Measurement shall not include the rolled down edge
strips of bituminous courses placed outside the edge of
paving shown on the Drawings.
copy 249
2 Bituminous prime and tack coats are measured as 4.4.3 Job Mix and Project Mix
prescribed in Sub-section 4.2. 1 The job mix formula shall be established by the
3 Bituminous overlays constructed by order of the Contractor in accordance with the procedures and
Engineer to correct deficiencies in total thickness of requirements of Sub-section 4.3.
bituminous courses or to compensate for major 2 The job mix for bituminous base course shall
deficiencies in the thickness of any underlying bituminous conform to the following composition limits as shown in
course, shall not be measured for direct payment, but Table 4.4.3.1.
shall be considered as subsidiary work the costs of which
will be deemed to be included in the respective rates for Parameter Value
bituminous courses. stated in the Bill of Quantities.
Marshall stability at 80ºC (Kg.) 1200
4 Establishment of the job mix formula, surface
preparation, construction of joints, hand painting of Flow (mms) 2- 3.5
contact surfaces, remedial treatment of surface 12%
irregularities, cutting of cores and slabs for testing or Voids in mineral aggregate, (VMA)
(minimum)
measurement purposes, reinstatement of core and slab
areas of pavement, rolled down longitudinal bituminous Air voids 4-7%
edge strips, additional thickness of bituminous course in Voids filled with bitumen, (VFB) 50 to 70%
excess of the specified thickness, and other ancillary items
Loss of Marshall stability by
shall not be measured for direct payment, but shall be
submerging specimens in water at 60°C
considered as subsidiary work the costs of which will be
for 24 h. compared to stability Max. 25%
deemed to be included in the respective rates for
measured after submersion in water at
bituminous courses stated in the Bill of Quantities.
60°C for 30 minutes

4.3.13 Basis of Payment

1 The amount of completed and accepted work,
measured as provided for above and as measured in the
various Sub-sections of Section 4, will be paid for at the
unit rates for the various items in the Bill of Quantities,
which rate shall be full compensation for supplying
materials, transporting and placing, labor, equipment,
tools and other items necessary for the proper completion
of the work.
4.4 Bituminous Base Course
4.4.1 Description
1 This Sub-section describes requirements for
furnishing materials, mixing at a central mixing plant, and
spreading and compacting conventional or polymer
modified bituminous base course on an approved
aggregate base course or granular subbase, as shown on
the Drawings.
4.4.2 Materials
1 All materials shall conform to the relevant
requirements of Sub-section 4.1.
2 Unless otherwise shown on the Drawings, bitumen
for base course construction shall be 60/70 penetration
graded bitumen.
3 For modified bitumen, unless otherwise shown on
the Drawings, bitumen for base course construction shall
not be lower than 60/70 penetration graded bitumen
modified with one of the polymers specified in Sub-
section 4.1, Paragraph 4.1.6.2 and as per these same
specification requirements.
% Air voids at refusal Min. 2%
Table 4.4.3.1: Job Mix Requirements for Bituminous Base
Course
3 Prior to final approval, the proposed job mix, but
with a bituminous content at the upper percentage limits
shall be compacted to refusal, (400, 500 and 600 blows)
and the resulting voids in the mix shall not be less than
2%.
4 After the job mix formula has been established and
approved, all mixes furnished shall conform to it within
the stated tolerances.
5 The job mix formula shall be re-established if the
source of aggregate, filler or bitumen changes.
4.4.4 Equipment
1 Plant and equipment for mixing, hauling, placing and
compacting bituminous base course material, shall
conform to the relevant requirements of Sub-section 4.3.
4.4.5 Construction of Trial Sections
1 Trial sections shall be constructed as and where
directed and in accordance with the relevant requirements
of Sub-section 4.3.
4.4.6 Mixing Procedures
1 Handling and mixing of bitumen (including modifier
and anti-stripping agent, if any) and aggregates (including
mineral filler if required) shall be in accordance with the
relevant requirements of Sub-section 4.3.

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4.4.7 Surface Preparation 4 The longitudinal regularity of the surfaces of base
course as measured by the rolling straight-edge set at 5
1 Preparation of the surface upon which the
mm shall be such that the number of surface irregularities
bituminous base course mix is to be laid, shall be
is within the relevant limits stated in Table 4.4.10-2. No
appropriate to the type and condition of such surface and
irregularity exceeding 10 mm shall be permitted.
shall conform with the relevant requirements of Sub-
section 4.3.
Length 300m 75m
4.4.8 Delivery, Spreading and Finishing
Max. permitted number of
20 9
4.4.8.1 General surface irregularities

1 The delivery, spreading and finishing of bituminous
mix for base course shall conform with the relevant
requirements of Sub-section 4.3 and to the following
particular requirements.
4.4.8.2 Rollers
1 The rollers, rolling sequence, pattern and speed shall
be as stipulated in Sub-section 4.3, Paragraph 4.3.8.5.
2 The number of rollers used for any stage of rolling
may be reduced by the Engineer to one, provided that the
base course width being compacted is less than 5.5 m and
provided an equivalent standby roller is available on Site
as replacement in the event of breakdown of the operating
roller.
4.4.8.3 Standard of Compaction
1 The compacted density of the bituminous base
course shall be equal to or greater than 98% of the
average Marshall bulk density for each day's production or
otherwise as directed by the Engineer.
4.4.9 Sampling and Testing
Table 4.4.10.2: Tolerances on bituminous base course
surface irregularity when tested by rolling straight-edge
4.4.11 Determination of Thickness
1 Procedures for determining the average compacted
thickness of bituminous base course shall conform with
the relevant requirements of Sub-section 4.3 and to the
following particular requirements.
2 Cores for thickness measurements shall be used to
determine if changes are necessary in the constructed
thickness of succeeding bituminous layers to rectify any
thickness deficiencies in the bituminous base course.
3 In cases where the bituminous base course will not
be covered by superimposed binder or wearing courses,
the base course shall be deemed to be the final (wearing)
course for the purposes of determining the proportion of
wearing course volume measured for payment or for the
purposes of any overlay ordered to correct deficiencies. In
such cases, the surface base course layer shall meet the
Surface Tolerance requirements specified under Clause
4.5.10 for wearing courses.

1 Sampling and testing shall conform to the relevant
requirements of Sub-section 4.3, and Table 4.3.9.1.
4.4.10 Surface Tolerances
1 Surface tolerances shall conform with the relevant
requirements of Sub-section 4.3 and to the following
particular requirements.
2 The tolerances on elevations of finished bituminous
base course surface shall be not greater than + 6 mm.
3 When the finished surface is tested with a 3 m long
straightedge, placed parallel to, or at right angles to the
centerline, the maximum deviation of the surface from the
testing edge between any two contact points shall not
exceed 5 mm (Table 4.4.10.1).
4.4.12 Method of Measurement
1 Conventional or polymer modified bituminous base
course shall each be measured in cubic meters of mix
furnished, spread, compacted, completed and accepted.
Measurement shall be based on the areas and thickness as
shown on the Drawings or otherwise directed by the
Engineer.
2 Where bituminous base course is intended to serve
as a wearing course, any deficiencies in thickness shall,
unless an overlay is constructed at the Contractor's
expense, result in a proportion only of the base course
volume being measured for payment. Proportions shall
be determined in accordance with the thickness
deficiencies stated in Sub-section 4.3, Table 4.3.11.1.

Property Tolerance Action 4.4.13 Basis of Payment

Max. Replace (min. 15m
Surface elevation
6mm length of road)
Surface irregularity Max. Replace (min. 15m
(3m straight edge) 5mm length of road)
Table 4.4.10.1: Tolerances on bituminous base course
surface elevation and straight edge irregularity
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at
the unit rates for the various items in the Bill of
Quantities, which rate shall be full compensation for
supplying materials, transporting and placing, for
labor, equipment, tools and other items necessary for
the proper completion of the work.

♦ 4-22 ♦
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4.4.14 Items in the Bill of Quantities 3 After the job mix formula has been established and
approved, all subsequent mixes shall conform to it within
i. Bituminous base course (Class A, B). the allowable tolerances, as shown in Table 4.5.3.1.
ii. Polymer modified bit. base course (Class A, B). 4 The Job mix formula shall be re-established if the
source of aggregate, filler or bitumen is changed.
4.5 Bituminous Binder and Wearing 5 When tested for resistance to water damage in
Courses accordance with AASHTO T-283 ‘Resistance of Compacted
Asphalt Mixtures to Moisture-Induced Damage’, the
4.5.1 Description conventional and polymer modified bituminous wearing
course mixtures shall have a retained tensile strength
1 This Sub-section describes requirements for
greater than or at least equal to 80%. In cases where the
furnishing materials, mixing at a central mixing plant, and
anti-stripping agents are not successful in providing the
spreading and compacting bituminous binder course and
specified tensile strength ratio, the Contractor shall
bituminous wearing course on an approved base course,
consider alternative means, such as the use of hydrated
as shown on the Drawings.
lime to achieve this purpose.

4.5.2 Materials
4.5.4 Equipment
1 All materials shall conform to the relevant
1 Plant and equipment for mixing, hauling, placing and
requirements of Sub-section 4.1
compacting bituminous binder and wearing courses
2 Unless otherwise shown on the Drawings, bitumen material shall conform to the relevant requirements of
for binder and wearing courses construction shall be 60/70 Sub-section 4.3.
penetration graded bitumen, or any other suitable grade
for the climatic condition of the project. 4.5.5 Construction of Trial Sections
3 For polymer modified bitumen, unless otherwise
1 Trial sections shall be constructed as and where
shown on the Drawings, bitumen for binder and wearing
directed and in accordance with the relevant requirements
courses construction shall not be lower than 60/70
of Sub-section 4.3..
penetration graded bitumen modified with one of the
polymers specified in Sub-section 4.1, Paragraph 4.1.6.2..
4.5.6 Mixing Procedures
4.5.3 Job Mix and Project Mix 1 Handling and mixing of bitumen (including modifier
and anti-stripping agent, if any) and aggregates (including
1 The job mix formula shall be established by the
mineral filler if required) shall be in accordance with the
Contractor in accordance with the procedures and
relevant requirements of Sub-section 4.3.
requirements of Sub-section 4.3.
2 The job mix for bituminous binder and wearing 4.5.7 Surface preparation
courses shall conform to the following composition limits
as shown in Sub-section, Table 4.5.3.1. 1 Preparation of the surface upon which the
bituminous binder and wearing course mixes are to be
Binder Wearing laid, shall be appropriate to the type and condition of such
Property
Course Course surface and shall conform to the relevant requirements of
Marshall stability at 80ºC (Kg.) 1300 1400 Sub-section 4.3.

Flow (mms) 2- 4.5 2- 5 4.5.8 Delivery, Spreading and Finishing

Voids in mineral aggregate
13- 14% 14- 15% 4.5.8.1 General
(VMA)
Air voids 4- 7% 4- 7% 1 The delivery, spreading and finishing of bituminous
mix for binder and wearing courses shall conform with the
50 to 50 to
Voids filled with bitumen, (VFB) relevant requirements of Sub-section 4.3 and to the
70% 70%
following particular requirements.
Loss of Marshall stability by
submerging specimens in water 4.5.8.2 Rollers
at 60°C for 24 h. compared to Max Max
stability measured after 25% 25% 1 The rollers, rolling sequence, pattern and speed shall
submersion in water at 60°C for be as stipulated in Sub-section 4.3, Paragraph 4.3.8.5.
30 minutes 2 The number of rollers used for any stage of rolling
% Air voids at refusal Min 2% Min 2% may be reduced by the Engineer to one, provided that the
course width being compacted is less than 5.5 m in width,
Table 4.5.3-1: Job Mix Requirement for Bituminous Binder and provided an equivalent stand-by roller is available on
and Wearing Course

♦ 4-23 ♦
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Site as replacement, in the event of breakdown of the
operating roller.
4.5.8.3 Standard of Compaction
1 The compacted density of the bituminous binder and
wearing courses shall be not less than 98% of the average
Marshall bulk density for each day's production.
5 The combination of the permitted tolerances in the
levels of the different pavement layers, excluding
aggregate base and sub-base courses, shall not result in a
reduction of thickness by more than 10 mm from the
specified thickness, as shown on the Drawings, nor a
reduction in the final wearing course thickness by more
than 5 mm from that specified or shown on the Drawings.

4.5.8.4 Skid Resistance and Surface Texture 4.5.11 Determination of Thickness

1 Surface Texture: Conventional and polymer modified
bituminous wearing course layer shall have a texture
depth of at least 0.8mm tested in accordance with the
Sand Patch Test ASTM E 965. One Test shall be done
every 500m length of constructed road.
4.5.9 Sampling and Testing
1 Sampling and testing shall conform to the relevant
requirements of Sub-section 4.3 and Table 4.3.9.1.
4.5.10 Surface Tolerances
1 Procedures for determining the average compacted
thickness of bituminous binder and wearing courses shall
conform to the relevant requirements of Sub-section 4.3,
Clause 4.3.11 and the tolerances/deficiencies shall comply
with the relevant requirements of Table 4.3.11.1 and with
the requirements of Item 2 following.
2 Cores for thickness measurements of the binder
course shall be used to determine if changes are
necessary in the constructed thickness of the wearing
course to rectify any thickness deficiencies in the binder
course.

1 Surface tolerances shall conform with the relevant 4.5.12 Method of Measurement
requirements of Sub-section 4.3 and to the following
particular requirements. 1 Conventional and polymer modified bituminous
binder course and bituminous wearing courses shall each
2 Tolerances on elevations of finished bituminous
be measured by the cubic meter of mix transported,
binder and wearing course surfaces shall be not greater
furnished, spread, compacted, completed and accepted.
than + 6 mm when compared to the design profile shown
Measurement shall be based on the areas and thickness as
on the drawings.
shown on the Drawings or otherwise directed by the
3 When the finished binder or wearing course surface Engineer.
is tested with a 3 m long straightedge, placed parallel to,
2 Deficiencies in thickness of the wearing course shall,
or at right angles to the centerline, the maximum
unless an overlay is constructed at the Contractor's
deviation of the surface from the testing edge between
expense, result in a proportion only of the wearing course
any two contact points shall not exceed 3 mm (Table
area being measured for payment. Proportions shall be
4.5.10-1).
determined in accordance with the thickness deficiencies
stated– in Sub-section 4.3, Table 4.3.11.1
Property Tolerance Action
Surface Replace (minimum 4.5.13 Basis of Payment
Max. 6mm
elevation 15m length of road)
1 The amount of completed and accepted work,
Surface
Replace (minimum measured as provided for above, will be paid for at the
irregularity (3m Max. 3mm
15m length of road) unit rates for the various items in the Bill of Quantities ,
straight edge)
which rate shall be full compensation for supplying
Table 4.5.10.1: Tolerances on bituminous wearing course materials, transporting and placing, labor, equipment,
surface elevation and straight edge irregularity tools and other items necessary for the proper completion
of the work.
4 The longitudinal regularity of the surfaces of the
finished binder or wearing course as measured by the
rolling straight-edge set at 5 mm shall be such that the
4.5.14 Items in the Bill of Quantities
number of surface irregularities is within the relevant i. Bituminous binder course.
limits stated in Table 4.5.10-2. No irregularity exceeding 10 ii. Bituminous wearing course (Class A, B).
mm shall be permitted.
iii. Polymer modified bituminous binder course.
Length 300m 75m iv. Polymer modified bituminous wearing course
(Class A, B).
Max. permitted number of
15 7
surface irregularities

Table 4.5.10.2: Tolerances on bituminous wearing course

surface irregularity when tested by rolling straight-edge

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4.6 Bituminous Seal Coats – Surface
Dressings
4.6.1 Description
1 This Sub-section describes requirements for
furnishing of materials and one or more applications of
cutback bitumen and cover material, or a single
application of emulsified bitumen, or spreading emulsified
bitumen slurry, to previously prepared base course or
wearing course surfaces, as shown on the Drawings.
2 Bituminous slurry seal coat (BSSC) shall consist of
spreading and screeding a mixture of emulsified bitumen,
sand aggregate and water.
3 Single bituminous surface treatment (SBST) shall
consist of a single application of cutback or straight run
bitumen, and sand aggregate or as specified.
4 Double bituminous surface treatment (DBST) shall
consist of an application of cutback or straight run
bitumen and coarse graded cover aggregate followed not
less than 5 days later by a second application of cutback or
straight run bitumen and medium graded aggregate, or as
specified.
4.6.4 Construction of Trial Sections
1 Before commencement of Site seal coat applications,
the Contractor shall construct trial sections using varying
application rates for bitumen and for aggregates, as
selected by the Engineer. Each trial section shall be two
lanes wide by 50 m long, at approved locations on or close
to the Site.
2 Each trial section shall be constructed using the same
materials, mixing, spraying, spreading, rolling and
brooming equipment, and construction procedures,
proposed for use in the Works. Trial sections for slurry
seals shall be along existing bituminous pavements in the
vicinity of the Site.
3 The objectives of these trials shall be to determine
the adequacy of the Contractor's equipment, the most
suitable application rates for cutback bitumen, emulsified
bitumen and the various gradations of aggregate, and the
most suitable consistency of slurry seal to fill cracks and
leave a residual coating of 3 mm over the entire
bituminous wearing surface.
4 The Contractor shall not proceed with any seal coat
applications until the methods and procedures established
in the trials have been approved.

4.6.2 Materials
4.6.5 Rates of Application
4.6.2.1 Bitumen
1 Application rates for cutback and emulsified bitumen
1 Bitumen for SBSD and DBSD (surface dressing) and for the various cover aggregate gradations, will be
applications shall be rapid-curing RC-800 grade, determined by the Engineer from the trial sections and
conforming to the relevant requirements of Sub-section shall be generally within the ranges given in Table 4.6.5.1.
4.1 and AASHTO M-81.
2 Bitumen for BSSC (slurry) applications shall be a Approx. Rate of Application
cationic, slow setting emulsified bitumen Grade CSS-1 Types of Seal Coat
Aggregate Binder
conforming to the relevant requirements of Sub-section
(kg/sq.m.) (kg/sq.m.)
4.1.
Coarse aggregate Seal
12.5- 20.0 1.00-1.80
4.6.2.2 Aggregates coat (DBST)
Slurry aggregate Seal
1 Cover aggregates shall consist of screenings of 10.0-15.0 0.90-1.80
coat
crushed stone or crushed gravel. Aggregate for slurry
Generally 5-6 kg./sq.m.
seals shall consist of crushed stone or gravel fines or Slurry seal (SBSC)
for the mix
natural sand blended with not less than 50% crushed fines.
For heavy duty applications slurry aggregate shall consist Table 4.6.5-1: Application Rates
of 100% crushed fines. 2 The Engineer may order additional trial sections and
2 The properties of cover and slurry seal aggregates alter the previously established rates of application during
and their gradations shall be in accordance with the progress of the work.
relevant requirements of Sub-section 4.1.
4.6.6 Construction Requirements
4.6.3 Equipment
4.6.6.1 General
1 All plant and equipment used for pugmill mixing of
slurry mixes, heating and spraying of cutback and 1 Applications of bitumen and aggregate and
emulsified bitumen, spreading, rolling and brooming of subsequent rolling shall be completed between sunrise
cover aggregate, and applying and spreading slurry seals, and sunset and under favorable weather conditions as
shall conform with the requirements of the relevant determined by the Engineer. The atmospheric
sections of this Specification and with the Contractor's temperature shall be above 15 degrees C and the weather
approved equipment list. shall not be foggy, rainy, dusty or unduly windy.
2 Generally, where the seal coat is to carry traffic prior
to final sweeping, speed signs shall be erected to control

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the speed of traffic. Provision for traffic control shall be in
accordance with the requirements of Section 1, Sub-
section 1.8.
3 When bituminous coatings are applied to sections of
highway which are to be promptly opened to traffic, and
the ambient temperature is contributing to slow curing
and excessive pickup, the Contractor shall suspend
operations until the Engineer approves continuation of
sealing work.
4 The surface to be treated shall be dry or slightly
damp and the moisture content of aggregates at the time
of application to the coated surface shall not exceed 3% by
weight.
5 Unless otherwise directed, the minimum time
interval between successive seal coats, in DBSD
applications, shall be 5 days.
4.6.6.2 Surface Preparation
1 Granular surfaces shall be primed in accordance with
the requirements of Sub-section 4.2 prior to application of
the surface treatment. If there are delays in scheduling the
seal coating, which results in deterioration of the surface,
the Engineer may order appropriate repairs or corrective
treatment prior to seal coating.
2 When coatings are applied to existing pavement
surfaces, all pavement repairs shown on the Drawings
shall first be completed. Where applicable, the positions
of traffic markings shall be surveyed and recorded to
enable their accurate replacement after the seal coatings
have been applied.
3 Immediately before applying any bituminous
material, all dirt, dust and other objectionable material
shall be removed from the surface and cracks shall be
repaired or sealed as directed. If required, the surface
shall be slightly dampened with a light application of
water immediately prior to application of bitumen.
4 Surfaces to be slurry sealed shall be lightly sprayed,
immediately prior to spreading the slurry, with a slow-
setting 3:1 water/emulsion mixture applied at the rate of
0.4-0.8 kg./sq.m.
4.6.6.3 Heating of Bitumen
1 The temperature of cutback bitumen and of
emulsified bitumen at the time of application shall be as
specified in Sub-section 4.1.
4.6.6.4 Spreading Slurry Seal
1 Spreading of slurry seal shall be by means of an
approved type spreader box which shall be capable of
spreading at least one traffic lane width. It shall have
flexible rubber or similar strips fastened on each side to
prevent loss of slurry and shall have baffles incorporated
in the box to ensure uniform application. A rear, flexible,
adjustable strike-off blade shall be fitted to the box.
2 Areas inaccessible to the slurry spreader box shall be
slurry sealed using hand or other approved methods.
♦ 4-26 ♦
3 The slurry seal coat shall be uniform and
homogeneous after spreading and shall not show signs of
separation of the emulsion and aggregate after setting.
4.6.6.5 Spraying of Bitumen
1 The bitumen cutback or emulsified bitumen for fog
and seal coats shall be applied by means of a pressure
distributor uniformly and continuously over the section to
be treated. The rate of application shall be as designated
by the Engineer.
2 A strip of building paper or heavy polyethylene
sheeting, at least one m in width, and with a length equal
to that of the spray bar of the distributor plus 300 mm,
shall be used at the beginning of each application. If the
cut-off is not positive, the paper shall be used at the end of
each spread. The paper shall be removed and disposed of
after use. The distributor shall be moving forward at
proper application speed at the time the spray bar is
opened. Any skipped areas or deficiencies shall be
corrected immediately as directed.
3 The length of spray run shall not exceed that which
can be covered by the aggregate spreading equipment.
4 The application width of bitumen shall be not more
than 150 mm wider than the width covered by the
aggregate spreader. Under no circumstances shall
operations proceed in such a manner that the bitumen will
be allowed to chill, set up, dry, or otherwise impair
retention of the cover aggregate.
5 The Contractor shall keep a complete record of
bitumen used, based on distributor tank measurements
and on areas to which the bitumen has been applied.
These records shall be submitted to the Engineer as
verification of the accuracy of the tachometer as well as
verification of application rates designated by the
Engineer.
6 Distribution of bitumen shall be so regulated and
sufficient material left in the distributor at the end of each
application, that there will be a uniform distribution across
the spray bar. In no case shall the distributor be allowed
to expel air with the bitumen, thereby causing uneven
coverage.
7 The angle of the spray nozzles and the height of the
spray bar shall be adjusted and regularly checked to
ensure uniform distribution. The height of the spray bar
above the pavement surface should remain constant
throughout the spraying process. Distribution shall cease
immediately upon any clogging or partial blocking of any
nozzle and corrective measures shall be taken before
application is resumed.
4.6.6.6 Application of Aggregate
1 If directed, aggregates shall be washed prior to use in
order to eliminate or reduce any dust coating or salts
before delivery to the spreader.
2 Operation of the aggregate spreader at speeds which
cause the particles to roll over after striking the bitumen
covered surface will not be permitted.
copy 249
3 Immediately upon application of bitumen, aggregate
of the required gradation shall be spread at the rate
designated by the Engineer. Spreading shall be
accomplished in such a manner that the tires of the
hauling units or aggregate spreader do not come in
contact with the uncovered bitumen surface.
4 Where adjacent spreads are to be made, the first
aggregate spread shall not extend closer than 150 mm to
the edge of bitumen application. The adjacent spread of
bitumen shall overlap this 150 mm and complete
aggregate coverage shall be achieved on the second
spread promptly upon completion of the first spread to
ensure a smooth riding surface.
5 Immediately after aggregate has been spread,
deficient areas shall be covered by additional aggregate.
Humps, ridges or uneven distributions of aggregate shall
be removed and corrected to ensure that there are no
permanent ridges, bumps, or depressions in the
completed surface. Additional aggregate shall be spread
in whatever quantities necessary to prevent pick-up by
rollers or traffic, after which the surface shall be rolled as
directed.
6 Care shall be taken to prevent aggregate from
entering ditches or inlets of any type. The Contractor shall
be responsible for removing any such aggregate materials
or other accumulated debris arising out of his operations.
4.6.6.7 Rolling and Brooming
1 Aggregate shall not be spread more than 150 m
ahead of initial rolling operations.
2 Rollers shall not stop, start or turn on the surface
being rolled. Any damage to the surface arising out of
non-compliance with these requirements shall be made
good as directed, at the Contractor's expense.
3 Initial breakdown rolling shall proceed behind the
spreader (after any adjustments by hand methods to
correct for uneven distribution, etc). One complete
coverage shall be achieved using 2-axle self-propelled
steel-wheeled rollers of 6-8 tons weight and operating at a
maximum speed of 5 km/h. Initial rolling shall be
completed within 30 minutes of spreading aggregate.
4 The Engineer may order the alternative use of
pneumatic-tired rollers for initial rolling if adequate
embedment of the aggregate is liable to result in
excessive crushing when steel-wheeled rollers are used.
5 Immediately following completion of the initial
rolling, the surface shall be rolled using self-propelled
pneumatic-tired rollers operated at a maximum speed of 8
km/h, until at least 3 complete coverages have been
achieved.
6 If necessary during rolling operations, additional
screenings shall be lightly spread by hand methods and
re-rolled, to make good any small areas visibly deficient in
cover material.
7 Light drag brooming of the surface shall be carried
out 24 hours after completion of rolling and in such a
manner that embedded aggregate particles will not be
dislodged. This brooming shall result in uniform
distribution of loose screenings over the surface which
shall then be re-rolled using pneumatic-tired rollers until
at least 2 complete coverages have been achieved.
8 Light drag brooming and re-rolling shall be repeated
24 hours after the initial brooming, if so directed.
9 Excess screenings shall be salvaged and stockpiled
or disposed of as directed.
4.6.6.8 Maintenance and Protection of Sealed Surfaces
1 BSSC shall be protected from traffic until such time
as the coatings have cured sufficiently and will not be
damaged by, adhere to or be picked up by, the tires of
vehicles.
2 Each coat of SBSD and DBSD shall be maintained
and protected from traffic for at least 3 days after
completion of rolling.
3 At the end of the 3-day maintenance period for each
seal coat, or earlier if directed, the surface shall be finally
swept, using a rotary broom, to remove loose screenings.
Surplus screenings shall be stockpiled or disposed of as
directed.
4.6.7 Tolerances and Records
1 The Contractor shall be responsible for ensuring the
accurate calibration of pressure distributors and for the
correct rates of application of bitumen as designated by
the Engineer.
2 Readings shall be taken of bitumen tanker contents
and temperature immediately prior to, and immediately
upon completion of each spraying run and the actual
application rate in kg./sq.m. shall be calculated. Complete
records shall be maintained of all such measurements and
the specific locations, width and lengths of the respective
runs.
3 The tolerances on temperature-adjusted application
rates of cutback bitumen shall be plus or minus 5% of the
designated rate.
4 Applications of cutback bitumen varying by more
than 5% but less than 10%, after temperature adjustment,
below the specified rate of application shall, if accepted,
be subject to a 10% reduction in quantity or area
measurements as appropriate.
5 Applications of cutback bitumen varying by more
than 10%, after temperature adjustment, above or below
the specified rate of application shall be rejected and the
unsatisfactory material replaced or made good as directed,
at the Contractor's expense.
6 The Contractor shall maintain, on a daily basis,
complete records of the volumes and tonnage of each
type of aggregate delivered to the Site and used in each
section of the Works for seal coat applications.
7 All records and calculations of bitumen applications,
and aggregate delivery and use, shall be submitted to the
Engineer at the end of each day when seal coat
applications have been carried out. No measurements will
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be made of bitumen applications which are not supported
by adequate, verifiable records.
4.6.8 Method of Measurement
1 Single bituminous surface treatment, double
bituminous surface treatment and bituminous slurry seal
coat shall each be measured in square meters of net area
covered as shown on the Drawings or directed by the
Engineer. Rates are deemed to include for all related work,
including, without limitation, trial sections, tests and
reports and wastage of materials.
4.6.9 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities ,
which rate shall be full compensation for supplying
materials, transporting and placing, labor, equipment,
tools and other items necessary for the proper completion
of the work.
4.6.10 Items in the Bill of Quantities
i. Single bituminous surface treatment.
ii. Double bituminous surface treatment.
iii. Bituminous slurry seal coat.
4.7 Bituminous Leveling Course and
Patching Work
4.7.1 Description
1 This Sub-section describes requirements for
furnishing materials, mixing at a central mixing plant, and
spreading and compacting bituminous leveling course on
an existing pavement surface, as shown on the Drawings
or directed.
2 Patching works shall be limited to localized deficient
areas as jointly determined by the Engineer and the
Contractor. These areas are usually not exceeding 3m in
length and one lane width and the distance between two
individual patches is normally not less than 5m.
4.7.2 Materials
1 All materials shall conform to the requirements of
Sub-section 4.1.
4.7.3 Job Mix and Project Mix
1 The job mix formula shall be established by the
Contractor in accordance with the procedures and
requirements of Sub-section 4.3.
2 The job mix for bituminous leveling shall conform to
the requirements for binder course as provided in Sub-
section 4.5.
♦ 4-28 ♦
4.7.4 Equipment
1 Plant and equipment for mixing, hauling, placing and
compacting bituminous leveling course materials shall
conform to the relevant requirements of Sub-section 4.3.
4.7.5 Construction of Trial Sections
1 Trial sections shall be constructed as and where
directed and in accordance with the relevant requirements
of Sub-section 4.3.
4.7.6 Mixing Procedures
1 Handling and mixing of bitumen (including modifier
and anti-stripping agent, if any) and aggregates (including
mineral filler if required) shall be in accordance with the
relevant requirements of Sub-section 4.3.
4.7.7 Surface Preparation
1 Damaged pavement surfaces shall, where directed,
be repaired by patching prior to receiving the bituminous
leveling course. The extent of patching shall be as shown
on the Drawings or as directed.
2 Areas of existing pavement to be patched shall be cut
out to neat lines to a depth ordered by the Engineer,
thoroughly cleaned, and the exposed edges of pavement
painted or sprayed with a thin coat of rapid curing cutback
bitumen grade RC-70 or RC-250 in accordance with the
relevant requirements of Sub-section 4.2. The cut out
pavement shall be patched with bituminous material as
shown on the Drawings or as directed and conforming
with the relevant requirements of Sub-section 4.1.
3 Patching shall be carried out in accordance with the
relevant requirements of Sub-section 4.3.
4 Patching shall be carried out in layers not exceeding
80 mm in thickness. Each layer shall be thoroughly
compacted by means of approved pneumatic tampers
prior to placing the succeeding layer. Each layer shall be
protected from damage and all dirt or foreign material
shall be removed before placing subsequent layers. The
final layer shall be rolled with a heavy roller. Each layer
shall be approved prior to placement of subsequent layers.
5 All cut-out pavement material and surplus patching
material shall be removed from the site and disposed of
by the Contractor prior to placing the leveling courses.
6 In areas where leveling courses are required, as
shown on the Drawings or directed, the Contractor shall
take cross sections of the existing pavement after
completing any patching. The cross sections shall be
taken at intervals of 12.5 meters or as directed. When the
survey is approved, the Engineer will determine and
inform the Contractor of the locations, grades and
thicknesses of leveling courses to obtain the desired
surface.
7 Prior to placing the leveling courses, the existing
pavement surface shall be prepared in accordance with
the relevant requirements of Sub-section 4.3, including the
use of prime and tack coats as appropriate.
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4.7.8 Delivery, Spreading and Finishing
1 Delivery, spreading and finishing of leveling courses,
including compaction, shall conform to the relevant
requirements of Sub-section 4.5.
2 In areas where a specific grade and super-elevation
are to be achieved by the leveling courses, setting out and
level control shall be based on a reference line installed in
accordance with the relevant requirements of Sub-section
4.3. In areas of minor leveling such as filling of pits or
small isolated areas, a mobile reference line or alternative
control system may be approved.
4.7.9 Sampling and Testing
1 Sampling and testing of leveling courses shall
conform to the relevant requirements of Sub-section 4.3 -
and Table 4.3.9.1.
2 Where sampling and testing are not feasible due to
thickness or other constraints, the Engineer will determine
specification compliance based on an approved rolling
pattern or other basis.
4.7.10 Surface Tolerances
1 Surface tolerances for leveling courses shall conform
to the relevant requirements for binder courses in Sub-
section 4.5.
4.7.11 Determination of Thickness
1 The Engineer may use thickness measurements,
spread rates, cross section or other methods to verify
quantities placed. Thickness measurements shall be in
accordance with the relevant requirements of Sub-section
4.3.
4.7.12 Method of Measurement
1 Bituminous leveling courses shall be measured by
the cu.m. of mix furnished, spread, compacted, completed
and accepted. Measurements shall be based on the areas
and thicknesses shown on the Drawings or as directed.
2 Bituminous patching work shall be measured by the
cu.m. of mix furnished, spread, compacted, completed
and accepted. Measurements shall be based on the areas
and thicknesses shown on the Drawings or as directed. No
measurements will be made of unauthorized areas or
extra thickness.
3 The rates for bituminous leveling course and for
patching work shall be deemed to include for all incidental
costs as stated in Sub-section 4.3, Clause 4.3.12.
4.7.13 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities ,
which rate shall be full compensation for supplying
materials, transporting and placing, for labor, equipment,
♦ 4-29 ♦
tools and other items necessary for the proper completion
of the work.
4.7.14 Items in the Bill of Quantities
i. Bituminous Leveling Course.
ii. Bituminous Patching Work.
4.8 Bituminous Cold Mix Courses
4.8.1 Description
1 This Sub-section describes requirements for
furnishing materials, mixing manually or at a central
mixing plant, or in a travel-mix plant and spreading and
compacting bituminous cold mix courses comprising
unheated mineral aggregate or cut-back asphalt on a
prepared surface, as shown on the Drawings or directed
by the Engineer.
4.8.2 Materials
1 All materials shall conform to the relevant
requirements of Sub-section 4.1.
2 The type and grade of bitumen for the paving
mixture shall be as shown on the Drawings or as directed.
The bitumen shall conform to the relevant requirements of
AASHTO M 81,M 82, M 140 or M 208.
4.8.3 Job Mix and Project Mix
1 The job mix formula shall be established by the
Contractor in accordance with the procedures and
requirements of Sub-section 4.3.
2 The job mix shall conform to the relevant
requirements of Sub-section 4.4 or Sub-section 4.5, as
appropriate.
4.8.4 Equipment
1 Plant and equipment for mixing, hauling, placing and
compacting bituminous cold mix courses shall conform to
the relevant requirements of Sub-section 4.3. In the
continuous mixing plant, the devices feeding bituminous
material, aggregate and water shall be interlocked to
maintain automatically the correct proportions. In a travel
mix plant, the equipment used may be either a hopper
type, or a rotary type mixer. Both types of equipment
shall be capable of thoroughly mixing the bituminous
material and aggregate, uniformly dispersing the
bituminous material, and adequately coating the
aggregate particles to produce a uniform mix.
4.8.5 Construction of Trial Sections
1 Trial Sections shall be constructed as and where
directed and in accordance with the relevant requirements
of Sub-section 4.3.
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4.8.6 Mixing Procedures
1 Handling and mixing of bitumen and aggregate shall
be in accordance with the relevant requirements of Sub-
section 4.3, with the following exceptions:
i. Aggregates shall not be heated but shall be fed
cold to the plant. The temperature of the
bitumen upon entering the pugmill shall be
adequate to ensure uniform application to the
cold aggregate. The bitumen temperature shall
be designated by the Engineer and shall
generally be in accordance with the relevant
requirements of Sub-section 4.1.
ii. Mixing time shall be the shortest time necessary
to remove excess volatiles or water and to
produce a satisfactory mixture.
4.8.7 Surface Preparation
1 Preparation of the surface upon which bituminous
cold mix courses are to be laid, and the use of prime and
tack coats shall be appropriate to the type and condition of
such surfaces and shall conform to the relevant
requirements of Sub-section 4.3.
4.8.8 Delivery, Spreading and Finishing
1 Delivery, spreading and finishing of bituminous cold
mix courses shall conform to the relevant requirements of
Sub-section 4.3.
2 Requirements for rolling and compaction shall
comply with the relevant requirements of Sub-section 4.4 -
or Sub-section 4.5, as appropriate.
4.8.9 Sampling and Testing
1 Sampling and testing shall conform to the relevant
requirements of Sub-section 4.3 and Table 4.3.9.1.
4.8.10 Surface Tolerances
1 Surface Tolerances shall conform to the relevant
requirements of Sub-section 4.4.
2 Finished elevations and straight edge tolerances shall
conform to the relevant requirements of Sub-section 4.4 -
or Sub-section 4.5, as appropriate.
4.8.11 Determination of Thickness
1 Procedures for determining the average compacted
thickness of bituminous cold mix courses shall conform to
the relevant requirements of Sub-section 4.3.
2 Cores for thickness measurements of bituminous
cold mix courses shall be used to determine if changes are
necessary in the thickness of succeeding layers in
accordance with the relevant requirements of Sub-section
4.4 or Sub-section 4.5, as appropriate.
♦ 4-30 ♦
4.8.12 Method of Measurement
1 Bituminous cold mix courses shall be measured by
the cubic meter of mix furnished, spread, compacted,
completed and accepted. Measurements shall be based
on the areas and thicknesses as shown on the Drawings.
2 Deficiencies in thickness of bituminous cold mix
wearing course shall, unless an overlay is constructed at
the Contractor's expense, result in a proportion only of the
wearing course volume being measured for payment.
Proportions shall be determined in accordance with the
thickness deficiencies and volume proportions stated Sub-
section 4.3, Table 4.3.11.1.
4.8.13 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities ,
which rate shall be full compensation for supplying
materials, transporting and placing, labor, equipment,
tools and other items necessary for the proper completion
of the work.
4.8.14 Items in the Bill of Quantities
i. Bituminous cold mix course.
4.9 Pavement Repairs and
Reinstatement
4.9.1 Description
1 This Sub-section describes requirements for surface
milling, removing defective bituminous pavement,
preparing surfaces to receive repairs, furnishing materials,
placing and finishing new pavement, as shown on the
Drawings or directed.
4.9.2 Materials
1 Subgrade materials shall conform to the relevant
requirements of Sub-section 2.6.
2 Aggregate sub-base and base course materials shall
conform to the relevant requirements of Sub-section 3.1.
3 Bituminous pavement materials shall conform to the
relevant requirements of Sub-section 4.1.
4.9.3 Equipment
1 All plant and equipment shall conform to the
requirements of the relevant Sections of this Specification.
4.9.4 Preparation of Pavement
1 Cracks in bituminous pavement which, in the opinion
of the Engineer, do not require reconstruction shall be
prepared by wire brushing and blowing out with
compressed air.
2 Prior to the application of bituminous overlays, the
existing pavement shall be planed or milled out by
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approved equipment to the depth shown on the Drawings
to remove the asphalt surface that contains hardened
asphalt, contaminated material, fuel spots, rubber
deposits, laitance and any undesirable material that
prevents proper bonding and adhesion with the new
asphalt overlay.
3 Defective bituminous pavement which, in the opinion
of the Engineer, requires reconstruction shall be cut back
to good material using pneumatic cutting tools. The cut
area shall be square or rectangular and in line with the
direction of traffic. The depth of cut shall be determined
by the Engineer and may include bituminous layers, base
and sub-base layers and subgrade layers (in the case of
failed pavement, excavation shall include a minimum of
300 mm of subgrade material). All excavated materials
shall be removed and disposed of off-site. When the
bottom of the excavation consists of earth or granular
material it shall be thoroughly compacted using
mechanical compactors to the satisfaction of the Engineer.
Exposed bituminous surfaces shall be thoroughly cleaned
and wire brushed prior to receiving repair materials.
4 Utility trench reinstatements in bituminous pavement
shall be prepared in the same way as defective bituminous
pavement. Excavation depth shall be a minimum of 300
mm from the top of subgrade layer.
4.9.5 Placing and Finishing Repair
Materials
1 Cracks of 3 mm to 7mm width or wider shall be filled
with clean, coarse sand then saturated with 1:1 diluted
emulsified bitumen, or as directed by the Engineer. Cracks
of less than 3 mm shall be filled with emulsified bitumen,
or as directed. Cracks shall be filled to the road surface.
Any excess bitumen shall be removed with a squeegee
and the bitumen surface shall be sprinkled liberally with
coarse sand.
2 Excavations below subgrade level shall be filled to a
level specified by the Engineer with subgrade material in
layers not exceeding 150 mm and compacted using
mechanical compactors to conform to the requirements of
Sub-section 2.6 and to the satisfaction of the Engineer.
3 Subbase and/or base course, if required, shall be
placed in layers not exceeding 150 mm and compacted
using mechanical compactors. They shall conform with
the relevant requirements of Sub-section 3.2 or Sub-
section 3.3, - as appropriate, and shall be to the grading
shown on the Drawings or specified by the Engineer.
4 Prior to receiving bituminous material, the
excavations shall be thoroughly cleaned. Subgrade, sub-
base or base course material shall be primed with a light
coating of MC cutback bitumen and existing bituminous
surfaces shall be lightly painted with emulsified bitumen,
all in accordance with the requirements of Sub-section 4.2
5 The excavation shall be filled with bituminous
pavement materials placed in layers not exceeding 70 mm
and compacted using vibratory compactors. Unless
ordered to the contrary by the Engineer, the top layer shall
be compacted by steel wheeled roller, first compacting the
150 mm strips adjacent to the traffic edges, then rolling in
the direction of traffic.
6 New utility trenches shall be backfilled to the details
shown on the Drawings, or ordered, including any
surrounds, haunching or protective materials.
Construction of subgrade and pavement shall be as for
pavement repairs.
7 No excavated areas shall remain open overnight
without adequate safety and protection measures subject
to the approval of authorities.
4.9.6 Sampling and Testing
1 Testing of repair materials shall conform to the
relevant requirements of Sub-section 3.3 and Table 4.3.9.1.
Sampling shall be as ordered by the Engineer.
4.9.7 Surface Tolerances
1 Levels shall be checked by straight edge in relation to
the adjacent existing pavement.
2 Surface tolerances for bituminous layers shall
conform to the relevant requirements of Sub-section 4.4
and Sub-section 4.5 as appropriate.
3 Any deficiency in the wearing course surface shall be
corrected by cutting out and replacing.
4.9.8 Method of Measurement
1 Sealing of cracks shall be measured by lin.m. of
cracks sealed and approved by the Engineer.
2 Milling shall be measured by the sq.m. of the area
milled to the specified depth, including equipment,
application, removal and disposal of the milled material
off the site.
3 Pavement repairs shall be measured by the sq.m. of
repair, prepared, filled, compacted, completed and
accepted. Measurement shall be of the areas shown on
the Drawings or ordered.
4 Trench reinstatements shall be measured by the
sq.m. of reinstatement prepared, filled, compacted,
completed and accepted. Measurement shall be of the
areas shown on the Drawings or ordered. New utility
trench construction will not be measured under this item.
5 No separate measurement will be made for
excavation, prime or tack coats, pavement materials,
subgrade, subbase, or base courses.
6 All other incidental items shall not be measured for
direct payment, as prescribed in Sub-section 4.3 - but
shall be considered as subsidiary work, the costs of which
will be deemed to be included in the rates and prices
stated in the Bill of Quantities.
4.9.9 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities ,
♦ 4-31 ♦
copy 249
which rate shall be full compensation for supplying 5 Quality control tests for density, thickness and mix
materials, transporting and placing, labor, equipment, properties shall be performed as instructed by the
tools and other items necessary for the proper completion Engineer.
of the work. 6 Any work needed to road shoulders, earthworks, side
slopes, road drainage and services shall be carried out as
4.9.10 Items in the Bill of Quantities shown on the Drawings and in accordance with the
i. Surface milling. relevant clauses of Sections 2, 8 and 18.

ii. Crack sealing. 4.10.3.2 Traffic Control

iii. Pavement repairs (overlay and surface
preparation). 1 Traffic control arrangements shall be implemented in
accordance with Section 1, Sub-section 1.8.
iv. Pavement repairs (complete reconstruction).
v. Trench reinstatement. 2 Widening shall be carried out only on one side of the
pavement at a time. The work shall be programmed to
permit continuity of excavation, placing widening material,
4.10 Bituminous Pavement Widening
rolling and finishing with minimum time of disruption to
traffic flow.
4.10.1 Description
3 Reflector barricades shall be placed along open
1 This Sub-section describes requirements for trenches. Lighting shall be placed at each barricade at
widening existing pavements, including excavation night Adequate provision shall be made to enable traffic to
adjacent to existing bituminous pavements and placing a cross at intersecting roads and at commercial, industrial
mixture of aggregates and bituminous binder in and private entrances.
compacted layers.
4.10.4 Method of Measurement
4.10.2 Materials
1 The approved work shall be measured in square
1 Materials for the construction of pavement widening meters of new asphalt surface. Excavation and removal of
shall conform to the requirements of Sub-sections 4.1, 4.2 curb and road drainage elements will not be measured
and 4.3 as appropriate. separately but will be considered subsidiary work, the cost
of which is deemed to be included in the rates for
4.10.3 Construction Requirements pavement widening.

4.10.3.1 Construction 2 Relocation of services will be measured separately

under the relevant items of Sub-section 18.2.
1 The edge of the existing road pavement shall be
excavated to the extent and depth shown on the Drawings, 4.10.5 Basis of Payment
Existing curbs, gullies and drain pipes shall be removed as
shown on the Drawings or instructed by the Engineer. The 1 The amount of completed and accepted work,
bottom of the excavation shall be compacted with suitable measured as provided for above, will be paid for at the
rollers or power rammers to the density specified in Sub- unit rate for Pavement Widening in the Bill of Quantities,
sections 2.5 and 2.6. Adequate provisions shall be made which rate shall be full compensation for excavation,
for drainage of the trench to prevent damage to the trimming, compacting of the excavation, shoulders and
existing road subgrade. side slopes, mixing, placing and compacting bituminous
material and for supplying materials, labor, equipment,
2 The excavation shall be cleaned of loose material and
tools and other items necessary for the proper completion
the edge of the existing pavement shall be cleaned. The
of the work.
excavated base shall be approved by the Engineer prior to
placement of bituminous material. If unsuitable or
4.10.6 Items in the Bill of Quantities
unstable soil is exposed on the excavation bottom it shall
be replaced with suitable material and compacted to the i. Pavement widening.
depth instructed.
3 Prior to placing bituminous material, the edge of the 4.11 Recycled Bituminous Mixes
existing asphalt road layers shall be painted or sprayed
with a thin coat of cut-back bitumen RC-70 or bitumen 4.11.1 Description
emulsion SS-1.
1 This Sub-section describes requirements for
4 Bituminous material shall be placed in the prepared
recycling existing pavement material, including removal,
excavation in layers not exceeding 80mm thick. Machine
crushing and stockpiling existing bituminous pavement,
laying shall be used except for confined areas where the
mixing with new aggregate, bitumen (and, if specified, an
use of a machine would be impracticable. Completion
approved modifying agent) at a central hot mixing plant,
shall be by roller as specified in Sub-sections 4.3, 4.4 or
and spreading and compacting recycled bituminous base
4.5.

♦ 4-32 ♦
copy 249
course on a prepared surface, as shown on the Drawings
or directed.
4.11.2 Materials
1 Recycled material shall consist of existing
bituminous pavement, processed such that 100% will pass
a 38 mm (1.5 inch) sieve.
2 If the Engineer determines that recycled bituminous
material is causing degradation of the aggregate, he shall
revise the job-mix as required.
3 New materials shall conform to the relevant
requirements of Sub-section 4.1.
4 Unless shown otherwise on the Drawings, bitumen
for recycled bituminous base course shall be graded to
suit the project climatic condition and type of work. If not
specified, or shown on the Drawings, grade 60-70
penetration conforming to the requirements of AASHTO M
20 shall be used.
5 Modifying agent used to soften the old bitumen shall
be used in accordance with the manufacturer’s
instructions and approved by the Engineer.
6 Existing pavement shall be removed in such a
manner as to prevent unnecessary intermixing with the
underlying base, sub-base or subgrade material.
7 The stockpile height shall not be greater than 3
meters. Construction equipment will not be permitted on
the stockpiles.
4.11.3 Job Mix and Project Mix
1 The job mix formula shall be established by the
Contractor in accordance with the procedures and
requirements of Sub-section 4.3..
2 The properties of the new modified mix shall meet all
the requirements of Sub-sections 4.1, 4.3 and 4.4, as
appropriate.
4.11.4 Equipment
1 Plant and equipment for recycled bituminous base
course shall conform to the relevant requirements of Sub-
section 4.4, subject to any modifications by the Engineer.
2 Plant and equipment for mixing, hauling, placing and
compacting recycled bituminous base course materials
shall conform to the relevant requirements of Sub-section
4.3.
4.11.5 Construction of Trial Sections
1 Trial sections shall be constructed as and where
directed and in accordance with the relevant requirements
of Sub-section 4.3.
4.11.6 Mixing Procedures
1 Handling and mixing of bitumen (including modifier
and anti-stripping agent, if any) and aggregate (including
recycled material, new aggregate and mineral filler if
required) shall be in accordance with the relevant
requirements of Sub-section 4.3.
2 Crushing of existing pavement materials for recycling
may be accomplished by portable or stationary crushers
or may be the direct result of the pavement removal
method such as cold milling.
3 Crushed pavement material shall be separated into a
minimum of two sizes prior to heating and mixing. The
fine size shall have a minimum of 80% passing a 4.75mm
(No.4) sieve. The coarse size shall have a minimum of
60% retained on a 4.75mm (No.4) sieve.
4 Heated and dried new aggregate shall be combined
in the appropriate proportions and gradations with the
recycled bituminous material and mixed at such
temperature and for such time necessary to achieve a
thorough coating of the new aggregate. New bitumen
and/or modifier shall then be incorporated into the
mixture and mixed to produce a homogenous mixture
with satisfactory coating of all aggregate.
5 If both bitumen and modifier are used they shall be
introduced into the mixing area through separate
metering devices.
6 Preheating of the crushed recycled bituminous
material immediately before introduction to the mixer may
be permitted subject to the approval of the Engineer.
Preheating methods shall not result in loss of bitumen
from the recycled material.
4.11.7 Surface Preparation
1 Preparation of the surface upon which the recycled
bituminous base course is to be laid shall be appropriate
to the type and condition of such surface and shall
conform to the relevant requirements of Sub-section 4.3.
4.11.8 Delivery, Spreading and Finishing
1 The delivery, spreading and finishing of recycled
bituminous base course shall conform to the relevant
requirements of Sub-section 4.4
4.11.9 Sampling and Testing
1 Sampling and testing of recycled bituminous base
course shall conform to the relevant requirements of
Section 4.3, and Table 4.3.9.1.
4.11.10 Surface Tolerances
1 Surface tolerances shall conform to the relevant
requirements of Sub-section 4.4.
4.11.11 Determination of Thickness
1 Procedures for determining the average compacted
thickness of recycled bituminous base course shall be in
accordance with the requirements of Sub-section 4.4.
♦ 4-33 ♦
copy 249
4.11.12 Method of Measurement
1 Recycled bituminous base course shall be measured
by the cubic meter of mix furnished, spread, compacted,
completed and accepted. Measurement shall be based on
the areas and thickness shown on the Drawings or as
directed.
2 Removal and crushing of existing pavement
materials for incorporation in recycled bituminous base
course shall not be measured for direct payment, but shall
be considered as subsidiary work, the costs of which will
be deemed to be included in the rates for recycled
bituminous base course stated in the Bill of Quantities.
3 Bituminous prime and tack coats shall be measured
as prescribed in Sub-section 4.2 "Bituminous Prime and
Tack Coats".
4 All other incidental items shall not be measured for
direct payment, but shall be considered as subsidiary work,
the costs of which will be deemed to be included in the
rates and prices stated in the Bill of Quantities.
4.11.13 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities ,
which rate shall be full compensation for supplying
materials, transporting and placing, for labor, equipment,
tools and other items necessary for the proper completion
of the work.
4.11.14 Items in the Bill of Quantities
i. Recycled bituminous base course
4.12 Surface Rideability Measurement
4.12.1 Description
1 This Sub-section summarizes testing procedures and
road surface rideability specifications for asphalt and
concrete surfaced pavements. The specifications are
based on the International Roughness Index (IRI) values
(average value from three runs and in units of m/km)
measured using a high-speed profiler tugged by a utility
vehicle. A minimum lead-in distance of 100 m and a
segment length of 150 m are suggested.
4.12.2 Reference Documents for Profiler
Rideability Testing
i. ASTM E 867 Terminology Relating to Vehicle-
Pavement Systems.
ii. ASTM E 950 Test Method for Measuring
Pavement Roughness Using a Profiler.
iii. AASHTO Designation PP 50-02: Standard
Equipment Specification for an Inertial Profiler.
iv. AASHTO Designation PP 51-02: Standard
Practice for Certification of Inertial Profiling
System.
♦ 4-34 ♦
v. AASHTO Designation PP 52-02: Standard
Practice for Operating Inertial Profilers and
Evaluating Pavement Profiles.
vi. AASHTO Designation PP 53-02: Standard
Practice for a Pavement Ride Quality
Specification when Measured Using Inertial
Profiling System.
4.12.3 Terminology
1 The current rideability specifications are based on
International Roughness Index (IRI). As an internationally
accepted scale for ride quality, IRI is a standardized
measure of the response of a standard vehicle to
pavement profile. IRI is an index computed from a single
longitudinal profile using a quarter-car model at a
simulated travel speed of (80 km/h). Lane IRI is the
average of the left and right wheel path IRI values.
4.12.4 Testing Equipment
1 The rideability testing shall be conducted using a
high-speed profiler (HSP). The HSP should conform to the
requirements of Class I equipment as defined in ASTM E
950 and to the requirements specified in AASHTO
Designation PP 50-02 and PP 51-02.
2 Prior to testing, calibration and verification
procedures should be in accordance with the
recommendations provided by the profiler manufacturer.
The equipment should be operated in accordance with the
recommendations provided by the manufacturer and
AASHTO PP 52-02.
4.12.5 Testing Procedure
1 Continuous and rigorous scrutiny of profiler output is
required. A constant testing speed shall be maintained
through the lead-in distance (100 m minimum) and the
test section. Two driving speeds of 65 to 95 km/h are
required.
2 The profiles measured for each run should be used to
compute the IRI value for each wheel path of each 150m
subsection within the test section. After three runs, the
test data (IRI values) should be reviewed by calculating the
average, standard deviation, and coefficient of variance
(COV) for each subsection wheel path. If a value of
standard deviation is greater than 0.016m/km or COV is
greater than 5%, then the test shall be repeated. Additional
testing should be done until standard deviation is less
than 0.016m/km or COV is less than 5% (with obvious
outliers excluded).
3 After five runs, if a value of standard deviation is
larger than 0.016 m/km or COV is greater than 5%,
compare the profiles from the five runs and attempt to
identify possible equipment or operational problems.
Recalibrate if necessary. Record all data.
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4.12.6 Submittals 4.12.9 Basis of Payment
1 Data for each test shall be stored on media such as 1 The amount of completed and accepted work,
CDs. measured as provided for above, will be paid for at the
2 Hard copy reports shall be provided for each test unit rates for the various items in the Bill of Quantities ,
section. The following information be reported and stored: which rate shall be full compensation for labor, equipment,
tools, materials, transportation and other items necessary
i. Date and time of day.
for the proper completion of the work.
ii. Operator(s) and equipment used.
iii. Weather conditions: temperature, cloud cover,
4.12.10 Items in the Bill of Quantities
and wind.
iv. Surface description: type of pavement and i. International Roughness Index (IRI)
condition. for asphalt pavement (length)
v. Location and description of section: Job ID, ii. International Roughness Index (IRI)
lane, beginning and ending stationing (or other for concrete pavement (length)
location information), and direction.
vi. Total section length.
vii. Data filter settings: High-pass filter setting =
100m.
viii. IRI value of each wheel path and the average of
the two wheel paths for each 150 m subsection.
ix. Raw data.

4.12.7 Required Rideability

1 The IRI value representing the rideability of each
road subsection shall not exceed 1.2 m/km.
2 The schedule provided in Table 4.12.7.1 shall be used
for payment adjustments to the final quantities of the top
layer of the bituminous wearing course paid under Clause
4.5.14 or the final quantities of concrete pavement paid
under Clause 5.7.6. Price adjustments are based on the
average IRI value of the two wheel paths (lane IRI) for each
150m subsection.

Final Roughness
Price Adjustment
IRI (m/km)
≤ 1.2 100%
1.2 – 1.4 98%
1.4 – 1.6 96%
1.6 – 1.9 92%
1.9 – 2.4 85%
Mill, remove and replace the top
2.4 and above wearing course layer
Plane concrete surface
Table 4.12.7.1: Wearing Course Price Adjustment for
Rideability

4.12.8 Method of Measurement

1 The IRI test shall be measured in linear meters for the
total length of pavement tested in each pavement lane
(covering two wheel paths per lane).The rates shall be
deemed to include for all costs including testing
equipment, calibration, interpretation of data and
reporting of results.

♦ 4-35 ♦
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copy 249
Ref. Title Page No. Ref. Title Page No.
5.1 Concrete Materials and Mixes 5-1 5.1.4.2  Job-Site Mixing 5-9 
5.1.4.3  Ready-Mixed Concrete 5-9 
5.1.1  Description 5-1 
5.1.4.4  Quality Control and Testing – General 5-10 
5.1.1.1  Definitions 5-1 
5.1.4.5  Quality Control – Testing
5.1.1.2  References 5-1 
on Fresh Concrete 5-10 
5.1.1.3  Submittals 5-2 
5.1.4.6  Quality Control – Testing on Hardened
5.1.1.4  Quality Assurance 5-2 
Concrete 5-11 
5.1.2  Materials 5-3 
5.1.5  Method of Measurement 5-12 
5.1.2.1  Portland Cement 5-3 
5.1.5.1  Measured Items 5-12 
5.1.2.2  Silica Fume 5-3 
5.1.5.2  Items Not Measured 5-12 
5.1.2.3  Supplementary Cementing
5.1.6  Basis of Payment 5-12 
Material (SCM) 5-4 
5.1.7  Items in the Bill of Quantities 5-13 
5.1.2.4  Blended Hydraulic Cement 5-4 
5.1.2.5  Aggregates 5-4  5.2 Reinforcing Steel 5-13
5.1.2.6  Water 5-5 
5.2.1  Description 5-13 
5.1.2.7  Admixtures 5-5 
5.2.1.1  References 5-13 
5.1.2.8  Fiber Reinforcement 5-6 
5.2.1.2  Submittals 5-13 
5.1.3  Concrete Mixes 5-6 
5.2.1.3  Quality Assurance 5-13 
5.1.3.1  Design Mixes 5-6 
5.2.1.4  Delivery, Storage and Handling 5-13 
5.1.3.2  Testing Agency 5-6 
5.2.2  Materials 5-13 
5.1.3.3  Reports 5-6 
5.2.2.1  Steel Reinforcement 5-13 
5.1.3.4  Concrete Classes 5-6 
5.2.2.2  Reinforcement Accessories 5-14 
5.1.3.5  Threshold Values for Supplementary
5.2.2.3  Fabricating Reinforcement 5-14 
Cementing Materials (SCM) 5-6 
5.2.3  Construction Requirements 5-14 
5.1.3.6  Limit Values for Supplementary
5.2.3.1  General 5-14 
Cementing Materials (SCM) 5-7 
5.2.3.2  Shipping, Storage and Cleaning 5-14 
5.1.3.7  Water-Cementitious Materials Ratio 5-7 
5.2.3.3  Placing 5-15 
5.1.3.8  Slump Limits 5-7 
5.2.3.4  Concrete Cover 5-15 
5.1.3.9  Total Salt Content 5-7 
5.2.4  Method of Measurement 5-15 
5.1.3.10  Initial Setting Time 5-8 
5.2.5  Basis of Payment 5-15 
5.1.3.11  Test Mixes – Structural Grade
5.2.6  Items in the Bill of Quantities 5-16 
Concrete 5-8 
5.1.3.12  Test Mixes – Blinding and Plain 5.3 Reinforced Concrete
Concrete 5-8  Structures 5-16
5.1.3.13  Adjustments to Concrete Mixes 5-8 
5.3.1  Description 5-16 
5.1.3.14  Absorption Test 5-8 
5.3.1.1  Definitions 5-16 
5.1.3.15  Permeability Tests 5-8 
5.3.1.2  References 5-16 
5.1.3.16  Synthetic Fiber 5-9 
5.3.1.3  Submittals 5-16 
5.1.3.17  Admixtures 5-9 
5.3.1.4  Quality Assurance 5-17 
5.1.4  Construction Requirements 5-9 
5.3.2  Materials 5-17
5.1.4.1  Concrete Mixing 5-9 

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Ref. Title Page No. Ref. Title Page No.
5.3.2.1  Form Materials 5-17  5.4.3.3  Placement of Anchorages 5-31 
5.3.2.2  Waterstops 5-18  5.4.3.4  Identification and Testing 5-31 
5.3.2.3  Concrete Curing Cover Sheets 5-18  5.4.3.5  Protection of Prestressing Steel 5-32 
5.3.2.4  Curing Compounds 5-19  5.4.3.6  Ducts 5-32 
5.3.2.5  Concrete Accessories 5-19  5.4.3.7  Grout 5-33 
5.3.2.6  Repair Materials 5-19  5.4.3.8  Tensioning 5-34 
5.3.3  Construction Requirements 5-19  5.4.3.9  Pretension Construction 5-35 
5.3.3.1  Formwork 5-19  5.4.3.10  Post-Tension Construction 5-36 
5.3.3.2  Falsework 5-20  5.4.3.11  Grouting 5-37 
5.3.3.3  Embedded Items 5-20  5.4.4  Method of Measurement 5-39 
5.3.3.4  Removing and Reusing Forms 5-20  5.4.5  Basis of Payment 5-40 
5.3.3.5  Vapor Retarders 5-21  5.4.6  Items in the Bill of Quantities 5-40 
5.3.3.6  Construction Joints 5-21 
5.5 Concrete Bridges and Erection
5.3.3.7  Contraction and Expansion Joints 5-21 
Procedures 5-40
5.3.3.8  Waterstops 5-22 
5.3.3.9  Concrete Placement 5-22  5.5.1  Description 5-40 
5.3.3.10  Hot-Weather Concreting 5-24  5.5.1.1  Scope 5-40 
5.3.3.11  Finishing Plastic Concrete 5-25  5.5.1.2  References 5-40 
5.3.3.12  Curing Concrete 5-25  5.5.2  Materials 5-40 
5.3.3.13  Formed Finishes 5-26  5.5.3  Construction Requirements 5-41 
5.3.3.14  Tolerances 5-26  5.5.3.1  Balanced Cantilever Construction
5.3.4  Method of Measurement, Basis with In-Situ Concrete 5-41 
of Payment and Bill of Quantities 5-27  5.5.3.2  Glued Precast Segmental
Construction 5-42 
5.4 Prestressed Concrete
5.5.3.3  Precast Beam and slab Construction 5-43 
Structures 5-27
5.5.3.4  In-Situ Construction 5-43 
5.4.1  Description 5-27  5.5.4  Method of Measurement, Basis of
5.4.1.1  Scope 5-27  Payment and Items in the Bills
5.4.1.2  Definitions 5-27  of Quantities 5-43 
5.4.1.3  References 5-27 
5.6 Vehicular and Pedestrian
5.4.1.4  Submittals 5-28 
Underpasses and Animal
5.4.2  Materials 5-28 
Crossings 5-44
5.4.2.1  Concrete 5-28 
5.4.2.2  Reinforcing Steel 5-29  5.6.1  Description 5-44 
5.4.2.3  Prestressing Steel 5-29  5.6.1.1  Scope 5-44 
5.4.2.4  Post-Tensioning Anchorages 5.6.1.2  References 5-44 
and Couplers 5-29  5.6.2  Materials 5-44 
5.4.2.5  Epoxy-Bonding Agents for Precast 5.6.3  Construction Requirements 5-44 
Segmental Construction 5-29  5.6.3.1  Excavation 5-44 
5.4.3  Construction Requirements 5-29  5.6.3.2  Structural Concrete 5-45 
5.4.3.1  Placement of Ducts 5-29  5.6.3.3  Concrete Piles 5-45 
5.4.3.2  Placement of Prestressing Steel 5-30  5.6.3.4  Waterproofing 5-45

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Ref. Title Page No. Ref. Title Page No.
5.6.3.5  Concrete Pavement Construction 5-45  5.7.3.20  Pavement Marking 5-57 
5.6.3.6  Bituminous Pavement Construction 5-45  5.7.3.21  Field Quality Control 5-57 
5.6.3.7  Electrical Works 5-45  5.7.3.22  Repairs and Protection 5-58 
5.6.4  Method of Measurement 5-45  5.7.3.23  Determination of Concrete Thickness 5-59 
5.6.5  Basis of Payment 5-45  5.7.4  Method of Measurement 5-59 
5.6.6  Items in the Bill of Quantities 5-45  5.7.5  Basis of Payment 5-59 
5.7.6  Items in the Bill of Quantities 5-59 
5.7 Cement Concrete Pavement 5-45
5.8 Joint Sealers for Concrete
5.7.1  Description 5-45 
Pavement 5-59
5.7.2  Materials 5-45 
5.7.2.1  Forms 5-46  5.8.1  Description 5-59 
5.7.2.2  Steel Reinforcement 5-46  5.8.2  Materials 5-59 
5.7.2.3  Concrete Materials 5-46  5.8.2.1  Materials, General 5-59 
5.7.2.4  Admixtures 5-47  5.8.2.2  Elastomeric Hot-Poured Joint Sealants 5-60 
5.7.2.5  Curing Materials 5-47  5.8.2.3  Joint Sealant Backing 5-60 
5.7.2.6  Related Materials 5-47  5.8.2.4  Miscellaneous Materials 5-60 
5.7.2.7  Concrete Mixes 5-47  5.8.3  Construction Requirements 5-60 
5.7.2.8  Concrete Mixing 5-48  5.8.3.1  Examination 5-60 
5.7.2.9  Limitations of Mixing: 5-48  5.8.3.2  Preparation 5-60 
5.7.3  Construction Requirements 5-48  5.8.3.3  Installation of Joint Sealers 5-60 
5.7.3.1  Preparation 5-48  5.8.3.4  Cleaning 5-61 
5.7.3.2  Edge Forms and Screed Construction 5-49  5.8.3.5  Protection 5-61 
5.7.3.3  Steel Reinforcement 5-49  5.8.4  Method of Measurement, Basis
5.7.3.4  Placement of Reinforcement 5-49  of Payment and Bill of Quantities 5-61 
5.7.3.5  Joints 5-49 
5.9 Reinforced Concrete Box Culverts
5.7.3.6  Conditioning of Underlying Course,
and Headwalls, Wingwalls,
Slip-Form Construction 5-52 
Cut-Off Walls and Aprons 5-61
5.7.3.7  Conditioning of Underlying Course,
Side-Form Construction 5-52  5.9.1  Description 5-61 
5.7.3.8  Handling, Measuring, and Batching 5.9.2  Materials 5-61 
Material 5-52  5.9.3  Construction Requirements 5-61 
5.7.3.9  Concrete Protection and Curing 5-53  5.9.4  Method of Measurement 5-62 
5.7.3.10  Concrete Placement 5-53  5.9.5  Basis of Payment 5-62 
5.7.3.11  Concrete Finishing 5-55  5.9.6  Items in Bill of Quantities 5-62 
5.7.3.12  Final Strike-Off, Consolidation
5.10 Waterproofing for Structures 5-62
and Finishing 5-55 
5.7.3.13  Surface Texture 5-56  5.10.1  Description 5-62 
5.7.3.14  Skid Resistant Surfaces 5-56  5.10.1.1  Scope 5-62 
5.7.3.15  Surface Test 5-56  5.10.1.2  References 5-62 
5.7.3.16  Removing Forms 5-57  5.10.2  Materials 5-62 
5.7.3.17  Sealing Joints 5-57  5.10.2.1  Asphalt 5-62 
5.7.3.18  Opening to Traffic 5-57  5.10.2.2  Bitumen 5-62 
5.7.3.19  Pavement Tolerance 5-57  5.10.2.3  Waterproofing Fabric 5-62

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Ref. Title Page No. Ref. Title Page No.
5.10.2.4  Self-Adhesive Polyethylene Sheet 5-62  5.11.4  Method of Measurement, Basis
5.10.2.5  Tar for Absorptive Treatment 5-62  of Payment and Bill of Quantities 5-67 
5.10.2.6  Tar Seal Coat 5-63 
5.12 Bridge Load Testing 5-67
5.10.2.7  Proprietary Waterproofing Systems 5-63 
5.10.2.8  Epoxy Coating System 5-63  5.12.1  Description 5-67 
5.10.3  Construction Requirements 5-63  5.12.2  Load Application 5-67 
5.10.3.1  Surface Preparation 5-63  5.12.2.1  Composition of Applied Load 5-67 
5.10.3.2  Inspection, Delivery and Storage 5-63 5.12.2.2  Testing by Static Load 5-68 
5.10.3.3  Asphalt and Bitumen Waterproofing 5.12.2.3  Testing by Moving Load 5-68 
Fabric 5-63  5.12.3  Visual Inspection 5-68 
5.10.3.4  Proprietary Waterproofing 5.12.4  Measurements 5-68 
Membranes 5-64  5.12.5  Method of Measurement 5-68 
5.10.3.5  Damage Patching of Waterproofing 5.12.6  Basis of Payment 5-68 
Fabrics 5-64  5.12.7  Items in the Bill of Quantities 5-68 
5.10.3.6  Dampproofing 5-64 
5.10.3.7  Protection of Waterproofing and
Dampproofing 5-64 
5.10.3.8  Testing 5-65 
5.10.4  Method of Measurement 5-65 
5.10.5  Basis of Payment 5-65 
5.10.6  Items in the Bill of Qquantities 5-65 

5.11 Protective Coating for Concrete 5-65

5.11.1  Description 5-65 
5.11.1.1  Scope 5-65 
5.11.1.2  Submittals 5-65 
5.11.1.3  Performance Requirements 5-65 
5.11.1.4  Quality Assurance 5-65 
5.11.1.5  Testing 5-66 
5.11.2  Materials 5-66 
5.11.2.1  General 5-66 
5.11.2.2  Primer 5-66 
5.11.2.3  Topcoat 5-66 
5.11.2.4  Specifications 5-66 
5.11.3  Construction Requirements 5-66 
5.11.3.1  General 5-66 
5.11.3.2  Inspection of Concrete 5-66 
5.11.3.3  Surface Preparation 5-67 
5.11.3.4  Approval Prior to Coating Application 5-67 
5.11.3.5  Application 5-67 

copy 249
5.1 Concrete Materials and Mixes ASTM C 114 Standard Test Methods for Chemical
Analysis of Hydraulic Cement
5.1.1 Description ASTM C 117 Standard Test Method for Materials
Finer Than 75 Micrometer (No. 200)
5.1.1.1 Definitions Sieve in Mineral Aggregates by
1 Concrete shall consist of a mixture of cementitious Washing
materials, aggregates, water and additives. ASTM C 127 Standard Test Method for Density,
2 Cementitious Materials: Portland cement alone or in Relative Density (Specific Gravity) and
combination with one or more of blended hydraulic Absorption of Coarse Aggregate
cement, fly ash and other pozzolans, ground granulated ASTM C 128 Standard Test Method for Density,
blast-furnace slag and silica fume. Relative Density (Specific Gravity) and
Absorption of Fine Aggregate
5.1.1.2 References
ASTM C 131 Standard Test Method for Resistance to
AASHTO T26 Standard Method of Test for Quality of Degradation of Small-Size Coarse
Water to be used in Concrete Aggregate by Abrasion and Impact in
1 American Association of State Highways and the Los Angeles Machine
Transportation Officials (AASHTO): ASTM C 142 Standard Test Method for Clay Lumps
2 American Concrete Institute (ACI): and Friable Particles in Aggregates

ACI 117 Specifications for Standard Tolerances ASTM C 143 Standard Test Method for Slump of
for Concrete Construction and Hydraulic Cement Concrete
Materials ASTM C 150 Standard Specification for Portland
ACI 301 Specifications for Structural Concrete Cement
for Buildings ASTM C 172 Standard Practice for Sampling Freshly
ACI 304 Guide for Measuring, Mixing, Mixed Concrete
Transporting, and Placing Concrete ASTM C 186 Standard Test Method for Heat of
3 American National Standards Institute (ANSI): Hydration of Hydraulic Cement

ANSI Q9001 Quality Systems – Model for Quality ASTM C 191 Standard Test Method for Time of
Assurance in Design, Development, Setting of Hydraulic Cement by Vicat
Production, Installation, and Servicing Needle

ANSI Q9002 Quality Systems – Model for Quality ASTM C192/C192M Standard Practice for Making
Assurance in Production, Installation, and Curing Concrete Test Specimens in
and Servicing the Laboratory (AASHTO T126)

4 American Society for Testing and Materials (ASTM): ASTM C 219 Standard Terminology Relating to
Hydraulic Cement
ASTM A 820 Standard Specification for Steel Fibers
for Fiber-Reinforced Concrete ASTM C 227 Standard Test Method for Potential
Alkali Reactivity of Cement-Aggregate
ASTM C31/C31M Standard Practice for Making and
Combinations (Mortar-Bar Method)
Curing Concrete Test Specimens in the
Field (AASHTO T23) ASTM C 289 Standard Test Method for Potential
Reactivity of Aggregates (Chemical
ASTM C 33 Standard Specification for Concrete
Method)
Aggregates
ASTM C 295 Standard Guide for Petrographic
ASTM C39/C39M Standard Test Method for Compressive
Examination of Aggregates for
Strength of Cylindrical Concrete
Concrete
Specimens (AASHTO T22)
ASTM C 311 Standard Test Methods for Sampling
ASTM C 40 Standard Test Method for Organic
and Testing Fly Ash or Natural
Impurities in Fine Aggregates for
Pozzolans for Use as a Mineral
Concrete
Admixture in Portland-Cement
ASTM C 42 Standard Test Method for Obtaining Concrete
and Testing Drilled Cores and Sawed
ASTM C 494 Standard Specifications for Chemical
Beams of Concrete
Admixtures for Concrete
ASTM C 88 Standard Test Method for Soundness of
ASTM C 586 Standard Test Method for Potential
Aggregates by Use of Sodium Sulfate
Alkali Reactivity of Carbonate Rocks for
or Magnesium Sulfate
Concrete Aggregates (Rock Cylinder
ASTM C 94 Standard Specifications for Ready- Method)
Mixed Concrete

♦ 5-1 ♦
copy 249
ASTM C 595 Standard Specifications for Blended BS EN 12350 Testing Fresh Concrete
Hydraulic Cements BS EN 12390 Testing Hardened Concrete
ASTM C 618 Standard Specifications for Coal Fly BS EN 12620 Specification for Aggregates
Ash and Raw or Calcined Natural
BS EN 197 Cement Specification
Pozzolan for Use as a Mineral
Admixture in Concrete Part 1: Composition and specification

ASTM C 989 Standard Specification for Ground Part 2: Conformity evaluation

Granulated Blast-Furnace Slag for Use 6 Commercial Standards (CS):
in Concrete and Mortars Concrete Plant Manufacturers Bureau - Concrete Plant
ASTM C 1064 Standard Test Method for Temperature Standards
of Freshly Mixed Portland Cement National Ready-Mixed Concrete Association (NRMCA) -
Concrete Check List
ASTM C 1077 Standard Practice for Laboratories 7 Corps of Engineers (CE):
Testing Concrete and Concrete
CE CRD-C119 Test for Flat and Elongated Particles
Aggregates for Use in Construction and
Criteria for Laboratory Evaluation 8 National Standard of Canada:
ASTM C 1105 Standard Test Method for Length CAN/CSA A23.5-M86 Supplementary Cementing
Change of Concrete Due to Alkali- Materials
Carbonate Rock Reaction
5.1.1.3 Submittals
ASTM C 1116 Standard Specification for Fiber-
Reinforced Concrete and Shotcrete 1 Product Data: For proprietary materials and items.
ASTM C 1202 Test Method for Electrical Indication of 2 Design Mixes: For each concrete mix. Include
Concrete’s Ability to Resist Chloride Ion alternative mix designs when characteristics of materials,
Penetration (AASHTO T 277) project conditions, weather, test results, or other
circumstances warrant adjustments.
ASTM D 512 Standard Test Methods for Chloride Ion
in Water 3 Qualification Data: For firms and persons specified in
Paragraph 5.1.1.4 "Quality Assurance" to demonstrate
ASTM D 516 Standard Test Method for Sulfate Ion in
their capabilities and experience. Include lists of
Water
completed projects with project names and addresses,
ASTM E 329 Standard Specification for Agencies names and addresses of engineers and owners, and any
Engaged in the Testing and/or other information required by the Engineer.
Inspection of Materials used in
4 Material Test Reports: From a qualified testing
Construction
agency indicating and interpreting test results for
ASTM E 548 Standard Guide for General Criteria compliance of the following with requirements indicated,
Used for Evaluating Laboratory based on comprehensive testing of current materials:
Competence
5 Material Certificates: Signed by manufacturers and
5 British Standards: Contractor certifying that each of the following items
BS 812 Testing Aggregates complies with specified requirements:
BS 1881 Methods of Testing Concrete i. Cementitious materials and aggregates.
BS 1199 and 1200 Specification for Building Sands from ii. Fiber reinforcement.
Natural Sources iii. Admixtures: Material certificates in lieu of
material laboratory test reports when permitted
BS 4027 Specification for Sulfate-Resisting
by the Engineer. Material certificates shall be
Portland Cement
signed by the manufacturer and the Contractor,
BS 5328 Methods for Specifying Concrete certifying that each material item complies with
Including Ready-Mixed Concrete specified requirements. Provide certification
BS EN 932 Tests of Aggregates for General from admixture manufacturers that chloride
Properties content complies with specified requirements.
BS EN 933 Tests of Aggregates for Geometric 6 Minutes of pre-installation conference.
Properties
5.1.1.4 Quality Assurance
BS EN 1097 Tests of Aggregates for Mechanical
Properties 1 Quality System: Comply with ISO 9001/9002 Quality
BS EN 1367 Tests of Aggregates for Thermal and System and ISO 14001 Environmental Management
Weathering Properties Systems as a minimum. Incorporate all the standard
procedures supplied by the Engineer and the Employer.
BS EN 1744 Tests of Aggregates for Chemical
Properties

♦ 5-2 ♦
copy 249
2 Codes and Standards: Comply with the latest version
of ACI Manual of Concrete Practice Parts 1, 2, 3, 4 & 5, and
CRSI "Manual of Standard Practice” except where more
stringent requirements are shown or specified.
3 Concrete Quality Control Engineer: Appoint a full-
time Concrete Quality Control Engineer (CQCE) to ensure
that concrete is properly produced, placed, cured and
protected. The CQCE shall be equivalent to a Member of
the Institute of Concrete Technology (MICT) or as
approved by the Engineer and shall be responsible for the
maintenance and submission of all specified records. The
CQCE shall not report to the site construction
management but to the Contractor’s management and to
the Engineer. The CQCE shall set standards of quality and
insist that these standards be followed, prepare a Quality
Control Program for the inspection and testing of concrete
and the maintenance of all reports and records to meet the
specified requirements and requirements of the Engineer.
Depending on the quantity of concrete works in specific
project, the Special Specifications may waive this
requirement.
4 The Contractor shall operate a Quality Assurance
System in accordance with ANSI Q9002. The Quality
Assurance Manager shall be responsible for the
preparation of a Quality Plan for approval of the
operations specified in this Section. The Quality Plan shall
include, among other things, the list and schedule of the
Quality Control audits that the Quality Assurance Manager
shall make.
5 Concrete Manufacturer Qualifications: A firm
experienced in manufacturing ready-mixed concrete
products complying with ASTM C 94/C94M requirements
for production facilities and equipment.
6 Engage an independent testing agency acceptable to
the Engineer to perform material evaluation tests and
qualified according to ASTM C 1077 and ASTM E 329 to
conduct the testing indicated, as documented according to
ASTM E 548 and to design concrete mixes.
i. Personnel conducting field tests shall be
qualified as ACI concrete field testing technician,
Grade 1 according to ACI CP-1 or an equivalent
certification program approved by the Engineer.
7 Materials and installed work may require testing and
retesting at any time during progress of work, if instructed
by the Engineer. Tests, including retesting of rejected
materials for installed work, shall be done at the
Contractor’s expense.
8 Source Limitations: Obtain each type or class of
cementitious material of the same brand from the same
manufacturer's plant, each aggregate from one source,
and each admixture from the same manufacturer.
9 Pre-installation Conference: Conduct conference at
Project site to comply with requirements as follows:
At least 35 days prior to submitting design mixes, conduct
a meeting to review detailed requirements for preparing
concrete design mixes and to determine procedures for
satisfactory concrete operations. Review requirements for
submittals, status of coordinating work, and availability of
materials. Establish preliminary work progress schedule
and procedures for materials inspection, testing, and
certifications. Require representatives of each entity
directly concerned with cast-in-place concrete to attend
conference, including, but not limited to, the following:
- Contractor’s superintendent.
- Agency responsible for concrete design mixes.
- Agency responsible for field quality control.
- Ready-mix concrete producer.
- Concrete subcontractor.
- Primary admixture manufacturers
5.1.2 Materials
5.1.2.1 Portland Cement
1 Portland Cement: Cement shall be low alkali with
chemical composition in accordance with Table 1 of ASTM
C 150 or BS EN 197: Part 1. The magnesia content shall be
limited to 4 percent by weight of cement, as tested in
accordance with ASTM C 114. Use one brand of cement
throughout Project unless otherwise approved by the
Engineer. Manufacturer’s test certification shall be
supplied for each delivery of cement and shall confirm
that the cement complies with the above requirements
and shall be submitted by the Contractor not later than the
day of delivery of the cement. The Engineer shall have the
right to call for tests, the cost of which is to be borne by
the Contractor, on each delivery of cement to confirm that
the cement meets the following requirements.
i. Ordinary Portland cement (OPC) conforms to
ASTM C 150, Type I or BS EN 197. The heat of
hydration shall not exceed 325 kj/kg when tested
in accordance with ASTM C 186. C3A content
shall be a minimum of 5 percent and a maximum
of 13 percent.
ii. Sulfate-resisting Portland cement conforms to
ASTM C 150, Type V or BS 4027; C3A content
shall not be more than 3.5 percent.
iii. Moderate Sulfate: conforms to ASTM C 150 type
II or BS EN 197. C3A content shall be a minimum
of 3.5 percent and a maximum of 8 percent.
2 Sampling shall be carried out in accordance with BS
EN 196: Part 7.
3 Test cement for fineness by air permeability
apparatus in accordance with ASTM C 204 to meet the
requirements of ASTM C 150.
4 Test cement for soundness. Autoclave expansion in
accordance with ASTM C 151.
5.1.2.2 Silica Fume
1 Silica fume (SF), also referred to as microsilica, used
as a cement replacement shall be in accordance with
Type U, specified in Canadian National Standard
CAN/CSA-A23.5 - M86. The silica fume shall be
obtained from an approved supplier.
♦ 5-3 ♦
copy 249
2 The approved supplier shall provide documentation source and shall not contain substances that cause
to establish the following: spalling. Only aggregates not susceptible to alkali
i. That the silica fume complies with Type U of aggregate reaction shall be used. The Contractor shall
CAN/CSA-A23.5 - M86. supply samples of the materials for approval by the
ii. The silica fume results from the production of Engineer and each aggregate source shall be subject to
silicon or ferro-silicon alloys containing at least monitoring by the Engineer. Grading of aggregate shall be
85 percent silicon dioxide. That source of supply to the compliance of BS EN 12620.
shall remain the same for the construction 2 Coarse aggregate for structural concrete shall be
period of the project. 20mm nominal size, free from material passing a 5mm
iii. That the supply shall be adequate to meet the sieve, and shall consist of crushed stone, selected, re-
anticipated peak requirement. crushed, finish screened and washed with water meeting
iv. Chemical analyses to give the percentages of the the requirements of Paragraph 5.1.2.6 as necessary, and
following materials: shall comply with the following:
Si O2 C
Freq. of
Ca O Fe2 O3 Tests Test Description Standard Limit
Al2 O3 Na2 O (min)

K2 O Mg O Los Angeles ASTM 25%

Initial Abrasion Loss
SO3 C 131 maximum
(Grading A or B)
v. Loss on ignition. Ratio of Los
vi. Percentage of particles greater than 44 μm. Angeles Abrasion ASTM
vii. Specific surface area and method of test, Loss at 100 & 500 0.25%
Initial C 131
together with corresponding particle size. Revolutions maximum
(100/500 Note 6
3 Delivery of silica fume to the concrete batching plant
Revolutions Value)
shall be in dry powder form, with a bulk density between
200 and 650 kg/cu m. Clay Lumps and ASTM 1.0%
1 per day
Friable Particles C 142 maximum
4 Manufacturer's test certification shall be supplied for
each delivery of silica fume and shall confirm that the Material Finer than ASTM 1.0%
1 per day
silica fume complies with the above requirements and 75 Microns C 117 maximum
shall be submitted by the Contractor no later than the day 1 per 7 ASTM 2.0%
of delivery of the silica fume. Water Absorption
days C 127 maximum
5 The Engineer shall have the right to call for tests, the 1 per 3 0.03%
cost of which are to be borne by the Contractor, on each Chlorides as Cl BS 812
days max *
delivery of silica fume, if necessary to establish or confirm
1 per 3 0.3% max
that the silica fume meets the above requirements. Sulfates as SO3 BS 812
days *
5.1.2.3 Supplementary Cementing Material (SCM) Magnesium ASTM
1 per 30 12%
Sulfate Soundness
1 Supplementary cementing materials, if permitted by days C 88 maximum
Loss (5 cycles)
the Engineer, shall be selected from subparagraphs below.
1 per 3 25%
Blending of fly ash or slag with Portland cement shall be Flakiness Index BS 812
days maximum
done at mixing plant.
1 per 3 25%
i. Pulverized Fly Ash: ASTM C 618, Class C or F. Elongation Index BS 812
days maximum
ii. Ground Granulated Blast-Furnace Slag: ASTM C
Per
989, Grade 100 or 120. Each Appendix
ASTM
production Reactive Silica X1.3.7 of
5.1.2.4 Blended Hydraulic Cement C 227
sample ASTM C
1 Blended Hydraulic Cement: conforming to ASTM C 33
595 shall be used solely for grouts if specified or approved 1 per 7 ASTM Minimum
Specific Gravity
by the Engineer. It shall not to be used for making days C 127 2.6
structural concrete. 1 per 2 BS EN
Moisture Content
days 1097-5
5.1.2.5 Aggregates
Each
1 Aggregates shall be normal-weight and shall be from 3%
production Shell Content BS812
maximum
approved sources and shall conform to the requirements sample
of ASTM C 33 and BS EN 12620. Petrographic analyses
Table 5.1.2.1: Coarse Aggregate Specifications and Testing
shall be made in accordance with ASTM C 295.
Aggregates for exposed concrete shall be from a single

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* Additionally, the limits specified in Paragraph 5.1.3.9 for tons of fine aggregate and every 80 tons
total salt content shall not be exceeded of coarse aggregate.
3 Fine aggregate, shall pass a 5mm sieve and shall - Chemical analyses shall be carried out on
consist of crushed gravel, crushed stone or natural sand every 100 tons of aggregate.
with rounded or surrounded particles, washed as ii. The Engineer shall have the right to call for
necessary, and shall comply with the following: additional samples at any time for testing of
aggregates delivered to the Site or of aggregates
Test Description Standard Limit at the source of supply in order to confirm that
Clay Lumps and the aggregates meet the above requirements.
ASTM C 142 1.0% maximum
Friable Particles 6 Transportation: During transportation to the Site, all
maximum 3% for aggregates shall be protected from wind-borne
Material Finer natural sand and 5% contaminants. If these contaminants are present at time
ASTM C 117
than 75 Microns for crushed sand of delivery, the aggregates shall be washed with water
with no plastic fines meeting the requirement of Paragraph 5.1.2.6. Transport
Water vehicles shall be cleaned to remove possible
ASTM C 128 1.0% maximum
Absorption contamination due to previous use.
Chlorides as Cl BS 812 0.06% maximum* 7 Storage: Aggregates shall be stored (under shade) on
hard concrete floors or other approved surface having
Sulfates as SO3 BS 812 0.30% maximum*
sufficient slope to ensure adequate drainage of aggregate
Organic Lighter than before being used for concrete. Each size and type shall be
ASTM C 40
Impurities Standard stored in separate heaps without intermixing. Storage
Sand Equivalent AASHTO T176 75% minimum shall prevent contamination of the aggregates by foreign
material including windblown dust. Fine and coarse
Five Cycles of
aggregates shall be separated by permanent substantial
Soundness in
BS 812 15% maximum partitions. Methods of storing, shading and cooling
Magnesium
Sulfate aggregates shall be approved by the Engineer.

Table 5.1.2.2: Fine Aggregate Specifications and Testing 8 Plums used in cyclopean concrete shall consist of
non-reactive broken stone spalls or boulders ranging in
* Additionally, the limits specified in Paragraph 5.1.3.9 for size from 200mm to 300mm. They shall be free from sharp
total salt content shall not be exceeded or angular edges and shall not form more than 30 percent
4 Certification: Obtain from each proposed source of of the total volume of concrete. They shall be evenly
supply test certification to confirm that the aggregates graded and shall be soaked in water prior to incorporation
comply with the above requirements. The following in the mix. Plums shall be evenly distributed in the
information shall be provided: concrete mix with a minimum cover of 100mm.
i. Quarry location. 5.1.2.6 Water
ii. Aggregate type.
iii. Petrographic analysis report. 1 Water used for mixing concrete, ice production,
iv. Grading curve. washing and cooling aggregates, and curing concrete
v. Shape and surface texture. shall be free from impurities, oil, acid, salts, alkali, organic
vi. Flakiness index. matter, and other potentially deleterious substances when
vii. 10 percent fines value. tested in accordance with AASHTO T26, ASTM D 512 and
viii. Impact test. ASTM D 516. Additionally, the limits specified in
ix. Shell content. Paragraph 5.1.3.9 for the total salt content of the concrete
x. Chloride and sulfate content. shall not be exceeded.
xi. Relative density. 2 Once a source of satisfactory supply has been
xii. Water absorption value and moisture content. established, further tests shall be made daily with a
xiii. Silt, clay, and dust content. portable electrical conductivity probe calibrated against
xiv. Results of reactive silica tests. the satisfactory supply. If the conductivity exceeds that of
xv. Organic impurities (fine aggregate only). the satisfactory supply, then further chemical tests shall be
5 Testing: performed.
i. When a source of supply for each aggregate type 5.1.2.7 Admixtures
has been established, samples of materials
delivered to the Site shall be taken for testing in 1 Admixtures containing chlorides shall not be used.
accordance with BS 812 as follows: 2 No admixture shall be used in the concrete without
- Tests for clay, silt and dust, and sieve the Engineer's written approval and under no
analysis shall be carried out for every 40 circumstances shall admixtures containing chlorides or

♦ 5-5 ♦
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other corrosive agents be allowed. Admixture i. Fiber: Type 1, cold-drawn wire, or Type 2, cut
compatibility with the type of cement used shall be proven. sheet.
3 The Contractor shall perform a trial batch and casting 2 Synthetic Fiber: Fibrillated or monofilament
to substantiate the manufacturer’s claims of workability, polypropylene fibers engineered and designed for use in
retardation as specified in Clause 5.1.3 Admixtures shall concrete, complying with ASTM C 1116, Type III. Project to
comply with the following standards: ASTM C494/C494 M, specify length.
BS EN 934 and BS EN 480. Also, admixture shall comply
with BS EN 12878 for pigments of cement. 5.1.3 Concrete Mixes
4 Air-Entraining Admixture: No air entraining agent
5.1.3.1 Design Mixes
shall be used.
5 Admixtures shall be incorporated into the mix design 1 Prepare design mixes for each type and strength of
strictly in accordance with the manufacturer’s written concrete determined by either laboratory trial mix or field
instructions. test data bases, according to ACI 211.1 and ACI 301.
6 High-Range Water-Reducing Admixture 5.1.3.2 Testing Agency
(Superplasticizer): ASTM C 494, Type G.
1 Use a qualified independent testing agency
i. If necessary, and only with the Engineer’s
acceptable to the Engineer for preparing and reporting
approval, a naphthalene sulphonate retarding
proposed mix designs for the laboratory trial mix basis.
superplasticizer shall be used to increase
workability of the concrete and retard the initial 2 Do not use the same testing agency for field quality
set. control.
ii. Products: Superplaticizer shall produce fluid,
5.1.3.3 Reports
easily flowing concrete with a slump value at
least 200 mm, but free from segregation, and 1 Submit written reports to the Engineer of each
having the same water/cement ratio as that of a proposed mix for each class of concrete at least 15 days
no slump concrete with admixture. The product prior to start of work. Do not begin concrete production
shall result in concrete that remains workable for until proposed mix designs have been reviewed and
a minimum of 3 hours at +20 deg.C and for a approved by the Engineer.
minimum of 1.5 hours at +40 deg. C.
iii. Obtain from the retarding superplasticizer 5.1.3.4 Concrete Classes
supplier, details of the material for review by the
Concrete class

Engineer and confirmation that it is in Minimum Cement Maximum

accordance with specified requirements. compressive content Water-
Confirmation shall be obtained that the retarding strength at 28 (kg/m3) Cementitious
superplasticizer is compatible with any pozzolan days (MPa) Minimum Materials
that is used. Cylinder / cube / Maximum Ratio

7 Water-Reducing Admixture (Plasticizer): ASTM C 494,

15 15 / 18.5 250 / 350 0.70
Type A.
25 25 / 31 300 / 400 0.52
8 Water-Reducing and Accelerating Admixture: ASTM
C 494, Type E. 30 30 / 37.5 350 / 450 0.50
9 Water-Reducing and Retarding Admixture: ASTM C 35 35 / 43.5 425 / 475 0.48
494, Type D. 40 40 / 50 425 / 500 0.45
10 Corrosion-Inhibiting Admixture: Commercially 45 45 / 56 450 / 500 0.42
formulated, mixed cathodic and anodic inhibitor based on
50 50 / 62.5 450 / 500 0.40
amines and alcohol; capable of forming a protective
barrier and absorbed on the reinforcement surface of 60 60 / 75 450 / 500 0.38
concrete for protecting steel bars and minimizing chloride Table 5.1.3.1: Concrete Classes
reactions with steel reinforcement in concrete.
5.1.3.5 Threshold Values for Supplementary
11 Glare-Reducing Agent: For landscape concrete
paving, provide material for reducing glare. Comply with Cementing Materials (SCM)
ASTM D 209.
1 Add SCM to the mix as necessary to achieve the
5.1.2.8 Fiber Reinforcement strength and durability requirements of the concrete
classes with due account of the maximum water-
1 Carbon-Steel Fiber: ASTM A 820, deformed, cementitious materials ratios specified in Table 5.1.3.1 and
minimum 60 mm long, and of diameter or effective Paragraph 5.1.3.7.
diameter indicated. 2 All the supplementary cementing materials (SCM)
have threshold values of addition below which significant

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durability or strength parameters do not develop. Nominal
(Equation 2)
threshold addition values are indicated in Table 5.1.3.2 for:
i. Silica fume
5.1.3.7 Water-Cementitious Materials Ratio
ii. Ground granulated blast-furnace slag (GGBFS)
iii. Pulverized fly ash (PFA) 1 The maximum water-cementitious materials ratio
shall be the lower of the values listed in Table 5.1.3.1 for
SCM Nominal threshold value
the concrete classes and the following values for the
01 Silica fume 7% on [cement + silica fume] exposure:
02 GGBFS 50% on [cement + GGBFS] i. 0.45 for concrete required to have low water
03 PFA 25% on [cement + PFA] permeability.
ii. 0.40 for corrosion protection of steel
Table 5.1.3.2Threshold Addition Values for SCM
reinforcement in concrete exposed to chlorides
3 The actual amount will depend on the quality of the from salt, saltwater, brackish water, seawater, or
supplementary cementing material and mix design spray from these sources.
parameters. iii. 0.45 for concrete subject to moderate sulfate
exposure.
5.1.3.6 Limit Values for Supplementary Cementing iv. 0.42 for concrete subject to severe or very severe
Materials (SCM) sulfate exposure.

1 The upper limiting addition percentage values for 2 The water-cementitious materials ratio shall be
each supplementary cementing material shall be as Table continuously checked at the mixer with due allowance
5.1.3.3. made for water contained in the aggregates. Under no
circumstance shall water be added between the mixer and
Max. the place of concrete placement. The Engineer may
SMA Applicable conditions
% require that the water-cementitious materials ratio be
Silica checked during tests performed on fresh concrete samples
01 10 For all exposures taken at the time of placement as specified in Paragraph
fume
For permanent dry [RH ≤ 50%] 5.1.4.4.
02 GGBFS 55 or damp [RH ≥ 85%]
conditions 5.1.3.8 Slump Limits
For underground damp
03 PFA 30 1 The slump of concrete mixes shall be such that the
exposures [RH ≥ 85%]
concrete can be transported, placed into the forms, and
04 GGBFS 70
For concrete buried in compacted without segregation in accordance with Sub-
05 PFA 45 permanently wet conditions Section 5.3. If no superplasticizer is required, the slump at
time of placement shall be 50-75 mm as measured in
Table 5.1.3.3: Limit Addition Values for SCM accordance with ASTM C 143. The concrete shall be
RH is the relative humidity. sufficiently workable to enable placement in its position
with minimum difficulty.
2 When mixtures of supplementary cementing
materials are designed into the same mix, calculations 5.1.3.9 Total Salt Content
based on proportionate replacement based on the limiting
values shown in Table 5.1.3.3 shall be derived by the use 1 Chlorides: The total chloride content (sum of both
of Equations 1 and 2. acid soluble and water soluble chlorides) of the concrete
from all sources, expressed as chloride ion, shall not
The following equations shall be used for calculating the
exceed the following percentages by weight of dry cement,
limiting partial proportions of each mineral additive in the
inclusive of pozzolan, when tested in accordance with BS
mix design:
1881:
Where
i. Unreinforced concrete 0.60%
x is the % of Silica fume incorporated ii. Concrete made with sulfate resisting
y is the % of GGBFS incorporated and cement 0.15%
z is the % of PFA incorporated iii. Concrete containing embedded metal (reinforced
concrete) made with ordinary Portland
For normal concrete (Table 5.1.3.3: conditions 01, 02 and
cement 0.30%
03)
iv. Prestressed concrete 0.06%
v. Heat cured concrete containing embedded metal
(Equation 1) (reinforced concrete) 0.10%
2 Sulfates: The total sulfate content of the concrete
For wet or dry situations (Table 5.1.3.3: conditions 01, 04 from all sources, expressed as SO3, when tested in
and 05) accordance with BS 1881, shall not exceed the lesser of 0.4

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percent by weight of aggregates or 3 percent by weight of
dry cement, inclusive of pozzolan.
5.1.3.10 Initial Setting Time
1 The initial setting time shall be not less than 90
minutes after the production concrete is discharged into
the form. With a maximum time between mixing and
placing concrete of 90 minutes, the total time between
mixing and initial set shall be a minimum of 2 hours.
Maximum setting time shall be 6 hours.
2 When trial mixes are made to determine the
workability of the concrete, the initial setting time of the
cement paste shall be determined using the method
defined in ASTM C 191 at the maximum allowable
temperature and with same proportions of pozzolan and
retarding superplasticizer as specified in this Specification.
5.1.3.11 Test Mixes – Structural Grade Concrete
1 When the proposed workability, proportions of
aggregates and superplasticizer, and strength for each
grade of concrete have been established, test concrete
shall be produced for approval by the Engineer. The
following shall be performed for each grade of concrete:
i. Six separate test mixes shall be made and cured
in accordance with ASTM C 192 and tested in
accordance with ASTM C 39.
ii. The 36 cylinders for each grade of concrete shall
be tested for compressive strength at 28 days
and the mean strength and standard deviation
established for each grade. The test mixes shall
be accepted provided that:
- The mix proportions and workability are
in accordance with this Specification.
- The standard deviation for each grade is
3.5 MPa or less.
- The mean strength for structural concrete
exceeds the specified design strength by
6 MPa.
5.1.3.12 Test Mixes – Blinding and Plain Concrete
1 Concrete for blinding, plain concrete or cyclopean
concrete shall be a designed mix with design strength of
15 MPa. The trial mix proportions shall be at the
discretion of the Contractor. Once they have been chosen,
three separate test mixes shall be made with those
proportions and three test cylinders shall be made from
each mix for testing at 28 days. The trial mix proportions
and water/cement ratio shall be approved if the average
strength of the nine cylinders is not less than 14 MPa.
2 No production test shall be made for this grade of
concrete but the Engineer will monitor the mix
proportions and water/cement ratio.
5.1.3.13 Adjustments to Concrete Mixes
1 Mix design adjustments may be required by the
Engineer when characteristics of materials, job conditions,
weather, test results, or other circumstances warrant.
♦ 5-8 ♦
Laboratory test data for revised mix design and strength
results shall be submitted to and approved by the
Engineer before using in the work.
5.1.3.14 Absorption Test
1 Hardened concrete from the trial mixes for structural
grades shall be tested for absorption to establish the
concrete’s ability to resist the ingress of aggressive salts.
No absorption tests shall be required for blinding, plain
concrete or cyclopean concrete. Absorption tests shall be
in accordance with modified BS 1881: Part 122 as follows:
i. After trial mixes have been accepted, three 150
mm cylinders shall be cast from each grade of
concrete and immersed in water at 20 deg. C for
7 days.
ii. At the end of the curing period, 75 mm diameter
core specimens shall be cut along the
longitudinal axis of each cylinder to a depth of
75 mm.
iii. The specimens shall be dried in an oven at 105
deg. C for 72 hours.
iv. The specimens shall be cooled in a dry airtight
vessel for 24 hours, weighed, and then
immediately immersed in a tank containing
water at 20 deg. C with the longitudinal axis of
the cores horizontal, and with 25 mm depth of
water over the specimens.
v. The specimens shall be immersed for 24 hours,
then removed, shaken, surface dried, and
reweighed. The water absorption shall be
calculated as the increase in mass resulting from
immersion, expressed as a percentage of the dry
mass.
vi. If the cores lengths differ from 75 mm, a
correction factor (graph given in BS 1881) shall
be applied.
vii. The mean of the corrected absorption figure for
each concrete grade shall be calculated and the
absorption of the concrete mixes shall be
acceptable if the mean absorption is less than 2
percent at 30 minutes. The mean absorption
figure and the lowest absorption figure shall be
recorded for each grade and used for
comparison purposes with absorption tests
carried out on cores cut from in-situ concrete, as
scheduled in Paragraph 5.1.4.6.
5.1.3.15 Permeability Tests
1 Depth of penetration tests shall be carried out to
establish the water permeability of concrete on prototype
samples of different components of the structure before
the mix design or manufacturing method are approved.
The prototype samples shall be short sections of not less
than 1.0m x 1.0m x full thickness. The samples shall be
fully reinforced and cast in similar environment as the
actual structure. The tests shall be carried out in
accordance with DIN 1048 at age 28 days and the
maximum value of penetration shall not exceed the
following limits:
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 In-situ construction: Less than 25 mm.
Precast units: Less than 20 mm.
2 Chloride permeability of the concrete shall be
determined using cores taken from the prototype samples,
in accordance with AASHTO T277 ‘Rapid Determination of
the Chloride Permeability of Concrete’. The following
limits shall not be exceeded:
In-situ construction: 1500 coulombs.
Precast units: 1000 coulombs.
3 The concrete will be deemed to comply with the
permeability requirements of this specification if all test
results comply with the limits indicated in Points 1 and 2.
4 If any of the DIN 1048 and the rapid chloride
permeability test results of unprotected surfaces of a
sample fail to meet the above requirements, then all the
concrete work represented by such sample shall be
deemed not to comply with the permeability requirements.
5 If, in the opinion of the Engineer, the concrete that
has failed to meet the permeability requirements of this
Specification is likely to cause durability problems, three
cores shall be cut from the area represented by failed
samples for additional DIN 1048 and rapid chloride
permeability testing. The location of the cores shall be
decided by the Engineer.
5.1.3.16 Synthetic Fiber
1 Uniformly disperse in concrete mix at manufacturer's
recommended rate, but not less than 0.60 kg/cu. m.
5.1.3.17 Admixtures
1 Use admixtures according to the manufacturer's
written instructions and in the proportions recommended.
2 Use water-reducing admixture or high-range water-
reducing admixture (superplasticizer) in concrete, as
required, for placement and workability.
3 Use water-reducing and retarding admixture when
required by high temperatures, low humidity, or other
adverse placement conditions.
4 Use water-reducing admixture in pumped concrete,
concrete required to be watertight, and concrete with a
water-cementitious materials ratio below 0.50.
5 Use corrosion-inhibiting admixture in concrete mixes
where indicated.
6 All admixtures shall be used as required and
approved by the Engineer for placement and workability
of concrete, and shall be used in accordance with the
manufacturer’s instructions. The equipment used for
dispensing and the method of incorporating the admixture
into the concrete shall be subject to approval. The
dispensing unit shall be translucent so that the operator
can see the discharge of the admixture.
5.1.4 Construction Requirements
5.1.4.1 Concrete Mixing
1 Concrete production shall be in accordance with ACI
304. A checklist for concrete production shall be produced,
such as that used by the NRMCA or approved equal.
2 Batching of materials shall be by weight. All
weighing equipment shall be calibrated and
documentation shall be provided to establish that the
accuracy is continuously maintained in accordance with
the requirements of ACI 304. Batching scale accuracy
shall be in accordance with the Concrete Plant Standards
of the Concrete Plant Manufacturers Bureau, or approved
equal.
3 Furnish equipment and establish accurate
procedures for determining the quantities of free moisture
in the aggregates. Moisture determinations shall be made
daily and whenever there is an apparent change in the
moisture content. The moisture content shall be recorded
and shall be taken into account in adjusting the weight of
aggregate and the quantity of water incorporated in the
mix.
5.1.4.2 Job-Site Mixing
1 All concrete mixed on Site shall be in a batch mixer
of approved size and design complying with ACI 304 and
producing a uniform distribution of the materials
throughout the mixed concrete in accordance with ASTM
C 94 uniformity test. The contents of the drum shall be
completely discharged before re-charging. After all the
materials are in the mixer, mixing shall continue until the
whole of the materials are uniformly distributed and the
mass is of uniform color and consistency. In the case of
concrete that contains silica fume with a density between
400-650 kg/cu.m, the mixing time shall be 50 percent
greater than the requirement for concrete without silica
fume.
2 Whenever mixing is to be suspended for half an hour
or longer, the drum of the mixer shall be thoroughly
washed out with clean water. Provide a competent
operator who shall be in continuous control of the mixer.
No re-tempering of concrete, which has partially hardened,
by the addition of cement, aggregate, or water shall be
allowed.
3 Provide batch ticket for each batch discharged and
used in the work, indicating Project identification name
and number, date, mix type, mix time, quantity, and
amount of water introduced as well as the load printout,
delivery printout, temperature readout and measured
slump.
5.1.4.3 Ready-Mixed Concrete
1 Ready-mixed concrete shall comply with the
requirements of ASTM C 94 or BS EN 206 and as follows:
i. Concrete shall be centrally mixed off site and
transported in an agitator truck. Truck mixing
shall not be permitted.
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 ii. The plant and trucks shall be certified as meeting i.
the requirements of the NRMCA Check List, or
approved equal.
iii. Details and information regarding the supplier
proposed by the contractor shall be submitted to
the Engineer for approval.
iv. The approved supplier of ready mixed concrete
shall not subsequently be changed without
further approval of the Engineer.
2 When air temperature is between 30 deg. C and 32
deg. C, delivery time from the time that water is added to
the mix until it is placed in its final position in the form
shall not exceed 90 minutes. When air temperature is
above 32 deg. C, delivery time shall not exceed 45 minutes.
Further time extension may be given if approved by the
Engineer.
3 Before discharging concrete at the point of delivery,
provide the Engineer with a delivery ticket for each batch
of concrete containing the following information as a
minimum:
i. Name or number of off-site concrete depot.
ii. Serial number for ticket.
iii. Date.
iv. Time of dispatch.
v. Truck number.
vi. Name of supplier.
vii. Grade or mix description of concrete.
viii. Type of cementitious materials.
ix. Cementitious materials content and constitution.
x. Water/cementitious materials ratio.
xi. Nominal maximum size of aggregate.
xii. Source of aggregate, maximum size, weight of
fine and coarse aggregate.
xiii. Type or name of admixture, if included.
ii.
xiv. Percentage variation between design and actual
values for all ingredients.
xv. Quantity of concrete in cubic meters.
xvi. Certifying that chlorides and sulfate contents are
within specified limits and stating their values.
5.1.4.4 Quality Control and Testing – General
1 Testing Laboratory:
i. Employ an independent testing agency to
perform tests and to submit test reports.
ii. Be responsible for taking, identifying and
delivering to the test laboratory all test samples
called for in this Specification. The testing
laboratory shall be responsible for the testing.
Collect all test results and deliver them to the
Engineer in the format and detail as specified.
2 Testing Laboratory Qualifications: The testing
laboratory shall be approved by the Engineer and shall
have a Quality System in accordance with ANSI Q9001.
5.1.4.5 Quality Control – Testing on Fresh Concrete
1 Compressive Strength Test for Structural Concrete:
♦ 5-10 ♦
Sampling, curing and testing shall be performed
using the relevant procedures in ASTM C 31,
ASTM C 39, and ASTM C 172 or BS EN 12350.
- Samples for production concrete cylinders
(or cubes if approved by the Engineer) shall
be taken at the point of placement at the
average rate of one per 100 cu. m of concrete
placed or one for each major placement, with
a minimum of one sample taken every day
that the mix is used. A sample shall consist
of eight 150 mm cylinders molded and stored
for laboratory-cured test specimens except
when field-cured test specimens are required.
Three cylinders are for testing at 7 days after
casting, three for testing at 28 days after
casting, and two reserved for later testing if
required.
- If frequency of testing provides fewer than 5
strength tests for a given class of concrete,
conduct testing from at least 5 randomly
selected batches or from each batch if fewer
than 5 are used.
- When total quantity of a given class of
concrete is less than 100 cu. m, the Engineer
may waive strength testing if adequate
evidence of satisfactory strength is provided
but not less than one sample per day.
- When strength of field-cured cylinders is less
than 85 percent of companion laboratory-
cured cylinders, re-evaluate current on-site
operations and provide corrective procedures
for protecting and curing the in-place
concrete.
Records shall be kept of the mix details and
position in the works of all batches of concrete
and of all samples taken for cylinders and other
specimens and of their test results. A copy shall
be supplied to the Engineer within 24 hours after
recording/testing. Records shall contain, but not
be limited to, the following information:
- Date, time, location, and volume of pour.
- Ambient temperature and humidity.
- Concrete temperature (at time of placement).
- Cementitious materials content and
constitution.
- Types of manufacturers of cementitious
materials.
- Concrete type and class.
- Aggregate type and source.
- Admixture details.
- Water/cementitious materials ratio.
- Identification of test cylinder.
- Name of concrete testing service.
- Date and time of sampling.
- Method of compaction.
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 - Date of testing and results of test.
- Age of sample in days, weight in grams,
density in kg/cu. m.
- Crushing load in Newtons and crushing
strength in MPa.
- Signatures of person preparing cylinder and
of person crushing cylinder.
- Results of testing.
iii. For the 28 day tests, the concrete will be deemed
to comply with the specified design strength if
the average strength determined from all sets of
3 consecutive tests is at least equal to the
specified design strength and no individual
strength test falls below the specified design
strength by more than 3.5 MPa. Any concrete
not complying with the specified design strength
shall be at risk for removal and replacement at
the Contractor’s expense.
iv. The 28-day cylinder crushing results shall be
grouped consecutively in groups of 40 and each
group shall have a standard deviation less than
3.5 MPa. If the standard deviation is greater than
or equal to 3.5 MPa, then concrete production
shall be investigated by the Engineer and further
tests on trial mixes may be required.
v. Tests shall be carried out at 7 days to establish a
relationship between the 7 day and 28 day
strengths. This relationship shall be used to
interpret future test results in order to predict the
corresponding 28 day strength. The Engineer
shall be advised without delay if any 7 day test
result indicates that the corresponding 28 day
strength is likely to fail to meet the specified
strength so that any necessary action can be
taken to minimize the effect of such possible
failure.
2 Compressive Strength Test for Blinding or Plain
Concrete: No production tests on blinding or plain
concrete are required. The Engineer may require
compressive strength tests if it is believed that the
characteristic strength is below 15 MPa. Characteristic
strength is defined as the minimum value of cube strength
achieved by 95 percent of all possible test results. If the
tests confirm that the characteristic strength is less than 15
MPa, then the Engineer will require revisions to the mix
design to ensure that the concrete meets the specified
requirements.
3 Measurement of Concrete Temperature: Temperature
measurements shall be in accordance with ASTM C 1064.
Concrete temperature shall be measured 50 mm below
the surface prior to and at the point of placement and
recorded on the pour card for each pour. One reading
shall be taken each hour when air temperature is 4 deg.C
and below and when air temperature is 27 deg.C and
above, and one reading for each set of compressive-
strength specimens. Concreting shall stop if the
temperature of the concrete does not meet the
requirements of Paragraph 5.3.3.10
4 Cementitious Materials Content and Water/
Cementitious Materials Ratio: Samples of freshly mixed
concrete shall be chosen by the Engineer at least once per
month from each structural grade and determination
made of cement content and water/cement ratio in
accordance with BS 1881. If the cement content is less
than 90 percent of the requirement in Paragraph 5.1.3.4 or
the water/cement ratio is greater than 110 percent of the
requirement in Paragraphs 5.1.3.4 and 5.1.3.7 the
Contractor and the Engineer shall investigate to establish
the cause and the Engineer may reject the cast concrete
for the pour from which the samples were taken. The
Engineer may request an analysis of fresh concrete from
any pour. No analysis of freshly mixed concrete is
required for blinding or plain concrete.
5 Salt Content: The total concentration of sulfates and
chlorides in fresh concrete shall be measured at least once
a week for all structural grades of concrete. Tests shall be
in accordance with BS 1881. Concentrations of each ion
shall not exceed the limits specified in Paragraph 5.1.3.9. If
these limits are exceeded, the concrete pour from which
the samples were taken shall be rejected and further tests
performed on the cast concrete in accordance with
paragraph 5.1.4.6 to determine the total extent of the
problem.
6 Slump: Slump tests shall be performed in accordance
with ASTM C 143. A minimum of one test shall be done at
the point of discharge for each day's pour for each type of
concrete. Additional tests shall be performed when
concrete consistency appears to have changed.
5.1.4.6 Quality Control – Testing on Hardened
Concrete
1 General: The Engineer may instruct samples to be
taken and tests carried out on any hardened structural
grade concrete as specified below if he suspects that the
concrete does not meet the specified requirements. If the
tests confirm that the concrete does not meet the
requirements of this Specification, then the Engineer may
require the concrete to be removed at the Contractor’s
expense. If the tests confirm that the concrete meets the
requirements of this Specification, then the cost of taking
the samples shall not be at the Contractor’s expense.
2 Compressive Strength Tests: The Engineer may
instruct cores to be drilled from a particular pour. 100 mm
diameter cores shall be drilled as requested, in accordance
with ASTM C 42, and sent for crushing. If the cores from
that pour have an average compressive strength less than
85 percent of the characteristic strength or if any
individual core has a compressive strength less than 75
percent of the characteristic strength, it shall be evidence
that the concrete from which it was taken is not in
accordance with the specified requirements.
3 Concrete Cover: The Engineer may check the
concrete cover over the reinforcement with a cover meter.
Any indication that the cover is generally less than the
requirements specified in Paragraph 5.2.3.4 shall be
checked by limited surface concrete removal. If it is
♦ 5-11 ♦
copy 249
confirmed that the actual cover is generally less than
specified, then the concrete shall be removed at the
Contractor’s expense. In the case of localized lack of cover
and where appearance is not important, a repair shall be
effected by removal of the inadequate cover and cutting
back of concrete for 50 mm behind the reinforcement.
Resurfacing of the concrete with the specified cover shall
be carried out as a repair by a specialist subcontractor.
4 Absorption: A sample of three 75 mm diameter cores,
75 mm long, shall be taken from hardened concrete if
directed by the Engineer and tested in accordance with
Paragraph 5.1.3.14. Should the absorption of any core
exceed by more than 1 percent the highest approved test
result, the concrete from which it was cut shall be
removed. No absorption test shall be required for
blinding or plain concrete.
5 Salt Content: Engineer may request samples to be
taken from two 20 mm diameter drillings into the concrete
surface, spaced 75 mm apart. Each drilling shall proceed
in 25 mm increments for a total depth of 100 mm and the
dust from the 4 samples in each hole shall be sent for
sulfate and chloride content analysis in accordance with
BS 1881. Should the tests show that the limits specified in
Paragraph 5.1.3.9 are exceeded, the concrete shall be
removed.
6 Nondestructive Testing: Impact hammer, sonoscope,
or other nondestructive device may be used but shall not
be used as the sole basis for acceptance or rejection of
cast concrete.
7 Additional Tests: The testing agency shall make
additional tests of in-place concrete, as directed by the
Engineer, when test results indicate that specified concrete
strengths or other characteristics have not been attained
in the structure. Testing agency may conduct tests to
determine adequacy of concrete by cored cylinders
complying with ASTM C 42, or by other methods as
directed.
5.1.5 Method of Measurement
5.1.5.1 Measured Items
1 Concrete is measured by the cubic meter for each
type and class, based on dimensions shown on the
Drawings or as otherwise directed by the Engineer.
2 Concrete works shall include mass, reinforced and
prestressed concrete of both in-situ and precast
construction of a general nature, but shall not include
specific components of highway structures, such as
concrete pavement, concrete piles, concrete parapets and
safety barriers, precast concrete curbs and tiles etc., which
are separately prescribed for measurement and payment
in other Sections.
3 Different classes of concrete are measured separately.
4 Concrete formed by different types of form and/or
falsework are each measured separately.
♦ 5-12 ♦
5 Concrete of the same class requiring the same
falsework but with a different class of surface finish are
each measured separately.
6 Voids, openings or gaps 0.05 cubic meters or more
shall be deducted from the volume of concrete in which
they occur.
7 All service ducts, irrespective of diameter, shall be
measured and deducted from the volume of concrete in
which they are located.
5.1.5.2 Items Not Measured
1 Volume of reinforcing bars is not deducted from the
measured volume of concrete.
2 Volume of prestressing ducts, anchors, cones,
couplers and grouting tubes is not deducted from the
measured volume of concrete.
3 Volume of embedded metals, bolts, nuts, anchorages,
hooks etc. is not deducted from the measured volume of
concrete.
4 Holes introduced, with the consent of the Engineer,
by the Contractor for the convenience of transportation,
erection or construction shall not be deducted from the
measured volume of concrete irrespective of the size of
the holes and whether or not the holes are made good.
5 Additional concrete placed, with the consent of the
Engineer, by the Contractor solely for the purpose of
facilitating his work shall not be measured for payment.
5.1.6 Basis of Payment
1 The amount of completed and accepted work,
measured as provided above, will be paid for at the unit
rate for the types and classes of concrete in the Bill of
Quantities, which rate shall be full compensation for:
- Cement and other cementitious materials,
aggregates, water and admixtures including
their testing, storage, handling and
transportation.
- Washing of aggregates, if required.
- Ice, if required, added in the mix water.
- Plant, machinery and equipment required for
the production of concrete.
- Design of mixes, taking samples and testing.
- Transportation and delivery of concrete to work
areas.
- Placing, compacting, vibrating and finishing of
concrete.
- All formwork irrespective of the material used
and the quality of surface finish specified.
- All falsework supporting and stabilizing
formwork.
- Curing of concrete.
- Tooling, if required, to achieve the specified
surface finish.
copy 249
 - Corrective measures and the means of carrying
them out required in the event of the concrete
being not in accordance with the Drawings
and/or specification.
- Handling, transportation and erection
precast concrete members.
- Grout and/or epoxy used in precast
construction including material and equipment
for temporary prestress, if required.
- Material, plant and equipment associated with
particular methods of construction.
- Joint fillers, joint sealants, weep holes, water
stops, dowel bars and other accessories as
shown on the Drawings including material,
plant handling, transportation testing, storage,
workmanship and associated ancillaries.
- Protective coating.
- All labor, materials and equipment.
5.1.7 Items in the Bill of Quantities
i Concrete (class) in (type of structure),
(location) and (finish) cu.m.
5.2 Reinforcing Steel
5.2.1 Description
5.2.1.1 References
1 American Concrete Institute (ACI):
ACI 315 Standard Practice for Detailing
Reinforced Concrete Structures
ACI 318 Building Code Requirements
Reinforced Concrete
2 American Society for Testing and Materials (ASTM):
ASTM A 82 Standard Specification for Steel Wire
Reinforcement, Plain, for Concrete
Reinforcement
ASTM A 185 Standard Specification for Steel Welded
Wire Fabric, Plain, for Concrete
Reinforcement
ASTM A 496 Standard Specification for Steel Wire,
Deformed, for Concrete Reinforcement
ASTM A 497 Standard Specification for Steel Welded
Wire Reinforcement, Deformed, for
Concrete Reinforcement
ASTM A 615M Standard Specification for Deformed
and Plain Billet- Steel Bars for Concrete
Reinforcement
ASTM A 706M Standard Specification for Low-Alloy
Steel Deformed and Plain Bars
ASTM A 780 Practice for Repair of Damaged and
Uncoated Areas of Hot-Dip Galvanized
Coatings.
3 British Standards (BS):
BS 4449 Specification for Carbon Steel Bars for
the Reinforcement of Concrete
BS 4483 Steel Fabric for the Reinforcement of
of Concrete
4 Concrete Reinforcing Steel Institute (CRSI):
CRSI Manual of Standard Practice
5.2.1.2 Submittals
1 Steel Reinforcement Shop Drawings: Details of
fabrication, bending, and placement, prepared according
to ACI 315, ‘Details and Detailing of Concrete
Reinforcement.’ Include material, grade, bar schedules,
stirrup spacing, bent bar diagrams, arrangement, and
supports of concrete reinforcement. Include special
reinforcement required for openings through concrete
structures.
2 Welding Certificates: Copies of certificates for
welding procedures and personnel.
3 Material Certificates: Signed by manufacturers and
Contractor certifying that the following items comply with
specified requirements:
i. Steel reinforcement and reinforcement
accessories: a copy of the manufacturer’s test
certificate for ultimate strength, elongation and
cold bending, together with the chemical
analysis of the steel shall be submitted to the
Engineer for each consignment of reinforcing
steel delivered to the Site.
5.2.1.3 Quality Assurance
1 Welding: Comply with AWS D1.4, ‘Structural Welding
for Code--Reinforcing Steel’ for procedures and qualification
of personnel for welding operations.
5.2.1.4 Delivery, Storage and Handling
1 Deliver, store, and handle steel reinforcement to
prevent bending and damage. Avoid damaging coatings
on steel reinforcement.
5.2.2 Materials
5.2.2.1 Steel Reinforcement
1 Reinforcing Bars: ASTM A 615M, Grade 60 (420 MPa)
specified yield strength, or BS 4449 grade 460 Type 2
deformed, uncoated. One test per 5000 m length
delivered to site.
2 Higher strength reinforcement bars may be used
subject to approval of the Engineer.
3 Low-Alloy-Steel Reinforcing Bars: ASTM A 706M,
deformed.
4 Plain-Steel Wire: ASTM A 82, as drawn.
5 Plain-Steel Wire: ASTM A 82, galvanized.
6 Deformed-Steel Wire: ASTM A 496 and Steel welded
wire reinforcement to ASTM A 497.
♦ 5-13 ♦
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7 Welded Wire Fabric: ASTM A 185, welded steel wire
fabric.
8 All reinforcement shall be new material on delivery
to the Site and at time of installation, material shall be free
from loose rust and loose mill scale, deleterious amounts
of salts and coatings that reduce or destroy bond. Tight
rust and mill scale or surface irregularities are acceptable
if the weight and dimensions, including height of
deformations and tensile properties, of a test specimen
that has been wire-brushed by hand, are not less than
those required by the applicable standards.
9 Galvanized steel shall not be used
10 Reinforcement shall be accurately bent, cut or
formed to the dimensions and configuration shown on
Drawings and within the tolerances specified in ACI 315.
Reinforcement shall be bent cold using approved bending
equipment in accordance with ACI 318. Bars may be
preheated only if prior approval is given by the Engineer.
Reinforcement shall not be rebent or straightened without
prior approval.
i. Reinforcement having a reduced section, kinks,
visible transverse cracks at bends, or otherwise
damaged in any way shall not be used.
ii. Reinforcement shall not be welded unless
specifically shown on Drawings or permitted as
an exception and then only after approval of the
welding method appropriate to the grade of steel
and the type of welding rod to be used.
5.2.2.2 Reinforcement Accessories
1 Provide and fix bar supports: bolsters, chairs, spacers,
and other devices for spacing, supporting, and fastening
reinforcing bars and welded wire fabric in place. Provide
bar supports according to CRSI's ‘Manual of Standard
Practice’ from steel wire, plastic, or precast concrete or
fiber-reinforced concrete of greater compressive strength
than concrete, and as follows:
i. For concrete surfaces exposed to view where
legs of wire bar supports contact forms, use
CRSI Class 1 plastic-protected or CRSI Class 2
stainless-steel bar supports.
ii. Other reinforcement supports shall consist of
concrete spacer blocks made of the same
materials, to the same specified requirements
and with the same inherent properties as the
parent material with the exception that the
maximum aggregate size shall be appropriate for
the thickness of cover to the reinforcement.
2 Joint Dowel Bars: Plain-steel bars, ASTM A 615M,
Grade 60 (420 MPa). Cut bars true to length with ends
square and free of burrs.
3 Mechanical splices (couplers) of deformed high yield
steel bars are to consist of two seamless steel sleeves and
interconnecting high tensile steel stud with plastic
protection caps for threaded section of sleeve and shall
be tested to exceed 135% of the specified yield strength of
grade 60 bar (or higher if higher strength bars are used).
♦ 5-14 ♦
5.2.2.3 Fabricating Reinforcement
1 Fabricate steel reinforcement according to CRSI's
‘Manual of Standard Practice’.
5.2.3 Construction Requirements
5.2.3.1 General
1 Accurately position, support, and secure
reinforcement against displacement. Locate and support
reinforcement with bar supports to maintain minimum
concrete cover. Do not tack weld crossing reinforcing bars.
2 Shop- or field-weld reinforcement according to AWS
D1.4, where indicated.
3 Set wire ties with ends directed into concrete, not
toward exposed concrete surfaces.
4 Install welded wire fabric in longest practicable
lengths on bar supports spaced to minimize sagging. Lap
edges and ends of adjoining sheets at least one mesh
spacing. Offset laps of adjoining sheet widths to prevent
continuous laps in either direction. Lace overlaps with
wire
5 Avoid cutting or puncturing vapor retarder/barrier
and waterproofing membranes during reinforcement
placement and concreting operations. Repair damages
before placing concrete.
5.2.3.2 Shipping, Storage and Cleaning
1 Reinforcement shall be handled and shipped in a
manner to avoid bending or other damage to the bars.
Bars shall be bundled, separated in sizes and clearly
marked by diameter size preferably for one placement, in
accordance with the placement schedule and as follows:
i. Bars for separate structures shall not be bundled
together. Bars for small structures may be
bundled together but each bar or group of bars
that have the same piece mark shall be tagged
and coded.
ii. Metal tags or approved equal shall be provided
and labeled with legible markings.
iii. All bundles shall be tagged at each end. Tags
shall show piece marks corresponding to the
mark numbers on the placement drawings and
on the bar list.
iv. Bars shall be bundled in the largest size practical
for handling and shipping.
2 Reinforcement shall be stored 1m above ground on
platforms, skids or other approved supports and suitably
spaced. Contact with the soil shall be avoided. Proper
drainage and protection from the elements shall be
provided to minimize corrosion.
3 Clean reinforcement of loose rust and mill scale,
earth, ice, and other materials that reduce or destroy bond
with concrete.
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5.2.3.3 Placing 5.2.4 Method of Measurement
1 Comply with CRSI's ‘Manual of Standard Practice’ for 1 Bar and mesh reinforcement is measured by the
placing reinforcement. theoretical quantity in metric tonnes complete in place as
shown on the Drawings or placed as ordered by the
2 Accurately position, support, and secure
Engineer. No allowance is made for clips, wire or other
reinforcement against displacement. Locate and support
fastening devices, reinforcement chairs to separate slab
reinforcement on concrete blocks of a size to give the
steel or similar reinforcement or to retain wall steel or
correct cover to the reinforcement
similar. The rates in the Bill of Quantities shall be deemed
3 Where cathodic protection is utilized, reinforcement to cover for the above.
shall be isolated from the electrical grounding system.
2 Measurement of splices or laps in reinforcement
4 Chairs made of reinforcement shall be used to not shown on the Drawings will not be made.
support the top mats of slab reinforcement and shall be so
3 Calculated weights for high tensile and mild steel
dimensioned as to be stable during concreting operations.
reinforced bars shall be based upon the following Table:
The chairs shall themselves be supported on concrete
blocks as specified in Clause 5.2.2.2.
5 Place reinforcement to maintain minimum coverage

Diameter

Diameter

Diameter
Weight

Weight

Weight
as indicated for concrete protection. Arrange, space, and

Kg/m

kg/m

kg/m
mm

mm

mm
securely tie bars and bar supports to hold reinforcement in
position during concrete placement operations. Ties at
intersections shall be made with 1.5 mm diameter
annealed wire with wire ends directed into concrete, not 5 0.154 18 2.000 34 7.130
toward exposed concrete surfaces. 6 0.222 20 2.470 36 7.990
6 All lap splices shall be in accordance with ACI 318 7 0.302 22 2.980 38 8.900
class B tension lap splice unless otherwise shown on
8 0.395 24 3.550 40 9.870
Drawings. All reinforcement bars shall be cut bent and
fixed in accordance with ACI 318 unless otherwise shown 10 0.617 26 4.170 45 12.500
on Drawings. 12 0.888 28 4.830 50 15.400
7 Welded wire fabric shall be lapped 1.5 mesh 14 1.210 30 5.550
(opening size) plus the extension on the wires unless 16 1.580 32 6.310
otherwise shown on Drawings. Table 5.2.4.1 Reinforcing Bars Weights

5.2.3.4 Concrete Cover 4 No separate measurement is made for bars of

different diameters. The unit rates in the Bill of Quantities
1 Concrete cover to reinforcement shall be as indicated
shall be deemed to cover for all diameters.
on Drawings but shall not be less than the following:
5 Fabric mesh reinforcement is measured separately
i. Concrete exposed to salt water and
by weight based on the theoretical quantity of metric
splash zone 100 mm
tonnes complete in place as shown on the Drawings or
ii. Concrete of all substructure elements cast
placed as ordered by the Engineer. No separate
against earth 100 mm
measurement is made for different mesh sizes or different
iii. Concrete of all substructure elements exposed to
wire diameters. For standard fabric, the weight will be
weather 75 mm
based on the mass in kg/sq.m. listed in Table A.1 of BS
iv. Apron slabs 60 mm
4483.
v. Superstructure cast-in-situ concrete exposed to
weather 60 mm 6 The quantity of steel reinforcing bars and fabric mesh
vi. Interior faces of superstructure cast-in-place reinforcement shall be calculated to the nearest three
concrete except slabs 40 mm decimal places.
vii. Cast-in-situ slabs 30 mm
viii. Precast superstructure elements, exposed 5.2.5 Basis of Payment
surfaces 40 mm
1 The amount of completed and accepted material,
ix. Precast superstructure elements, interior
measured as provided above, will be paid for at the unit
faces 30 mm
rate for reinforcing steel (bar and mesh), in the Bill of
x. Precast parapets, concrete barriers, curbs,
Quantities, which rate shall be full compensation for
etc. 30 mm
supplying, fabricating, transporting, delivering, erecting
2 Cover to reinforcement shall be checked before any and fixing, materials, labor, equipment, tools and other
concrete is cast. The bending of reinforcement at a cold items necessary for the proper completion of the work as
joint is not permitted. Concrete cover shall be checked specified in Sub-Section 5.2.
with a cover meter as soon as formwork is removed.

♦ 5-15 ♦
copy 249
5.2.6 Items in the Bill of Quantities ASTM C 171 Standard Specification for Sheet
Materials for Curing Concrete (AASHTO
i Mild steel bar reinforcement of any
M 171)
diameter t.
ASTM C 219 Standard Terminology Relating to
ii High tensile steel bar reinforcement
Hydraulic Cement
of any diameter t.
ASTM C 309 Standard Specification for Liquid
iii Fabric wire mesh reinforcement of
Membrane-Forming Compounds for
any size t.
Curing Concrete (AASHTO M 148)
ASTM C 881 Standard Specification for Epoxy-Resin-
5.3 Reinforced Concrete Structures Base Bonding Systems for Concrete
ASTM C 920 Standard Specification for Elastomeric
5.3.1 Description
Joint Sealants
5.3.1.1 Definitions ASTM C 1315 Specification for Liquid Membrane –
Forming compounds having Special
1 Forms and Formwork: Temporary works used to give
Properties for Curing and Sealing
the required shape and support to poured concrete,
Concrete
constructed mainly of sheet material, such as wood,
plywood, metal sheet or plastic sheet, in direct contact ASTM C 1059 Specification for Latex Agents for
with the concrete, and joists or stringers to support the Bonding Fresh To Hardened Concrete
sheeting. For bridges it is recommended to use only metal ASTM D 448 Classification for Sizes of Aggregates
sheets. for Road and Bridge Construction
2 Falsework: Temporary structure used to support a ASTM D 1751 Standard Specification for Preformed
permanent concrete structure while it is not self- Expansion Joint Filler for Concrete
supporting. Paving and Structural Construction
3 Scaffold: Temporary structure to provide access, to (AASHTO M213)
work under construction. ASTM D 1752 Specification for Preformed sponge
4 Tower: Composite structure to provide access to high Rubber and Cork Expansion Joint Fillers
work under construction and to carry vertical loading. for Concrete Paving and Structural
Construction (AASHTO M153).
5 Camber: Upward curvature of the formwork,
designed to compensate for subsequent deflection under ASTM D 994 Specification for Preformed Expansion
load. Joint Filler for Concrete (AASHTO M33).
ASTM D 4397 Specification for Polyethylene Sheeting
5.3.1.2 References
for Construction, Industrial, and
1 American Association of State Highway and Agricultural Applications
Transportation Officials (AASHTO): ASTM E 154 Test Methods for Water Vapor
AASHTO M182 Standard Specification for Burlap Cloth Retarders used in Contact with Earth
Made from Jute or Kenaf under Concrete Slabs, on Walls or as
Ground Cover.
2 American Concrete Institute (ACI):
ASTM E 1745 Specification for Plastic Water Vapor
ACI 117 Specifications for Standard Tolerances
Retarders used in Contact with Soil or
for Concrete Construction and Materials
Granular Fill under Concrete Slabs.
ACI 304 Guide for Measuring, Mixing,
4 Corps of Engineers (CE):
Transporting, and Placing Concrete
CE CRD-C300 Curing Compound
ACI 305 Hot Weather Concreting
CE CRD-C513 Rubber Waterstops
ACI 309 Guide for Consolidation of Concrete
CE CRD-C572 PVC Waterstops
ACI 347 Formwork for Concrete
ACI 504R Guide to Joint Sealants for Concrete 5.3.1.3 Submittals
Structures
1 Formwork Shop Drawings: Prepare shop drawings
3 American Society for Testing and Materials (ASTM): for formwork indicating fabrication and erection of forms
ASTM C 33 Specification for Concrete Aggregates for specified finish concrete surface. Show form
ASTM C 109/C109M Test Method for Compressive construction including jointing, especial form joints or
Strength of Hydraulic Cement Mortars reveals, location and pattern of form tie placement.
(Using 2-in. or 50 mm Cube Specimens i. Design of formwork includes design of
ASTM C 150 Standard Specification for Portland falsework, scaffold and towers as defined in
Cement Paragraph 5.3.1.1.

♦ 5-16 ♦
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 ii. Prepare formwork drawings by or under the i. Without prejudice to the Engineer’s rights to
supervision of a qualified professional engineer inspect, approve or reject or suspend any work,
detailing fabrication, assembly, and support of the CQCE shall be authorized to:
formwork. - Postpone concreting operations until
iii. Design and engineering of formwork for outstanding requirements are corrected.
structural stability and efficiency are the
- Reject materials or workmanship that do
Contractor's responsibility.
not conform to this Specification.
iv. Indicate proposed schedule and sequence of
stripping formwork, removing supports and re- - Prevent the use of equipment that could
shoring. cause improper construction relative to
v. If the Contractor intends to use readymade this Specification.
proprietary formwork and falsework, he shall - Stop any work that is not being done in
submit all relevant data, including independent accordance with specified requirements.
test certificates, to enable the Engineer to - Report within 24 hours and provide
determine if the proposals are acceptable. records to and as required by the
Engineer’s review of formwork design is limited Engineer upon discovery of non-
to architectural aspects only and shall not be compliance.
construed as approval of structural or other
3 Implement a Quality Assurance System as specified
matters, all of which are the Contractor’s sole
in Paragraph 5.1.1.4.
responsibility
4 Mockups: Before casting concrete that is exposed to
2 Material Certificates: Signed by manufacturers and
view in the completed structure, cast a mockup for each
Contractor certifying that each of the following items
exposed element to demonstrate typical joints, surface
complies with specified requirements:
finish, texture, color, tolerances, quality of materials and
i. Waterstops. standard of workmanship in the completed work. Where
ii. Curing materials. specified or directed by the Engineer, the mock up shall be
iii. Bonding agents. a trial construction representative of the actual structure
iv. Adhesives. (pier, cross-head, part of deck) in dimensions and all
v. Vapor retarders. details including reinforcement, using the Contractor’s
vi. Epoxy joint filler. proposed construction technique, concrete mix, formwork,
vii. Joint-filler strips. cutting and placing of reinforcement, etc.
viii. Repair materials.
i. Build mockups in the location and of the size
3 Samples: Samples of materials as requested by the indicated or, if not indicated, as directed by the
Engineer, with names, sources, and descriptions, Engineer.
including, but not limited to, the following: ii. Notify the Engineer seven days in advance of
i. Color finishes. dates and times when mockups will be
ii. Reglets. constructed.
iii. Waterstops, reinjectable hosing, water swelling iii. In the presence of the Engineer, damage parts of
gaskets. exposed surfaces as selected by the Engineer,
iv. Vapor retarder/barrier. and demonstrate materials and techniques
v. Form liners. proposed for repairs to match adjacent
vi. Joint fillers. undamaged surfaces.
vii. Sealants. iv. Obtain the Engineer's approval of mockups
before starting cast-in-place concrete elements
5.3.1.4 Quality Assurance exposed to view.
1 Codes and Standards: Comply with the latest edition v. If the Engineer determines that any mockup does
of not meet requirements, demolish and remove
from the site and cast another until the mockup
i. AASHTO LRFD Bridge Construction
is approved.
Specifications.
vi. Maintain mockups during construction in an
ii. ACI Manual of Concrete Practice Parts 1, 2, 3, 4 &
undisturbed condition as a standard for judging
5.
the completed work.
iii. CRSI "Manual of Standard Practice” except
vii. Demolish and remove mockups when directed.
where more stringent requirements are shown
or specified.
5.3.2 Materials
2 Concrete Quality Control Engineer: Appoint a full-
time Concrete Quality Control Engineer (CQCE) as 5.3.2.1 Form Materials
specified in Paragraph 5.1.1.4
1 Forms for Exposed Finish Concrete: Plywood, metal,
metal-framed plywood faced, or other acceptable panel-

♦ 5-17 ♦
copy 249
type materials to provide continuous, straight, smooth,
exposed surfaces. Furnish in largest practicable sizes to
minimize number of joints and to conform to joint system
shown on Drawings.
i. Use overlaid plywood complying with U.S.
Product Standard PS-1 "A-C or B-B High Density
Overlaid Concrete Form," Class I.
ii. Use plywood complying with U.S. Product
Standard PS-1 ‘B-B (Concrete Form) Plywood,’
Class I, Exterior Grade or better, mill-oiled and
edge-sealed, with each piece bearing legible
inspection trademark.
2 Forms for Unexposed Finish Concrete: Plywood,
lumber, metal, or another acceptable material. Provide
lumber dressed on at least two edges and one side for
tight fit.
3 Forms for Textured Finish Concrete: Units of face
design, size, arrangement, and configuration to match the
Engineer's control sample. Provide solid backing and
form supports to ensure stability of textured form liners.
4 Forms for Cylindrical Columns and Supports: Metal,
glass-fiber-reinforced plastic, or paper or fiber tubes that
will produce smooth surfaces without joint indications.
Provide units with sufficient wall thickness to resist wet
concrete loads without deformation.
5 Pan-Type Forms: Glass-fiber-reinforced plastic or
formed steel, stiffened to support weight of placed
concrete without deformation.
6 Carton Forms: Biodegradable paper surface, treated
for moisture-resistance, structurally sufficient to support
weight of plastic concrete and other superimposed loads.
7 Form Release Agent: Proprietary form release agent
with a maximum of 350 g/L volatile organic compounds
(VOCs) that will not bond with, stain, or adversely affect
concrete surfaces and will not impair subsequent
treatments of concrete surfaces.
i. Release agent for steel faced formwork shall
incorporate rust inhibitor.
8 Form Ties: Factory-fabricated, adjustable-length,
removable or snap-off metal form ties designed to prevent
form deflection and to prevent spalling of concrete upon
removal. Provide units that leave no embedded metal
closer than 38 mm to the surface of the exposed concrete.
No permanent metallic part shall have less concrete cover
than the reinforcement. Provide ties that, when removed,
will not leave holes larger than 25 mm in diameter in the
concrete surface. Provide ties with integral water-barrier
plates for walls indicated to receive damp-proofing or
waterproofing.
9 Void Forms: Biodegradable paper surface, treated for
moisture resistance structural sufficient to support weight
of plastic concrete and other superimposed loads.
10 Chamfer Strips: Wood, metal, PVC, or rubber strips of
the size indicated on the Drawings.
♦ 5-18 ♦
5.3.2.2 Waterstops
1 Waterstops: Provide flat, dumbbell-type waterstops
at construction joints and other joints in accordance with
AASHTO LRFD Bridge Construction Specifications Article
8.9.2.6 or as specified herein. Waterstops shall be sized to
suit joints and shall be of the profiles shown on the
Drawings or as directed or appropriate for the particular
application. Fittings for angles junctions etc shall be
factory formed.
i. Flexible Rubber Waterstops: CE CRD-C 513, for
embedding in concrete to prevent passage of
fluids through joints.
ii. Flexible PVC Waterstops: CE CRD-C 572, for
embedding in concrete to prevent passage of
fluids through joints.
2 Self-Expanding Strip Waterstops: Proprietory
rectangular or trapezoidal strip, sodium bentonite or other
hydrophylic material for adhesive bonding to concrete.
3 Re-injectable Hosing: Proprietary re-injectable hosing
complying with the following requirements:
- The hose shall consist of a hollow PVC core
with lateral openings covered by neoprene
valves. The hose shall be laid and injected by
an approved applicator. in 10 to 12 m lengths
with entry port and vent ends terminating in
junction boxes.
- Joints shall be hydraulically tested to a
pressure at least 2.0 bar higher than the
expected local conditions. If the hose fails to
hold the pressure for 10 minutes, it shall be
injected with a vinyl ester based flexible resin
as required to seal the joint and then retested.
5.3.2.3 Concrete Curing Cover Sheets
1 Vapor retarding sheet materials shall be one of the
types specified in paragraphs 2 to 5 below or as directed
by the Engineer.
2 ASTM E 1745, Class C, of one of the following
materials; or polyethylene sheet 0.25mm thick
i. Nonwoven, polyester-reinforced, polyethylene
coated sheet; 0.25 mm thick.
ii. Three-ply, nylon- or polyester-cord-reinforced,
laminated, high-density polyethylene sheet; 0.18
mm thick.
3 Vapor retarder: ASTM E 1745, Class B, five-ply,
nylon- or polyester-cord-reinforced, high-density
polyethylene sheet; 0.25 mm thick.
4 Vapor retarder: ASTM E 1745, Class A, three-ply,
nylon- or polyester-cord-reinforced, high-density
polyethylene sheet; laminated to a nonwoven geotextile
fabric, 0.76 mm thick.
5 Vapor retarder: 2.8 mm thick, semi-flexible, seven-ply
sheet membrane consisting of reinforced core and carrier
sheet with fortified asphalt layers, protective
weathercoating, and removable plastic release liner.
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Furnish manufacturer's accessories including bonding
asphalt, pointing mastics, and self-adhering joint tape.
i. Water-Vapor Permeance: ASTM E 154.
ii. Tensile Strength: 24.5 kN/m; ASTM E 154.
iii. Puncture Resistance: 400 N; ASTM E 154.
6 Absorptive Cover: Burlap cloth made from jute or
kenaf weighing approximately 0.29 kg/sq.m and
complying with AASHTO M182, Class 2.
7 Moisture Retaining Cover: ASTM C 171. polyethylene
sheet, polyethylene coated burlap or Kraft paper.
5.3.2.4 Curing Compounds
1 Curing compounds shall be one of the types
specified in paragraphs 2 to 6 below, or as directed by the
Engineer
2 Evaporation Retarder: Waterborne, monomolecular
film forming, manufactured for application to fresh
concrete
3 Clear, solvent-borne, membrane-forming curing
compound: ASTM C 309, Type 1, Class B.
4 Clear, waterborne, membrane-forming curing
compound: ASTM C 309, Type 1, Class B.
5 Clear, solvent-borne, membrane-forming curing and
sealing compound: ASTM C 1315, Type 1, Class A.
6 Clear, waterborne, membrane-forming curing and
sealing compound: ASTM C 1315, Type 1, Class A.
5.3.2.5 Concrete Accessories
1 Joint-Filler Strips: ASTM D 1751, asphalt-saturated
cellulosic fiber.
2 Joint-Filler Strips: ASTM D 1752, cork or self-
expanding cork.
3 Joint-Filler Strips: ASTM D 1751, asphalt-saturated
cellulosic fiber, or ASTM D 1752, cork or self-expanding
cork.
4 Epoxy Joint Filler: Two-component, semi-rigid, 100
percent solids, epoxy resin with a Shore A hardness of 80
per ASTM D 2240.
5 Bonding Agent: ASTM C 1059, Type II, non-
redispersible, acrylic emulsion or styrene butadiene.
6 Epoxy-Bonding Adhesive: ASTM C 881, two-
component epoxy resin, capable of humid curing and
bonding to damp surfaces, of class and grade to suit
requirements, and as follows:
i. Type II, non-load bearing, for bonding freshly
mixed concrete to hardened concrete.
ii. Types I and II, non-load bearing, for bonding
hardened or freshly mixed concrete to
hardened concrete.
iii. Types IV and V, load bearing, for bonding
hardened or freshly mixed concrete to
hardened concrete.
7 Reglets: Fabricated from not less than 0.55 mm thick
galvanized steel sheet. Temporarily fill or cover face
opening of reglet to prevent intrusion of concrete or debris.
8 Dovetail Anchor Slots: Hot-dip galvanized steel sheet,
not less than 0.85 mm thick, with bent tab anchors.
Temporarily fill or cover face opening of slots to prevent
intrusion of concrete or debris.
5.3.2.6 Repair Materials
1 Repair Underlayment: Cement-based, polymer-
modified, self-leveling product that can be applied in
thicknesses from 3 mm and that can be feathered at edges
to match adjacent floor elevations.
i. Cement Binder: ASTM C 150, Portland cement
or hydraulic or blended hydraulic cement as
defined in ASTM C 219.
ii. Primer: Product of underlayment manufacturer
recommended for substrate, conditions, and
application.
iii. Aggregate: Well-graded, washed gravel, 3 to 6
mm or coarse sand as recommended by
underlayment manufacturer.
iv. Compressive Strength: Not less than 30 MPa at
28 days when tested according to ASTM C
109M.
2 Repair Topping: Traffic-bearing, cement-based,
polymer-modified, self-leveling product that can be
applied in thicknesses from 6 mm.
i. Cement Binder: ASTM C 150, Portland cement
or hydraulic or blended hydraulic cement as
defined in ASTM C 219.
ii. Primer: Product of topping manufacturer
recommended for substrate, conditions, and
application.
iii. Aggregate: Well-graded, washed gravel, 3 to 6
mm or coarse sand as recommended by
topping manufacturer.
iv. Compressive Strength: Not less than 40 MPa at
28 days when tested according to ASTM C
109M.
5.3.3 Construction Requirements
5.3.3.1 Formwork
1 Design, erect, shore, brace, and maintain formwork,
according to ACI 301, to support vertical, lateral, static,
and dynamic loads, and construction loads that might be
applied, until concrete structure can support such loads.
Design of formwork shall be the sole responsibility of the
Contractor.
2 Construct formwork so that concrete members and
structures are of size, shape, alignment, elevation, and
position indicated, within tolerance limits of ACI 117.
3 Limit concrete surface irregularities, designated by
ACI 347R as abrupt or gradual, as follows:
i. Class A, 4 mm.
♦ 5-19 ♦
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 ii. Class B, 6 mm.
iii. Class C, 10 mm.
iv. Class D, 25 mm.
4 Construct forms rigid and tight enough to prevent
loss of concrete mortar.
5 Fabricate forms for easy removal without hammering
or prising against concrete surfaces. Provide crush or
wrecking plates where stripping may damage cast
concrete surfaces. Provide top forms for inclined surfaces
steeper than 1.5 horizontal to 1 vertical. Kerf wood inserts
for forming keyways, reglets, recesses, and the like, for
easy removal.
i. Do not use rust-stained steel form-facing
material.
6 Set edge forms, bulkheads, and intermediate screed
strips for slabs to achieve required elevations and slopes
in finished concrete surfaces. Provide and secure units to
support screed strips; use strike-off templates or
compacting-type screeds.
7 Provide temporary openings for cleanouts and
inspection ports where interior area of formwork is
inaccessible. Close openings with panels tightly fitted to
forms and securely braced to prevent loss of concrete
mortar. Locate temporary openings in forms at
inconspicuous locations.
8 Chamfer exterior corners and edges of concrete
receiving applied waterproofing membranes.
9 Unless otherwise indicated, provide 20x20 mm
chamfer on all exposed corners and edges of concrete.
10 Form openings, chases, offsets, recesses, keyways,
grooves, blocking, screeds, and bulkheads required in the
work.
11 Clean forms and adjacent surfaces to receive
concrete. Remove chips, wood, sawdust, dirt, and other
debris just before placing concrete.
12 Retighten forms and bracing before placing concrete,
to prevent mortar leaks and maintain proper alignment.
13 Coat contact surfaces of forms with specified form
release agent approved by the Engineer, according to the
manufacturer's written instructions, before placing
reinforcement Petrol oil may be used.
14 Where it is required to use internal ties and spacers,
their type, spacing and use shall be to the approval of the
Engineer. In no circumstances shall these ties protrude out
of the finished concrete, all ties must be cut back into the
structural concrete and the surface made good to satisfy
the requirements of the minimum spacing and cover.
5.3.3.2 Falsework
1 Falsework and centering shall be designed to provide
the necessary rigidity to support all vertical and horizontal
loads placed upon it without settlement or deformation in
excess of the permissible tolerance for the structure given
in the Specifications. Falsework columns shall be
supported on hardwood, concrete pads or metal bases if
the underlying ground is liable to sink under the column
♦ 5-20 ♦
load. Falsework shall not be supported on any part of the
structure, except the footings, without the written
permission of the Engineer. The number and spacing of
falsework columns, the adequacy of sills, caps and
stringers and the amount of bracing in the falsework
framing shall be subject to approval of the Engineer.
2 Timber for falsework shall be sound, in good
condition and free from defects that might impair its
strength. If the vertical members are of insufficient length
to cap at the desired elevation for the horizontal members,
they shall preferably be capped and frames constructed to
the proper elevation. Ends of the vertical members shall
be cut square for full bearing to preclude the use of
wedges. If vertical splices are necessary, the abutting
members shall be of the same approximate size, the ends
shall be cut square for full bearing, and the splices shall be
scabbed in a manner approved by the Engineer.
3 The Contractor shall compute falsework settlement
and deflection for bridges so that when the final
settlement is complete, the structure will conform to the
required camber, section and grade as shown on the
Drawings.
4 The Contractor shall provide means for accurately
measuring settlement in falsework during placement of
concrete, and shall provide a competent observer to
observe and correct the settlement.
5 Screw jacks, if used, shall be designed for use with a
slenderness ratio not exceeding 60. The slenderness ratio
shall be taken as the ratio of the clear distance between
effective bracing in both horizontal directions to the
diameter of the screw jack measured at the root of the
thread. The manufacturers' certificate showing the
ultimate load capacity of the screw jack shall be submitted
with the design calculations for the falsework. If directed
by the Engineer, the Contractor shall furnish a test
certificate carried out at an approved independent
laboratory.
6 Props and towers supporting forms or partially
completed structures shall be interconnected in plan
orthogonally at levels to be determined in the design.
They shall also be interconnected by diagonal bracings in
orthogonal vertical planes.
7 If the concrete is required to be post-tensioned in the
field, the falsework shall be designed to support any
increased or readjusted loads caused by the prestressing
forces.
5.3.3.3 Embedded Items
1 Place and secure anchorage devices and other
embedded items required for adjoining work that is
attached to or supported by cast-in-place concrete. Follow
templates, diagrams, instructions, and directions
furnished with items to be embedded.
5.3.3.4 Removing and Reusing Forms
1 General: Formwork, for sides of beams, walls,
columns, and similar parts of the work, that does not
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support weight of concrete may be removed after
cumulatively curing at not less than 10 deg.C for 24 hours
after placing concrete provided concrete is hard enough to
not be damaged by form-removal operations and
provided curing and protection operations are maintained.
2 The Engineer shall be notified when the Contractor
intends to remove any formwork at least 6 hours in
advance
i. Leave formwork, for beam soffits, joists, slabs,
and other structural elements that supports
weight of concrete in place until concrete has
achieved: At least 70 percent of 28-day design
compressive strength but not less than 7 days
after casting.
ii. Determine compressive strength of in-place
concrete by testing representative field- or
laboratory-cured test specimens according to
ACI 301.
iii. Remove forms only if shores have been
arranged to permit removal of forms without
loosening or disturbing shores.
3 Clean and repair surfaces of forms to be reused in
the work. Split, frayed, delaminated, or otherwise
damaged form-facing material will not be acceptable for
exposed surfaces. Apply new form release agent.
When forms are reused, clean surfaces, remove fins and
laitance, and tighten to close joints. Align and secure
joints to avoid offsets. Do not use patched forms for
exposed concrete surfaces unless approved by the
Engineer.
5.3.3.5 Vapor Retarders
1 Vapor Retarder: Place, protect, and repair vapor
retarder sheets according to ASTM E 1643 and
manufacturer's written instructions. Cover with fine
graded granular material or fill as specified in paragraphs
2 or 3 below.
2 Fine-Graded Granular Material: Cover vapor retarder
with fine-graded granular material, moisten, and compact
with mechanical equipment to elevation tolerances of plus
0 mm or minus 20 mm.
3 Granular Fill: Cover vapor retarder with granular fill,
moisten, and compact with mechanical equipment to
elevation tolerances of plus 0 mm or minus 20 mm.
i. Place and compact a 15 mm thick layer of fine-
graded granular material over granular fill.
4 Place vapor retarder/barrier sheeting in position with
longest dimension parallel with direction of pour.
Lap joints 150 mm and seal with manufacturer's
recommended mastic or pressure-sensitive tape. Cover
vapor retarder/barrier with sand cushion and compact to
depth indicated.
5.3.3.6 Construction Joints
1 Follow the requirements of AASHTO LRFD Bridge
Construction Specifications Sub-Section 8.8 as
complemented herein.
2 Construct joints true to line with faces perpendicular
to surface plane of concrete.
3 Construction joints shall be made only where
specified in the contract documents, or shown in the
pouring schedule, unless otherwise approved by the
Engineer.
4 Unless otherwise specified in the contract documents,
horizontal joints may be made without keys, and vertical
joints shall be constructed with shear keys in accordance
with AASHTO LRFD Bridge Construction Specifications
Article 8.8.2.
5 All construction joints shall be cleaned of surface
laitance, curing compound, and other foreign materials
before fresh concrete is placed against the surface of the
joint. Abrasive blast or other approved methods shall be
used to clean horizontal construction joints to the extent
that clean aggregate is exposed. All construction joints
shall be flushed with water and allowed to dry to a surface
dry condition immediately prior to placing concrete.
6 Bonding and doweling to existing structures shall be
as specified in AASHTO LRFD Bridge Construction
Specifications Article 8.8.3.
7 The use of expanded metal or other perforated
material is prohibited in construction joints.
8 Place construction joints perpendicular to main
reinforcement. Continue reinforcement across
construction joints except as indicated otherwise. Do not
continue reinforcement through sides of strip placements.
9 Where needed, unscheduled, construction joints shall
be placed as directed by the Engineer and, if directed,
additional reinforcement steel dowels shall be placed
across the joint. Such additional steel shall be furnished
and placed at the Contractor’s expense.
10 Space vertical joints in walls as indicated, or as
required by the Engineer.
11 Use a bonding agent at locations where fresh
concrete is placed against hardened or partially hardened
concrete surfaces.
12 Use epoxy-bonding adhesive at locations where
fresh concrete is placed against hardened or partially
hardened concrete surfaces.
13 Waterstops/Re-injectable Hoses: Provide waterstops
or re-injectable hoses in construction joints as indicated.
Install waterstops to form a continuous diaphragm in each
joint. Support and protect exposed waterstops during
progress of work. .
5.3.3.7 Contraction and Expansion Joints
1 Follow the requirements of AASHTO LRFD Bridge
Construction Specifications Sub-section 8.9 as
complemented herein.
♦ 5-21 ♦
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2 Expansion and contraction joints shall be constructed
at the locations and in accordance with the details
specified in the contract documents. Such joints include
open joints, filled joints, joints sealed with sealants or
waterstops, and joints with combinations of these features.
3 Contraction Joints in Slabs-on-Grade: Form
weakened-plane contraction joints, sectioning concrete
into areas as indicated. Construct contraction joints for a
depth equal to at least one-fourth of concrete thickness, as
follows:
i. Grooved Joints: Form contraction joints after
initial floating by grooving and finishing each
edge of joint to a radius of 3 mm. Repeat
grooving of contraction joints after applying
surface finishes. Eliminate groover tool marks
on concrete surfaces.
ii Sawed Joints: Form contraction joints with
power saws equipped with shatterproof
abrasive or diamond-rimmed blades. Cut 3
mm wide joints into concrete when cutting
action will not tear, abrade, or otherwise
damage surface and before concrete develops
random contraction cracks.
4 Isolation Joints in slabs-on-grade: After removing
formwork, install joint-filler strips at slab junctions with
vertical surfaces, such as column pedestals, foundation
walls, grade beams, and other locations, as indicated.
i. Extend joint-filler strips full width and depth of
joint, terminating flush with finished concrete
surface, unless otherwise indicated.
ii. Terminate full-width joint-filler strips not less
than 12 mm or more than 25 mm below
finished concrete surface where joint sealants,
are indicated.
iii. Install joint-filler strips in lengths as long as
practicable. Where more than one length is
required, lace or clip sections together.
5 Dowel Joints: Install dowel sleeves and dowels or
dowel bar and support assemblies at joints where
indicated.
i. Use dowel sleeves or lubricate or asphalt-coat
one-half of dowel length to prevent concrete
bonding to one side of joint.
6 Pourable sealants for placement along top edges of
contraction or filled expansion joints shall be one of the
following:
i. Hot-poured sealants shall conform to ASTM D
3406 (AASHTO M 282), except when the
sealant will be in contact with asphaltic
material, it shall conform to AASHTO M 301.
ii. Cold-poured sealant shall be silicone type, as
specified in AASHTO LRFD Bridge Construction
Specifications Article 8.9.2.4. The sealant shall
be a one-part, low-modulus silicone rubber
type with an ultimate elongation of 1200
percent.
♦ 5-22 ♦
iii. Polyethylene foam strip, for use when shown
in the contract documents, shall be of
commercial quality with a continuous,
impervious, glazed top surface, suitable for
retaining the liquid sealant at the proper
elevation in the joint while hardening.
5.3.3.8 Waterstops
1 Install waterstops in accordance with AASHTO LRFD
Bridge Construction Specifications Sub-section 8.9.3.4.
2 Flexible Waterstops: Install in construction joints as
indicated to form a continuous diaphragm. Install in
longest lengths practicable. Support and protect exposed
waterstops during progress of work.
3 Self-Expanding Strip Waterstops: Install in
construction joints and at other locations indicated,
according to manufacturer's written instructions, bonding
or mechanically fastening and firmly pressing into place.
Install in longest lengths practicable.
5.3.3.9 Concrete Placement
1 General: Comply with AASHTO LRFD Bridge
Construction Specifications Sub-sections 8.6 and 8.7 as
complemented herein for protection from environmental
conditions during placing and curing and for handling and
placement of concrete.
2 Concrete shall be handled, placed, and consolidated
by methods that will not cause segregation of the mix and
will result in a dense homogeneous concrete that is free of
voids and rock pockets. The methods used shall not cause
displacement of reinforcing steel or other materials to be
embedded in the concrete. Concrete shall be placed and
consolidated prior to initial set and in no case more than
1.5 hours after the water was added to the mix. Concrete
shall not be re-tempered.
3 Inspection: Before placing concrete, inspect and
complete formwork installation, reinforcing steel, and
items to be embedded or cast in. Notify other trades to
permit installation of their work. Concrete shall not be
placed until the condition of the reinforcement, other
embedded items, and the formwork has been inspected
and approved by the Engineer. All mortar from previous
placements, debris, and foreign material shall be removed
from the forms and steel prior to commencing placement.
The forms and subgrade shall be thoroughly moistened
with water immediately before concrete is placed against
them. Temporary form spreader devices may be left in
place until concrete placement precludes their need, after
which they shall be removed.
4 Transportation: Concrete, after being discharged
from the mixer, shall be transported as rapidly as possible
to its final position in the Work by agitator trucks, which
shall prevent adulteration, segregation, loss of workability
or contamination of the ingredients. The containers that
convey the concrete shall be kept clean and free from
hardened or partially hardened concrete.
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 i. The addition of water at the point of discharge
is prohibited and trucks shall have the water
tank completely disconnected from the drum.
ii. The use of chutes, spouts, skips and pumps
shall be permitted if approval is obtained.
Under no circumstances shall any aluminum
pipe or other conveying equipment containing
aluminum be allowed to contact fresh concrete
when it is conveyed to its point of placement.
iii. Method of pouring and pouring sequence shall
be submitted by the Contractor to the
Engineer’s approval.
5 Concrete exposed to salt or brackish water shall
follow the requirements of AASHTO LRFD Bridge
Construction Specifications Sub-section 8.6.6.
6 Do not add water to concrete during delivery, at
Project site, or during placement, unless approved by the
Engineer.
7 Placement of concrete for each section of the
structure shall be done continuously without interruption
between planned construction or expansion joints. The
delivery rate, placing sequence, and methods shall be
such that fresh concrete is always placed and consolidated
against previously placed concrete before initial set has
occurred in the previously placed concrete.
8 During and after placement of concrete, care shall be
taken not to damage the concrete or break the bond with
reinforcing steel. Workers shall not walk in fresh concrete.
Platforms for workers and equipment shall not be
supported directly on any reinforcing steel. Once the
concrete is set, forces shall not be applied to the forms or
to reinforcing bars which project from the concrete until
the concrete is of sufficient strength to resist damage.
9 Sequence of Placement: Whenever a concrete
placement plan or schedule is specified or approved, the
sequence of placement shall conform to the plan.
10 Placement of Vertical Members: Concrete for
columns, substructure and culvert walls, and other similar
vertical members shall be placed and allowed to set and
settle for a period of time before concrete for integral
horizontal members, such as caps, slabs, or footings, is
placed. Such period shall be adequate to allow completion
of settlement due to loss of bleed water and shall be not
less than 12 h for vertical members over 4500 mm in
height and not less than 30 min for members over 1500
mm but not over 4500 mm in height. When friction collars
or falsework brackets are mounted on such vertical
members and unless otherwise approved, the vertical
member shall have been in place at least seven days and
shall have attained its specified strength before loads from
horizontal members are applied
11 Placement of Superstructure: Unless otherwise
permitted, no concrete shall be placed in the
superstructure until substructure forms have been
stripped sufficiently to determine the character of the
supporting substructure concrete.
i. Concrete for T-beam or deck girder spans
whose depth is less than 1200 mm may be
placed in one continuous operation or may be
placed in two separate operations; first, to the
top of the girder stems, and second, to
completion. For T-beam or deck girder spans
whose depth is 1200 mm or more, and unless
the falsework is non-yielding, such concrete
shall be placed in two operations, and at least
five days shall elapse after placement of stems
before the top deck slab is placed.
ii. Concrete for box girders may be placed in two
or three separate operations consisting of
bottom slab, girder stems, and top slab. In
either case, the bottom slab shall be placed
first and, unless otherwise permitted by the
Engineer, the top slab shall not be placed until
the girder stems have been in place for at least
five days.
12 Placement of Box Culverts: In general, the base slab
or footings of box culverts shall be placed and allowed to
set before the remainder of the culvert is constructed. For
culverts whose wall height is 1500 mm or less, the
sidewalls and top slab may be placed in one continuous
operation. For higher culvert walls, the requirements for
vertical members shall apply.
13 Placement of Precast Elements: The sequence of
placement for concrete in precast elements shall be such
that sound, well-consolidated concrete that is free of
settlement or shrinkage cracks is produced throughout the
member.
14 Placing Methods: Concrete shall be placed as nearly
as possible in its final position, and the use of vibrators for
extensive shifting of the weight (mass) of fresh concrete
will not be permitted.
i. Concrete shall be placed in horizontal layers of
a thickness not exceeding the capacity of the
vibrator to consolidate the concrete and merge
it with the previous lift. In no case shall the
depth of a lift exceed 600 mm. The rate of
concrete placement shall not exceed that
assumed for the design of the forms as
corrected for the actual temperature of the
concrete being placed.
ii. When placing operations would involve
dropping the concrete more than 1500 mm, the
concrete shall be dropped through a tube fitted
with a hopper head or through other approved
devices, as necessary to prevent segregation of
the mix and spattering of mortar on steel and
forms above the elevation of the lift being
placed.
15 Equipment:
i. All equipment used to place concrete shall be
of adequate capacity and designed and
operated so as to prevent segregation of the
mix or loss of mortar. Such equipment shall
♦ 5-23 ♦
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 not cause vibrations that might damage the
freshly placed concrete. No equipment shall
have aluminum parts which come in contact
with the concrete. Between uses, the mortar
coating inside of placing equipment which sets
or dries out shall be cleaned from the
equipment before use is resumed.
ii. Chutes shall be lined with smooth watertight
material and, when steep slopes are involved,
shall be equipped with baffles or reverses.
iii. Concrete pumps shall be operated such that a
continuous stream of concrete without air
pockets is produced. When pumping is
completed, the concrete remaining in the
pipeline, if it is to be used, shall be ejected in
such a manner that there will be no
contamination of the concrete or separation of
the ingredients.
16 Consolidation:
i. All concrete, except concrete placed under
water and concrete otherwise exempt, shall be
consolidated by mechanical vibration
immediately after placement.
ii. Except as noted herein, vibration shall be
internal. External form vibrators may be used
for thin sections when the forms have been
designed for external vibration.
iii. Vibrators shall be of approved type and design
and of a size appropriate for the work. They
shall be capable of transmitting vibration to the
concrete at frequencies of not less than 75 Hz.
iv. The Contractor shall provide a sufficient
number of vibrators to properly compact each
batch of concrete immediately after it is placed
in the forms. The Contractor shall also have at
least one spare vibrator immediately available
in case of breakdown.
v. Vibrators shall be manipulated so as to
thoroughly work the concrete around the
reinforcement and embedded fixtures and into
the corners and angles of the forms. Vibration
shall be applied at the point of deposit and in
the area of freshly deposited concrete. The
vibrators shall be inserted and withdrawn out
of the concrete slowly. The vibration shall be of
sufficient duration and intensity to thoroughly
consolidate the concrete but shall not be
continued so as to cause segregation. Vibration
shall not be continued at any one point to the
extent that localized areas of grout are formed.
Application of vibrators shall be at points
uniformly spaced and not farther apart than 1.5
times the radius over which the vibration is
visibly effective.
vi. Vibration shall not be applied either directly to,
or through the reinforcement, or to sections or
layers of concrete which have hardened to the
♦ 5-24 ♦
degree that the concrete ceases to be plastic
under vibration. Vibrators shall not be used to
transport concrete in the forms.
vii. Vibration shall be supplemented by such
spading as is necessary to ensure smooth
surfaces and dense concrete along form
surfaces and in corners and locations
impossible to reach with the vibrators.
viii. When approved by the Engineer, concrete for
small noncritical elements may be consolidated
by the use of suitable rods and spades.
17 Underwater Concreting:
i. Only concrete used in cofferdams to seal out
water may be placed under water, unless
otherwise specified in the contract documents
or specifically approved by the Engineer.
ii. If other than concrete class 50 or 60 is to be
placed under water, the minimum cement
content of the mix shall be increased by ten
percent to compensate for loss due to wash.
iii. A tremie shall consist of a watertight tube
having a diameter of not less than 250 mm and
fitted with a hopper at the top. The tremies
shall be supported so as to permit free
movement of the discharge end over the entire
top surface of the work and so as to permit
rapid lowering when necessary to retard or
stop the flow of concrete. The discharge end
shall be sealed closed at the start of work so as
to prevent water from entering the tube before
the tube is filled with concrete.
iv. After placement has started, the tremie shall be
kept full of concrete to the bottom of the
hopper. If water enters the tube after
placement is started, the tremie shall be
withdrawn, the discharge end resealed, and the
placement restarted.
v. When a batch is dumped into the hopper, the
flow of concrete shall be induced by slightly
raising the discharge end, always keeping it in
the deposited concrete. The flow shall be
continuous until the work is completed. When
cofferdam struts prevent lateral movement of
tremies, one tremie shall be used in each bay.
vi. Concrete pumps used to place concrete under
water shall include a device at the end of the
discharge tube to seal out water while the tube
is first being filled with concrete. Once the flow
of concrete is started, the end of the discharge
tube shall be kept full of concrete and below
the surface of the deposited concrete until
placement is completed.
5.3.3.10 Hot-Weather Concreting
1 When hot weather conditions exist that would impair
quality and strength of concrete, place concrete complying
with ACI 305 and as specified.
copy 249
2 Cool ingredients before mixing to maintain concrete
temperature at time of placement to below 25 deg.C.
Mixing water may be chilled or chopped ice may be used
to control temperature, provided water equivalent of ice is
calculated to total amount of mixing water.
3 Concrete temperature shall not exceed 32 degree C
and the temperature differential shall not exceed 25
degree C.
4 No concreting operation shall be carried out at
ambient temperature of 40 deg. C or more.
5 For bridge decks that are located over or adjacent to
salt water the maximum temperature of the concrete at
time of placement shall be 27 deg. C.
6 Cover reinforcing steel with water-soaked burlap if it
becomes too hot, so that steel temperature will not exceed
the ambient air temperature immediately before
embedding in concrete.
7 Fog spray forms, reinforcing steel, and subgrade just
before placing concrete. Keep subgrade moisture uniform
without puddles or dry areas.
8 Use water-reducing retarding admixture when
required by high temperatures, low humidity, or other
adverse placing conditions, as acceptable to the Engineer.
9 Shade mixing plant and trucks, aggregates, water
tank, and cement silo.
10 Paint the mixing plant, trucks, water tank, and
cement silo with white or reflective paint
11 Insulate the water tank and supply piping.
12 Protect concrete during pouring, and formwork, from
direct sunlight by use of shades and keep shades in
position for 7 days from time of pouring, .
13 Concrete placing shall be completed as quickly as
possible to reduce transit time.
14 Curing of exposed concrete shall be immediately
carried out.
5.3.3.11 Finishing Plastic Concrete
1 General: Unless otherwise specified in the contract
documents, after concrete has been consolidated and
prior to the application of cure, all surfaces of concrete
that are not placed against forms shall be struck-off to the
planned elevation or slope and the surface finished by
floating with a wooden float sufficiently to seal the surface.
While the concrete is still in a workable state, all
construction and expansion joints shall be carefully tooled
with an edger. Joint filler shall be left exposed.
2 Roadway Surface Finish: All bridge decks, approach
slabs, and other concrete surfaces for use by traffic shall
be finished to a smooth skid-resistant surface in
accordance with AASHTO LRFD Bridge Construction
Specifications Sub-section 8.10.2 for the following
sequence of operations:
i. Striking-off and floating, Article 8.10.2.1. Bridge
decks or top slabs of structures serving as
finished pavements shall be finished using
approved power-driven finishing machines.
Hand-finishing methods may be used if
approved by the Engineer for short bridges 15
m or less in length or for irregular areas where
the use of a machine would be impractical.
ii. Straightedging, Sub-section 8.10.2.2.
iii. Texturing, Sub-section 8.10.2.3
iv. Surface testing and correction, Sub-section
8.10.2.4.
3 Pedestrian Walkway Surface Finish: comply with
AASHTO LRFD Bridge Construction Specifications Sub-
section 8.10.3.
4 Troweled and Brushed Finish: comply with AASHTO
LRFD Bridge Construction Specifications Sub-section
8.10.4.
5 Surface under Bearings: comply with AASHTO LRFD
Bridge Construction Specifications Sub-section 8.10.5.
5.3.3.12 Curing Concrete
1 All newly placed concrete shall be cured so as to
prevent loss of water by use of one or more of the
methods specified in AASHTO LRFD Bridge Construction
Specifications Sub-section 8.11. Unless otherwise
specified in the contract documents, curing shall
commence immediately after the free water has left the
surface and finishing operations are completed. If the
surface of the concrete begins to dry before the selected
curing method can be applied, the surface of the concrete
shall be kept moist by a fog spray applied so as not to
damage the surface.
2 Curing shall continue uninterrupted for seven days
except for when pozzolans in excess of ten percent, by
weight (mass), of the Portland cement are used in the mix.
When such pozzolans are used, the curing period shall be
ten days.
3 For other than top slabs of structures serving as
finished pavements, the above curing periods may be
reduced and curing terminated when test cylinders cured
under the same conditions as the structure indicate that
concrete strengths of at least 70 percent of that specified
have been reached but not in any case less than 3 days.
4 When directed by the Engineer during periods of hot
weather, water shall be applied to concrete surfaces being
cured by the liquid membrane method or by the forms-in-
place method, until the Engineer determines that a cooling
effect is no longer required. Such application of water will
be paid for as extra work.
5 Methods:
i. Forms-in Place Method: Formed surfaces of
concrete may be cured by retaining the forms
in place for the required time without
loosening.
ii. Water Method: Concrete surface shall be kept
continuously wet by ponding, spraying, or
covering with absorptive materials that are
kept continuously and thoroughly wet.
♦ 5-25 ♦
copy 249
 iii. Liquid Membrane Curing Compound Method: as fins and surface discoloration shall, however, be made
The liquid membrane method shall not be good as and when required by the Engineer,
used on surfaces where a rubbed finish is 4 Class F4. No special requirements. To be used in the
required or on surfaces of construction joints earth-face or below ground structures if no waterproofing
unless it is removed by sand blasting prior to membrane will be applied.
placement of concrete against the joint. Type 2,
5 Permanently exposed concrete surfaces to classes F1,
white pigmented, liquid membranes may be
F2 and F3 finish shall be protected from rust marks and
used only on the surfaces of bridge decks, on
stains of all kinds. Internal ties and embedded metal parts
surfaces that will not be exposed to view in the
will not be permitted.
completed work, or on surfaces where their
use has been approved by the Engineer. 5.3.3.14 Tolerances
Details of the application are set in AASHTO
LRFD Bridge Construction Specifications Sub- 1 In-Situ Construction
section 8.11.3.3. i. Length: The horizontal and vertical dimensions
iv. Waterproof Cover Method: This method shall of in-situ concrete members, but not cross-
consist of covering the surface with a sections, shall be within the following
waterproof sheet material so as to prevent tolerances:
moisture loss from the concrete. This method Length (mm) Tolerance (mm)
may be used only when the covering can be Up to 3000 ±3
secured adequately to prevent
3001-4500 ±6
moisture loss. Details of the application are set
in AASHTO LRFD Bridge Construction Vertical lines out of plane ± 5 + (1 for every 3000 out
Specifications Sub-section 8.11.3.4. of true line)
v. Steam or Radiant-Heat Curing Method: This ii. Cross-Section: Slab and wall thicknesses and
method may be used only for precast concrete the cross-sectional dimensions of beams,
members manufactured in established plants. columns, piers etc., shall be within the
Details of the application are set in AASHTO following tolerances:
LRFD Bridge Construction Specifications Sub- Member Dimensions (mm) Tolerance (mm)
section 8.11.3.5. Up to 500 ±6
6 Bridge Decks: The top surfaces of bridge decks shall 501-750 ± 10
be cured by a combination of the liquid membrane curing
Additional for every subsequent
compound method and the water method. The liquid
100 mm ± 1 mm
membrane shall be Type 2, white pigmented, and shall be
applied from finishing bridges progressively and 2 Precast Construction
immediately after finishing operations are complete on i. Length: The horizontal and vertical dimensions
each portion of the deck. The water cure shall be applied of members, but not cross-sections, shall be
not later than 4 h after completion of deck finishing or, for within the following tolerances:
portions of the decks on which finishing is completed.
Length (mm) Tolerance (mm)
5.3.3.13 Formed Finishes Up to 3000 ±2
3000 and over ±5
1 Class F1. This class of surface finish denotes a
special finish required from aesthetic considerations as ii. Cross-Section: Slab and wall thicknesses and
stated in the Special Specification. the cross-sectional dimensions of beams,
columns, piers etc., shall be within the
2 Class F2. Formwork shall be lined with a material
following tolerances:
approved by the Engineer to provide a smooth finish of
uniform appearance. This material shall leave no stain on Member Dimensions (mm) Tolerance (mm)
the concrete and shall be so joined and fixed to its backing Up to 500 ±6
so that it imparts no blemishes. It shall be of the same
501-750 ±9
type and obtained from only one source for any one
structure. The Contractor shall make good any Additional for every subsequent
imperfections in the finish as directed by the Engineer. 250 mm ± 3 mm
Internal ties and embedded metal parts will not be 3 Squareness: For in-situ and precast construction the
permitted unless otherwise approved by the Engineer. tolerance between the short side and the long side shall
3 Class F3. Irregularities in the finish shall be no be within the following limits:
greater than those resulting from the use of wrought thick Member Size (mm) Tolerance (mm)
square edged boards arranged in a uniform pattern. The Up to 3000 ±3
finish is intended to be left as struck. Imperfections such
3000 and over ±6

♦ 5-26 ♦
copy 249
4 Straightness: For in-situ and precast construction the 3 Pretensioning: The process when the prestressing
straightness or bow, defined as deviation from the steel is tensioned against independent anchorages before
intended line, shall be within the following tolerances: the concrete is placed round it. The prestressing strand or
Member Length (mm) Tolerances (mm) tendons are stressed prior to casting the concrete. After
the concrete has attained the required strength, the
Up to 3000 ±3
prestressing force is released from the external
3000 and over ±6 anchorages and transferred, by bond, into the concrete.
5 Alignment: The alignment of members shall be 4 Combined Method: Part of the reinforcement is
within the following tolerances: pretensioned and part post-tensioned.
Columns and piers. : 1:400 of column or pier 5 Cable and Tendon: Cable and tendon both refer to a
length. bundle of prestressing steel of the same type and size
Others. : 1:600 of length bundled together to be contained within a duct and
6 Flatness: The flatness of a surface, measured with a stressed, individually or collectively, from the same
straight edge of 1.5 meter, shall be not greater than 6 mm anchorage.
at any point. 6 Prestressing System: A proprietary system of
7 Twist: Twist, measured as the deviations of any applying prestress and includes anchorages, couplers and
corner from the plane containing the other three corners, jacks but does not necessarily include prestressing steel
shall be within the following limits: and cable ducts.
Member Length (mm) Tolerance (mm)
5.4.1.3 References
Up to 6000 ± 6
1 American Association of State Highway and
Above 6000 ± 12
Transportation Officials (AASHTO):
AASHTO 2008 AASHTO LRFD Bridge Construction
5.3.4 Method of Measurement, Basis of
Specifications, 2nd Edition, 2004, 2008
Payment and Bill of Quantities
Interim Revisions.
1 No separate items are measured or included in the AASHTO 2008 AASHTO LRFD Bridge Design
Bill of Quantities for any part of Sub-section 5.3 and no specifications, 3rd Edition, 2004, 2008
separate payment will be made therefore. The costs are Interim Revisions.
deemed to be covered in the rates and prices in the Bill of
AASHTO 1999 Guide Specifications for Design and
Quantities for Sub-sections 5.1 and 5.2.
Construction of Segmental Concrete
Bridges, 2nd Edition.
5.4 Prestressed Concrete Structures
2 American Society for Testing and Materials (ASTM):

5.4.1 Description ASTM A 416/A 416 M Specification for Steel Strand,

Uncoated Seven-Wire for Prestressed
5.4.1.1 Scope Concrete (AASHTO M 203).

1 This Sub-section specifies the requirements for ASTM A 421/A 421 M Specification for Uncoated
prestressing precast or cast-in-situ concrete by furnishing, Stress-Relieved Steel wire for
placing, and tensioning of prestressing steel. It includes Prestressed Concrete (AASHTO M 204).
prestressing by either the pre-tensioning or post- ASTM A 722/ A 722 M Specification for Uncoated
tensioning methods or by a combination of these methods. High-Strength Steel Bars for
2 This work includes furnishing and installation of any Prestressing Concrete (AASHTO M 275).
appurtenant items necessary for the particular ASTM C 939 Test Method for Flow of Grout for
prestressing system to be used, including but not limited Preplaced-Aggregate Concrete (Flow
to ducts, anchorage assemblies, and grout used for Cone Method).
pressure grouting ducts. ASTM C940 Test Method for Expansion and
Bleeding of Freshly Mixed Grouts for
5.4.1.2 Definitions
Preplaced-Aggregate Concrete in the
1 Prestressing Steel: Steel wire, strand or bars used for Laboratory.
prestressing of concrete. ASTM C1202 Test Method for Electrical Indication of
2 Post-Tensioning: The process when the prestressing concrete’s Ability to Resist Chloride Ion
steel is tensioned after the concrete has hardened. The Penetration (AASHTO T 277)
tendons are installed in voids or ducts within the concrete 3 British Standards:
and are stressed and anchored against the concrete after
BS4447 Specification for the Performance of
the development of the required concrete strength. As a
Prestressing Anchorages for Post-
final operation under this method, the voids or ducts are
Tensioned Construction
pressure-grouted.

♦ 5-27 ♦
copy 249
BS EN 5896 Specification for High Tensile Steel
Wire and Strand for the Prestressing of
Concrete.
5.4.1.4 Submittals
1 Design:
i. Where the design for the prestressing work is
not fully detailed in the contract documents,
the Contractor shall determine the details or
type of prestressing system for use and select
materials and details conforming to this
Specification as needed to satisfy the
prestressing requirements specified. The
system selected shall provide the magnitude
and distribution of pre-stressing force and
ultimate strength required by the contract
documents without exceeding allowable
temporary stresses.
ii. Unless otherwise shown in the contract
documents, all design procedures, coefficients
and allowable stresses, friction, and prestress
losses, as well as tendon spacing and
clearances, shall be in accordance with either
or both the AASHTO LRFD Bridge Design
Specifications.
2 Working Drawings and Shop Drawings
i. Where the contract documents do not include
complete details for a prestressing system and
its method of installation, or where complete
details are provided in the contract documents
and the Contractor wishes to propose any
change, the Contractor shall prepare and
submit to the Engineer working drawings of
the prestressing system proposed for use.
Fabrication or installation of prestressing
material shall not begin until the Engineer has
approved the drawings.
ii. The working drawings of the prestressing
system shall show complete details and
substantiating calculations of the method,
materials, and equipment the Contractor
proposes to use in the prestressing operations,
including any additions or rearrangement of
reinforcing steel and any revision in concrete
dimensions from that specified in the contract
documents. Such details shall outline the
method and sequence of stressing and shall
include complete specifications and details of
the prestressing steel and anchoring devices,
working stresses, anchoring stresses, tendon
elongations, type of ducts, and all other data
pertaining to the prestressing operation,
including the proposed arrangement of the
prestressing steel in the members.
iii. Working drawings shall be submitted
sufficiently in advance of the start of the
affected work to allow time for review by the
♦ 5-28 ♦
Engineer and correction by the Contractor of
the drawings without delaying the work.
iv. Shop drawings for post-tensioning and other
embedments, such as expansion joints,
bearings, and anchor bolts submitted by
suppliers shall be reviewed and approved by
the Engineer for conformance with the design
concept and compliance with the design
drawings and Specifications.
v. Where contract-document information on post-
tensioning systems is modified by the
Contractor, or where contract drawings do not
provide detailed dimensional information on
the post-tensioning system, it is the
Contractor's responsibility to coordinate the
placement of the post-tensioning system with
other embedments, and to correct any
interferences created by the Contractor-
supplied prestressing system or other
substitutions. The post-tensioning layout shall
govern the layout of the secondary
nonprestressed reinforcement. Where
necessary, location of nonpre-stressed
reinforcement should be adjusted to clear
tendons, subject to the approval of the
Engineer.
3 Integrated Drawings: Where required by the contract
documents, in addition to all required working drawings,
the Contractor shall prepare composite placing drawings
to scale and in sufficient detail to show the relative
positions of all items that are to be embedded in the
concrete, and their embedment depth, for the portions of
the structure that are to be prestressed. Such embedded
items shall include the prestressing ducts, vents,
anchorage reinforcement and hardware, reinforcing steel,
anchor bolts, earthquake restrainers, deck joint seal
assemblies, drainage systems, utility conduits, and other
such items. Such drawings shall be in sufficient detail to
confirm that there will be no conflict between the planned
positions of any embedded items and that concrete cover
will be adequate.
4 Material Certificates: Signed by manufacturers and
contractor certifying that each of the following items
complies with specified requirements:
i. Prestressing steel
ii. Prestressing system.
iii. Records for the anchorage device acceptance
test as specified in AASHTO LRFD Bridge
Construction Specifications Article 10.3.2.3.12.
5.4.2 Materials
5.4.2.1 Concrete
1 Concrete for prestressed construction shall be
produced and supplied in accordance with the relevant
requirements of Section 5.1 “Concrete Materials and
Mixes”.
copy 249
5.4.2.2 Reinforcing Steel
1 Non-prestressed reinforcing steel shall be supplied,
cut, bent and fixed in accordance with the relevant
requirements of Section 5.2 “Reinforcing Steel”.
5.4.2.3 Prestressing Steel
1 Steel Wire: Steel wire shall comply with ASTM A
421/A 421 M (AASHTO M 204), or with BS 5896.
2 Stress-Relieved Seven-Wire Strand: Stress-Relieved
Seven-Wire Strand shall comply with ASTM A 416/A416 M
low relaxation (AASHTO M 203) or with BS 5896 low
relaxation.
3 High Tensile Steel Bar: High tensile steel bars for
prestressed concrete shall comply with ASTM A 722/A 722
M (AASHTO M 275) or with BS 4486.
5.4.2.4 Post-Tensioning Anchorages and Couplers
1 Post-tensioning anchorages and couplers shall be in
accordance with the requirements of AASHTO LRFD
Bridge Construction Specifications Article 10.3.2.
2 Prestressing components, such as cable ducts,
anchorages and couplers, shall be of approved types
suitable for types of cables and bars used.
3 All anchorages and couplers shall develop at least 96
percent of the actual ultimate strength of the prestressing
steel, when tested in an unbonded state, without
exceeding anticipated set.
4 The coupling of tendons shall not reduce the
elongation at rupture below the requirements of the
tendon itself. Couplers and/or coupler components shall
be enclosed in housings long enough to permit the
necessary movements. Couplers for tendons shall be used
only at locations specifically indicated in the contract
documents and/or approved by the Engineer. Couplers
shall not be used at points of sharp tendon curvature
5 If the Engineer is not satisfied with the testing
certificates submitted for the prestressing system, he may
request post-tensioning anchorages and couplers to be
tested in accordance with AASHTO LRFD Bridge
Construction Specifications Article 10.3.2 at no extra cost.
5.4.2.5 Epoxy-Bonding Agents for Precast Segmental
Construction
1 Epoxy bonding agents for match cast joints shall be
thermosetting 100 percent solid compositions that do not
contain solvent or any nonreactive organic ingredient
except for pigments required for coloring. Epoxy bonding
agents shall be of two components, a resin and a hardener.
The two components shall be distinctly pigmented, so that
mixing produces a third color similar to the concrete in the
segments to be joined, and shall be packaged in pre-
portioned, labeled, ready-to-use containers.
2 Epoxy bonding agents shall be insensitive to damp
conditions during application and, after curing, shall
exhibit high bonding strength to cured concrete, good
water resistivity, low creep characteristics, and tensile
strength greater than the concrete. In addition, the epoxy
bonding agents shall function as a lubricant during the
joining of the match cast segments, as a filler to accurately
match the surface of the segments being joined, and as a
durable, watertight bond at the joint.
3 The physical, chemical and mechanical properties of
epoxy bonding agents shall satisfy the recommendations
of the AASHTO LRFD Bridge Design Specifications or the
Federation Internationale de la Precontrainte (FIP)
"Proposals for a standard for acceptance tests and
verifications of epoxy bonding agents for segmental
construction".
5.4.3 Construction Requirements
5.4.3.1 Placement of Ducts
1 Ducts shall be rigidly supported at the proper
Iocations in the forms by ties to reinforcing steel which are
adequate to prevent displacement during concrete
placement. Supplementary support bars shall be used
where needed to maintain proper alignment of the duct.
Hold-down ties to the forms shall be used when the
buoyancy of the ducts in the fluid concrete would lift the
reinforcing steel.
2 Polyethylene duct and metal duct for longitudinal or
transverse post-tensioning in the flanges shall be
supported at intervals not to exceed 600 mm. Polyethylene
duct in webs for longitudinal post-tensioning shall be tied
to stirrups at intervals not to exceed 600 mm, and metal
duct for longitudinal post-tensioning in webs shall be tied
to stirrups at intervals not to exceed 1200 mm.
3 Joints between sections of duct shall be coupled with
positive connections which do not result in angle changes
at the joints and will prevent the intrusion of cement paste.
Joints in adjacent ducts shall be staggered by at least 300
mm.
4 After placing of ducts, and reinforcement and
forming is complete, an inspection shall be made to locate
possible duct damage. All unintentional holes or openings
in the duct shall be repaired prior to concrete placing.
5 Grout openings and vents shall be securely anchored
to the duct and to either the forms or to reinforcing steel
to prevent displacement during concrete-placing
operations.
6 After installation in the forms, the ends of ducts shall
at all times be sealed as necessary to prevent the entry of
water or debris.
7 Where members are made up of precast units
stressed together, the ducts in the joints between the units
shall be in perfect alignment and joined securely so as to
allow unimpeded cable threading and pulling and prevent
the ingress of the epoxy mortar used for gluing the several
units together before stressing. Details of such joints shall
first be approved by the Engineer. The tolerance in the
location of the sheath shall be plus or minus 3 mm.
8 Additionally the following shall apply:
♦ 5-29 ♦
copy 249
 i. Entrance and exit angles of tendon paths at
anchorages and/or at faces of concrete shall be
within ± 3 degrees of desired angle measured
in any direction and any deviations in the
alignment are accomplished with smooth
transitions without any kinks.
ii. Angle changes at duct joints shall not be
greater than ±3 degrees in any direction and
must be accomplished with smooth transitions
without any kinks.
iii. Locate anchorages within ± 3 mm of desired
position laterally and ±25 mm along the tendon
except that minimum cover requirements shall
be maintained.
iv. Position anchorage confinement reinforcement
in the form of spirals, multiple U-shaped bars
or links to be properly centered around the
duct and to start within 12 mm of the back of
the main anchor plate.
v. If conflicts exist between the reinforcement and
post-tensioning duct, position the post-
tensioning duct and adjust the reinforcement
locally with the Engineer's approval.
9 Ducts shall be kept free of any matter detrimental to
the bond between the sheath and the grout and, except for
material sealing a sheath joint, between the sheath and
the concrete.
10 All ducts for continuous structures shall be supplied
with outlets at the high and low points of the duct profile,
except where the profile changes are small, as in
continuous slabs, and at additional locations as specified
in the contract documents. Low-point outlets shall remain
open until grouting is started.
11 Upon completion of concrete placement, the
Contractor shall prove that the post-tensioning ducts are
free and clear of any obstructions or damage and are able
to accept the intended post-tensioning tendons by passing
a torpedo through the ducts. The torpedo shall have the
same cross-sectional shape as the duct, and 6 mm smaller
all around than the clear nominal inside dimensions of the
duct. No deductions shall be made to the torpedo section
dimensions for tolerances allowed in the manufacture or
fixing of the ducts. For straight ducts, a torpedo at least
600 mm long shall be used. For curved ducts, the length
shall be determined so that when both ends touch the
outermost wall of the duct, the torpedo is 6 mm clear of
the innermost wall. If the torpedo will not travel
completely through the duct, the Engineer shall reject the
member, unless a workable repair can be made to clear
the duct, to the satisfaction of the Engineer. Upon
completion of the repairs, the torpedo shall pass through
the duct easily, by hand, without resorting to excessive
effort or mechanical assistance.
12 Before stressing and grouting internal or external
tendons, install all grout caps, inlets and outlets and test
the tendon with compressed air to determine if duct
connections require repair. In the presence of the Engineer,
♦ 5-30 ♦
pressurize the tendon to 345 kPa and lock-off the outside
air source. Record pressure loss for 1 minute. A pressure
loss of 170 kPa is acceptable for tendons having a length
of equal to or less than 45 m and a pressure loss of 100
kPa is acceptable for tendons longer than 45 m. If the
pressure loss exceeds the allowable, repair the leaking
connections using methods approved by the Engineer and
re-test.
13 The ends of all ducts shall be sealed and protected until
the tendon is threaded through and the stressing
operations are commenced. Where tendons in sheaths or
sheath on its own are left exposed to atmosphere, rust
inhibitors shall be used as per the maker's specification to
prevent rusting and corrosion of the inside of sheaths.
They shall be flushed with clean water before the tendons
are grouted. The Contractor is responsible for carrying
out these measures at his own expense
5.4.3.2 Placement of Prestressing Steel
1 General:
i. All wires or strands stressed at the same time
shall be taken from the same parcel. Each
cable shall be tagged with its number and the
coil number of the steel used.
ii. Tendons shall not be welded within the length
to be tensioned and, unless other methods of
cutting are approved by the Engineer, tendons
shall be sawn or cropped using an abrasive
disc cutter.
iii. Tendons shall be built into the work strictly in
accordance with the system which is being
employed.
iv. Tendons shall not be kinked or twisted and
individual wires or strands shall be readily
identifiable at each of the members. No strand
which has become unravelled shall be used in
the work.
2 Placement for Pretensioning:
i. Prestressing steel shall be accurately installed
in the forms and held in place by the stressing
jack or temporary anchors and, when tendons
are to be draped, by hold-down devices. The
hold-down devices used at all points of change
in slope of tendon trajectory shall be of an
approved low-friction type.
ii. Prestressing steel shall not be removed from
its protective packaging until immediately prior
to installation in the forms and placement of
concrete. Openings in the packaging shall be
resealed as necessary to protect the unused
steel. While exposed, the steel shall be
protected as needed to prevent corrosion.
3 Placement for Post-Tensioning:
i. All prestressing steel preassembled in ducts
and installed prior to the placement of concrete
shall be accurately placed and held in position
during concrete placement.
copy 249
 ii. When the prestressing steel is installed after
the concrete has been placed, the Contractor
shall demonstrate to the satisfaction of the
Engineer that the ducts are free of water and
debris immediately prior to installation of the
steel. The total number of strands in an
individual tendon may be pulled into the duct
as a unit, or the individual strand may be
pulled or pushed through the duct.
iii. Anchorage devices or block-out templates for
anchorages shall be set and held so that their
axis coincides with the axis of the tendon and
anchor plates are normal in all directions to the
tendon.
iv. The prestressing steel shall be distributed so
that the force in each girder stem is equal or as
required by the contract documents, except as
provided herein.
v. For box girders with more than two girder
stems, at the Contractor's option, the
prestressing force may vary up to five percent
from the theoretical required force per girder
stem provided the required total force in the
superstructure is obtained and the force is
distributed symmetrically about the centerline
of the typical section.
4 Protection of Steel after Installation:
i. Prestressing steel used in post tensioned
concrete members that is not grouted within
the time limit specified below, shall be
continuously protected against rust or other
corrosion by means of a corrosion inhibitor
placed in the ducts or directly applied to the
steel. The prestressing steel shall be so
protected until grouted or encased in concrete.
Prestressing steel installed and tensioned in
members after placing and curing of the
concrete and grouted within the time limit
specified below will not require the use of a
corrosion inhibitor described herein and rust
which may form during the interval between
tendon installation and grouting will not be
cause for rejection of the steel.
ii. The permissible interval between tendon
installation and grouting without use of a
corrosion inhibitor for various exposure
conditions shall be taken as follows:
- Very Damp Atmosphere or over saltwater
(Humidity > 70 percent) 7 days
- Moderate Atmosphere (Humidity from 40
percent to 70 percent) 15 days
- Very Dry Atmosphere (Humidity < 40
percent) 20 days
iii. After tendons are placed in ducts, the openings
at the ends of the ducts shall be sealed to
prevent entry of moisture.
iv. When steam curing is used, unless anchorage
systems mandate its installation, steel for post-
tensioning shall not be installed until the steam
curing is completed.
v. Such tendons shall be protected against
corrosion by means of a corrosion inhibitor
placed in the ducts or on the steel, or shall be
stressed and grouted within seven days after
steam curing.
vi. Whenever electric welding is performed on or
near members containing prestressing steel,
the welding ground shall be attached directly
to the steel being welded. All prestressing steel
and hardware shall be protected from weld
spatter or other damage.
5.4.3.3 Placement of Anchorages
1 The Contractor is responsible for the proper
placement of all materials according to the design
documents of the Engineer and the requirements
stipulated by the anchorage device supplier. The
Contractor shall exercise all due care and attention in the
placement of anchorage hardware, reinforcement,
concrete and consolidation of concrete in anchorage zones.
2 Modifications to the local zone details verified under
provisions of AASHTO LRFD Bridge Design Specifications
Article 5.10.9.7.3 and AASHTO LRFD Bridge Construction
Specifications Article 10.3.2.3, ‘Special Anchorage Device
Acceptance Test’, shall be approved by both the Engineer
and the anchorage device supplier.
5.4.3.4 Identification and Testing
1 All wire, strand, or bars to be shipped to the site shall
be assigned a lot number and tagged for identification
purposes. Anchorage assemblies to be shipped shall be
likewise identified.
2 Before approval, at least two samples of the
prestressing steel shall be tested at the Contractor's
expense, at an approved independent laboratory for
chemical composition, mechanical strength, relaxation
and physical characteristics.
3 Subsequently, each lot of wire or bars and each reel
of strand reinforcement shall be accompanied by a
manufacturer's certificate of compliance, a mill certificate,
and a test report. The mill certificate and test report shall
include:
i. Chemical composition (not required for strand),
ii. Cross-sectional area,
iii. Yield and ultimate strengths,
iv. Elongation at rupture,
v. Modulus of elasticity, and
vi. Stress strain curve for the actual prestressing
steel intended for use.
All values certified shall be based on test values and
nominal sectional areas of the material being certified
♦ 5-31 ♦
copy 249
4 The Contractor shall furnish to the Engineer for
verification testing samples selected at random from each
lot as follows. The actual strength of the prestressing steel
shall not be less than specified by the applicable ASTM
Standard stated in Paragraph 5.4.2.3.
i. Pretensioning Tendons: one sample at least
1500 mm long shall be furnished in accordance
with the requirements of Sub-Section 9.1 of
ASTM A 416/A 416M.
ii. Post-Tensioning Tendons: for 20 tonnes, or
portion thereof, lot of material used in the
work:
- For wires not requiring heading: sufficient
length to make up one parallel-lay cable 1500
mm long consisting of the same number of
wires as the cable to be furnished.
- For strand to be furnished with fittings: 1500
mm between near ends of fittings.
- For bars to be furnished with threaded ends
and nuts: 1500 mm between threads at ends.
5 Anchorages:
i. Before approval, at least two anchorages shall
be tested at the Contractor's expense, at an
approved laboratory to BS 4447. Subsequently,
the Engineer may require additional samples,
selected at random from materials on site, to
be similarly tested.
ii. For each anchorage type used in the Works, the
characteristic value of anchorage efficiency,
determined in accordance with BS 4447, shall
be not less than 90%.
6 For prestressing systems previously tested and
approved on projects having the same tendon
configuration, the Engineer may waive the anchorage
testing.
7 Epoxy Bonding Agents: Epoxy bonding agents shall
be tested for and satisfy the requirements of all the tests
listed in the recommendations of FIP "Proposal for a
standard for acceptance tests and verification of epoxy
bonding agents for segmental construction".
5.4.3.5 Protection of Prestressing Steel
1 All prestressing steel shall be protected against
physical damage and rust or other results of corrosion at
all times from manufacture to grouting. Prestressing steel
shall also be free of deleterious material such as grease,
oil, wax or paint. Prestressing steel that has sustained
physical damage at any time shall be rejected. The
development of pitting or other results of corrosion, other
than rust stain, shall be cause for rejection.
2 Prestressing steel shall be packaged in containers or
shipping forms for the protection of the strand against
physical damage and corrosion during shipping and
storage. A corrosion inhibitor which prevents rust or other
results of corrosion shall be placed in the package or form,
or shall be incorporated in a corrosion inhibitor carrier-
♦ 5-32 ♦
type packaging material, or when permitted by the
Engineer, may be applied directly to the steel. Packaging
or forms damaged from any cause shall be immediately
replaced or restored to original condition.
3 The shipping package or form shall be clearly marked
with a statement that the package contains high-strength
prestressing steel, and the type of corrosion inhibitor used,
including the date packaged.
4 All anchorages, end fittings, couplers, and exposed
tendons, which will not be encased in concrete or grout in
the completed work, shall be permanently protected
against corrosion.
5 Corrosion Inhibitor:
i. The corrosion inhibitor shall have no
deleterious effect on the steel or concrete or
bond strength of steel to concrete or grout.
ii. Corrosion inhibitor shall consist of a vapor
phase inhibitor (VPI) powder conforming to the
provisions of Federal Specification MIL-P-
3420F-87 or as otherwise approved by the
Engineer.
iii. When approved, water soluble oil may be used
on tendons as a corrosion inhibitor.
5.4.3.6 Ducts
1 Ducts formed by sheath left in place shall be a type
that will not permit the intrusion of cement paste. They
shall transfer bond stresses as required and shall retain
shape under the weight (mass) of the concrete and shall
have sufficient strength to maintain their correct
alignment without visible wobble during placement of
concrete.
2 Metal Ducts:
i. Sheathing for ducts shall be metal, except as
provided herein. Such ducts shall be
galvanized ferrous metal and shall be
fabricated with either welded or interlocked
seams. Galvanizing of welded seams will not
be required.
ii. Rigid ducts shall have smooth inner walls and
shall be capable of being curved to the proper
configuration without crimping or flattening.
iii. Semi-rigid ducts shall be corrugated and, when
tendons are to be inserted after the concrete
has been placed, their minimum wall thickness
shall be as follows: 0.45 mm for ducts less than
or equal to 65 mm diameter 0.60 mm for ducts
greater than 65 mm diameter.
iv. When bar tendons are preassembled with such
ducts, the duct thickness shall not be less than
0.25 mm.
3 Plastic Ducts:
i. For locations in saltwater environment, plastic
duct material shall be considered and is
recommended.
copy 249
 ii. Corrugated plastic duct to be completely metal polyolefin (polyethylene or
embedded in concrete shall be constructed polypropylene), and shall be air and watertight
from either polyethylene or polypropylene. The and of sufficient strength to prevent distortion
minimum acceptable radius of curvature shall or displacement of the ducts during concrete
be established by the duct supplier according placement and/or tendon grouting.
to standard test methods. The duct shall have a ii. All ducts or anchorage assemblies shall be
thickness as below: provided with pipes or other suitable
Duct Shape Duct Diameter Duct Thickness connections at each end of the duct for the
in millimeters in millimeters injection of grout after prestressing. As
specified in Article 5.4.3.1(10), ducts shall also
Flat any size 2.0
be provided with ports for venting or grouting
Round 23 2.0 at high points and for draining at intermediate
Round 60 2.0 low points.
Round 75 2.5 iii. Vent and drain pipes shall be at least 20 mm
Round 85 2.5 diameter for strand and at least 12 mm
diameter for single-bar tendons and three or
Round 100 3.0
four strand flat duct tendons. Connection to
Round 115 3.5 ducts shall be made with metallic or plastic
Round 130 4.0 structural fasteners. The vents and drains shall
Round 145 4.0 be mortar tight, taped as necessary, and
constructed with either mechanical or shrink
iii. Ducts shall have a white coating on the outside
wrap connections. Vents and drains shall
or shall be of white material with ultraviolet
provide means for injection of grout through
stabilizers added.
the vents and for sealing to prevent leakage of
iv. Polyethylene duct shall be fabricated from grout.
resins meeting or exceeding the requirements
of ASTM D 3350 with a cell classification of 5.4.3.7 Grout
345464A.
1 Grout shall be in accordance with the requirements
v. Polypropylene duct shall be fabricated from of AASHTO LRFD Bridge Construction Specifications Sub-
resins meeting or exceeding the requirements section 10.9.
of ASTM D 4101 with a cell classification range
2 Grouts may be either a unique design for the project
of PP0340B14541 to PP0340B67884.
or supplied in a pre-bagged form by a grout manufacturer.
vi. Use resin containing antioxidant(s) with a
3 Unless otherwise directed or agreed as a result of
minimum Oxidation Induction Time (OIT)
grouting trials, uniquely designed grouts shall consist only
according to ASTM D 3895 of not less than 20
of ordinary Portland cement and water. The water-cement
minutes. The OIT test shall be performed on
ratio shall be as low as possible consistent with necessary
samples taken from the finished product.
workability and under no circumstances be higher than
vii. Rigid smooth black polyethylene ducts for use 0.45 and not be subject to bleeding in excess of 2 percent
where the tendon is not embedded in concrete after 3 hours, or 4 percent maximum. When measured at
shall be rigid pipe manufactured from 100 18 degrees C in a covered glass cylinder approximately
percent virgin polyethylene resin meeting the 100 mm water shall be reabsorbed after 24 hours.
requirements of ASTM D 3350 with a minimum
4 Grout shall be mixed for a minimum of two minutes
cell class of 344464C. A resin containing
and until a uniform consistency is obtained. The
antioxidant(s) with a minimum oxidation
pumpability of the grout may be determined in
induction time (OIT) according to ASTM D 3895
accordance with the US Corps of Engineers Method CRD-
of not less than 40 min shall be used. The OIT
C79 in which case the efflux time of the grout sample
test shall be performed on samples taken from
immediately after mixing shall not be less than 11 seconds.
the finished product. The duct shall be
manufactured with a dimensional ratio (DR) of 5 Admixture containing chlorides or nitrates shall not
17.0 as established by either ASTM D 3350 or be used. Other admixtures may be used only with the
ASTM F 714 as appropriate for the written permission of the Engineer and shall be applied
manufacturing process used. strictly in accordance with the manufacturer's instruction.

4 Duct Area: The provisions of AASHTO LRFD Bridge
Design Specifications, Article 5.4.6.2, ‘Size of Ducts,’ shall
apply.
5 Duct Fittings:
i. Coupling and transition fittings for ducts
formed by sheathing shall be of either ferrous
6 The design for grout mix shall be tested in
accordance with ASTM C 49 for longitudinal change. Each
design mix and each batch mix shall be tested for vertical
dimensional change.
7 Daily field testing of the grout for the following
properties shall be required:

♦ 5-33 ♦
copy 249
 i. Fluidity to ASTM C 939 or the modified test
described in AASHTO LRFD Bridge
construction Specification Table 10.9.3-2,
ii. Bleed at 3 h to ASTM C 940 as modified in
AASHTO LRFD Bridge construction
Specification Table 10.9.3-2,
iii. Permeability to ASTM C1202 (AASHTO T 277).
8 Manufacturers of pre-bagged post-tensioning grout
shall submit for approval certified test reports from an
audited and independent Cement Concrete Research
Laboratory (CCRL) which shows the material meets all the
requirements specified herein.
9 Preapproved pre-bagged grout shall be mixed in
accordance with the Manufacturer's recommendations.
10 Grouts shall achieve a non-bleeding characteristic.
Grout shall not contain aluminum powder or gas
generating system that produces hydrogen, carbon
dioxide, or oxygen. Cementitious grout shall meet or
exceed the specified physical properties stated herein as
determined by the following standard and modified ASTM
test methods.
11 Grout Classes shall be taken as specified in AASHTO
LRFD Bridge Construction Specifications Table 10.9.3-1
and Grout Properties shall be as specified in AASHTO
LRFD Bridge Construction Specifications Table 10.9.3-2.
5.4.3.8 Tensioning
1 Tensioning may be accomplished by pre-tensioning,
post-tensioning, or the combined method; as specified in
the contract documents, or on the approved working
drawings, or approved in writing by the Engineer.
2 During stressing of strand, individual wire failures
may be accepted by the Engineer, provided not more than
one wire in any strand is broken and the area of broken
wires does not exceed two percent of the total area of the
prestressing steel in the member.
3 Concrete Strength: Prestressing forces shall not be
applied or transferred to the concrete until the concrete
has attained the strength specified for initial stressing. In
addition, cast-in-place concrete for other than segmentally
constructed bridges shall not be post-tensioned until at
least ten days after the last concrete has been placed in
the member to be post-tensioned.
4 Prestressing Equipment:
i. Hydraulic jacks used to stress tendons shall be
capable of providing and sustaining the
necessary forces and shall be equipped with
either a pressure gage or a load cell for
determining the jacking stress.
ii. All jacks used for prestressing shall be of the
5 Sequence of Stressing: When the sequence of
type applicable to the system adopted. The
stressing individual tendons is not otherwise specified in
accuracy of the load metering equipment shall
the contract documents or on the approved working
be checked to the satisfaction of the Engineer
drawings, the stressing of post-tensioning tendons and
at the start of the work each day it has to be
the release of pretensioned tendons shall be done in a
used and whenever the equipment is moved to
sequence that produces a minimum of eccentric force in
a different job.
the member.
♦ 5-34 ♦
iii. Documentary proof shall be provided
confirming that all jacks have been fully
overhauled and checked by an agent approved
by the manufacturer of the equipment. Each
jack shall be accompanied by a test certificate
indicating that it has been tested and calibrated
by the manufacturer or by an approved testing
laboratory up to a load equal to the full
capacity of the jack within a period of six
months prior to the commencement of
prestressing.
iv. The jacking system shall provide an
independent means by which the tendon
elongation can be measured. The pressure
gage shall have an accurate reading dial at
least 150 mm in diameter or a digital display,
and each jack and its gage shall be calibrated
as a unit with the cylinder extension in the
approximate position that it will be at final
jacking force, and shall be accompanied by a
certified calibration chart or curve.
v. All gages, load cells, dynamometers and other
devices used for measuring the stressing force
shall have an accuracy of within plus or minus
1.5 percent. Pressure gages shall have a
capacity and calibrated cell such that the
working pressure required to stress the
tendons to the fully stated load lies within the
central half of the range of the gage.
vi. Each gage shall have a calibration certificate
issued by an approved test laboratory. All
pressure gages shall be so constructed that
they may be calibrated, either directly by an
approved testing laboratory, or by
compressing with a meter gage which has
itself been calibrated by an approved testing
laboratory.
vii. All pressure gages shall be re-calibrated before
use and at intervals of 14 days during the
prestressing operation. The Engineer will
order re-calibration of any pressure gage at any
time should he have reason to suspect damage
to or faulty operation of the gage.
viii. The accuracy of all prestressing and load
measuring equipment shall be checked
whenever required by the Engineer. The
Contractor shall provide a rig suitable in the
opinion of the Engineer, for all checking and
calibration of any jacking system consisting of
jacks and associated load devices, pressure
gages and dynamometers.
copy 249
6 Measurement of Stress:
i. A record of gage pressures and tendon
elongations for each tendon shall be provided
by the Contractor for review and approval by
the Engineer. Elongations shall be measured to
an accuracy of 1.5 mm. Stressing tails of post-
tensioned tendons shall not be cut off until the
stressing records have been approved.
ii. The stress in tendons during tensioning shall
be determined by the gage or load-cell
readings and shall be verified with the
measured elongations. Calculations of
anticipated elongations shall utilize the
modulus of elasticity, based on nominal area,
as furnished by the Manufacturer for the lot of
steel being tensioned, or as determined by a
bench test of strands used in the work.
iii. All tendons shall be tensioned to a preliminary
force as necessary to eliminate any take-up in
the tensioning system before elongation
readings are started. This preliminary force
shall be between 5 and 25 percent of the final
jacking force. The initial force shall be
measured by a dynamometer or by other
approved method, so that its amount can be
used as a check against elongation as
computed and as measured. Each strand shall
be marked prior to final stressing to permit
measurement of elongation and to ensure that
all anchor wedges set properly.
5.4.3.9 Pretension Construction
1 The strand stress prior to seating (jacking stress)
shall not exceed 80 percent of the minimum ultimate
tensile strength of the prestressing steel. This allowable
stress, which slightly exceeds the values allowed in
AASHTO LRFD Bridge Design Specifications, Article 5.9.3,
may be permitted to offset seating losses and to
accommodate compensation for temperature differences
specified below.
2 In pretensioned members where tendons are
specified as debonded from the concrete, they shall be
covered with sleeves of PVC or other material approved by
the Engineer. The ends of the sleeves shall be taped to
the tendon to prevent the ingress of grout.
3 Stressing shall be accomplished by either single-
strand stressing or multiple-strand stressing. The amount
of stress to be given to each strand shall be as shown in
the contract documents or on the approved working
drawings.
4 All strands to be stressed in a group (multiple-strand
stressing) shall be brought to a uniform initial tension
prior to being given their full pre-tensioning. The amount
of the initial tensioning force shall be within the range
specified in Article 5.4.3.8 (6) Measurement of Stress, and
shall be the minimum required to eliminate all slack and to
equalize the stresses in the tendons as determined by the
Engineer. The amount of this force will be influenced by
the length of the casting bed and the size and number of
tendons in the group to be tensioned.
5 Draped Pretensioned Tendons:
i. Draped pretensioned tendons shall either be
tensioned partially by jacking at the end of the
bed and partially by uplifting or depressing
tendons, or they shall be tensioned entirely by
jacking, with the tendons being held in their
draped positions by means of rollers, pins, or
other approved methods during the jacking
operation.
ii. Approved low-friction devices shall be used at
all points of change in slope of tendon
trajectory when tensioning draped
pretensioned strands, regardless of the
tensioning method used.
iii. If the load for a draped strand, as determined
by elongation measurements, is more than five
percent less than that indicated by the jack
gages, the strand shall be tensioned from both
ends of the bed, and the load as computed
from the sum of elongation at both ends shall
agree within five percent of that indicated by
the jack gages.
6 When ordered by the Engineer, prestressing steel
strands in pretensioned members, if tensioned
individually, shall be checked by the Contractor for loss of
prestress not more than 3 hours prior to placing concrete
for the members. The method and equipment for checking
the loss of prestress shall be subject to approval by the
Engineer. All strands that show a loss of prestress in
excess of three percent shall be retensioned to the original
computed jacking stress.
7 Stress on all strands shall be maintained between
anchorages until the concrete has reached the
compressive strength required at time of transfer of stress
to concrete.
8 When prestressing steel in pretensioned members is
tensioned at a temperature more than 14 deg. C lower
than the estimated temperature of the concrete and the
prestressing steel at the time of initial set of the concrete,
the calculated elongation of the prestressing steel shall be
increased to compensate for the loss in stress due to the
change in temperature, but in no case shall the jacking
stress exceed 80 percent of the specified minimum
ultimate tensile strength of the prestressing steel.
9 Members shall be free to accommodate the
horizontal and vertical movements due to the application
of prestress. Side and flange forms that restrain deflection
shall be removed before release of pre-tensioning
reinforcement.
10 When the concrete has attained the specified
strength, the load shall be transferred gradually without
severance of the tendons
11 Except when otherwise shown in the contract
documents, all pretensioned prestressing strands shall be
cut off flush with the end of the member, and the exposed
♦ 5-35 ♦
copy 249
ends of the strand and a 25 mm strip of adjoining concrete iv.
shall be cleaned and painted. Cleaning shall be by wire
brushing or abrasive blast cleaning to remove all dirt and
residue that is not firmly bonded to the metal or concrete v.
surfaces. The surfaces shall be coated with one thick coat
of zinc-rich paint conforming to the requirements of U.S.
Military Specification MIL-P-24441/20. The paint shall be
thoroughly mixed at the time of application, and shall be
vi.
worked into any voids in the strands.
12 All members shall be indelibly marked to show the
specified member mark, the production line on which they
were manufactured, the date on which the concrete was
cast, the load applied and, if they are of symmetrical
vii.
section, the face which will be uppermost when the
member is in its correct position in the work. The
markings shall be so located that they are not exposed to viii.
view when the member is in its permanent position.
5.4.3.10 Post-Tension Construction
1 The standard stress prior to seating (jacking stress)
and the stress in the prestressing steel immediately after ix.
seating shall not exceed the values allowed in AASHTO
LRFD Bridge Design Specifications, Sub-section 5.9.3.
2 Immediately before tensioning, the Contractor shall
demonstrate to the satisfaction of the Engineer that all
tendons are free to move between jacking points and that
members are free to accommodate the horizontal and x.
vertical movements due to the application of prestress.
3 Unless otherwise specified, concrete shall not be
stressed until it has reached the age at which at least 2 test xi.
specimens taken from it attain the specified transfer
strength. The test specimens shall be cured in similar
conditions to the concrete to which they relate. The
Contractor shall cast sufficient specimens to demonstrate
that the required strength of the concrete at transfer has
been reached. 6 Records: A record of the following post-tensioning
4 Where members consist of jointed elements the operations shall be kept for each tendon installed:
strength at transfer of the jointing material shall be at least i.
equivalent to the specified transfer strength of the ii.
member.
iii.
5 Tension Procedures:
iv.
i. The Contractor shall establish the datum point
v.
for measuring extension and jack pressure to
the satisfaction of the Engineer.
vi.
ii. The Contractor shall add to the specified forces
an allowance where necessary for anchorage vii.
friction, wedge pull-in, jack losses and friction viii.
due to duct alignment and curvature. The total ix.
forces and calculated extensions shall be
x.
agreed with the Engineer before stressing is
commenced. xi.
iii. Immediately after anchoring, the stresses in the xii.
tendons shall not exceed 75 percent of their xiii.
ultimate tensile strength or as defined in the xiv.
contract documents. During stressing the
value shall not exceed 80 percent.
xv.
♦ 5-36 ♦
The tendons shall be stressed at a gradual and
steady rate until they attain the force and
extension specified.
If the measured extension differs by more than
5 percent from the estimated extension,
corrective action shall be taken as directed by
the Engineer.
The force in the tendons shall be obtained from
reading on a load cell or pressure gage, and
the extension of the tendons measured. Due
allowance must be made for taking up slack in
the tendons.
Stressing shall be from both ends unless
otherwise specified or agreed by the Engineer.
Where stressing from one end only, the pull-in
at the end remote from the jack shall be
accurately measured and the appropriate
allowance made in the measured extension at
the jacking end.
When the specified force, including any
overload of short duration, has been applied, to
the satisfaction of the Engineer, the tendons
shall be anchored. The jack pressures shall
then be released in such a way as to avoid
shock to the anchorage of tendons.
If the pull-in of the tendons at completion of
anchoring is greater than that stipulated by the
Engineer, tensioning shall be carried out afresh.
If it is necessary to cut the tendons to enable
the ducts to be grouted, this shall be delayed
as long as practicable up to the time of
grouting. In all other cases, unless agreed
otherwise by the Engineer, the tendons shall
not be cropped less than 3 days after grouting.
Project name, number,
Contractor and/or subcontractor,
Tendon location, size and type,
Date tendon was first installed in ducts,
Coil/reel number for strands or wires and heat
number for bars and wire,
Assumed and actual cross-sectional area,
Assumed and actual modulus of elasticity,
Date stressed,
Jack and gage numbers per end of tendon,
Required jacking force,
Gage pressures,
Elongations (anticipated and actual),
Anchor sets (anticipated and actual),
Stressing sequence (i.e., tendons before and
after this tendon),
Stressing mode (one end/two
ends/simultaneous),
copy 249
 xvi. Witnesses to stressing operation (Contractor
and Inspector),
xvii. Date grouted, days from stressing to grouting,
grouting pressure applied, and injection end,
xviii. Record any other relevant information
including pour back and bitumastic installation
dates.
The Engineer shall be provided with a complete copy of
stressing operations, and the jack calibration forms within
24 hours of each tensioning operation.
7 Protection of Tendons: Within 4 hours after stressing
5 Preparation of Ducts:
and prior to grouting, tendons shall be protected against
corrosion or harmful effects of debris by temporarily
plugging or sealing all openings and vents; cleaning rust
and other debris from all metal surfaces which will be
covered by the grout cap; and placing the grout cap,
including a seal, over the wedge plate until the tendon is
grouted.
5.4.3.11 Grouting
1 Grout should be injected from low points pumping
toward the high-point vent. For segmental, span-by-span
construction, grout shall be injected through a grout inlet
at midspan.
2 Ducts shall be grouted as soon as practicable after
the tendons have been stressed and the Engineer's
permission to commence has been obtained. The ducts
shall be completely filled with grout. Grout shall be
injected in one continuous operation and allowed to flow
from the vents until the consistency is equivalent to that
6 Equipment:
being injected or more than 11 seconds.
3 Grout shall not be above 32 deg. C during mixing or
pumping. If necessary, cool the mixing water.
4 A grouting operation plan shall be submitted for
approval at least 45 days in advance of any scheduled
grouting operations. Written approval of the grouting
operation plan by the Engineer shall be required before
any grouting of the permanent tendons in the structure
takes place. At a minimum, the following items shall be
provided in the grouting operation plan:
i. Provide names, and proof of training and
experience records for the grouting crew and
7 Mixing of Grout:
the crew supervisor in conformance with this
Specification;
ii. Type, quantity, and brand of materials used in
grouting including all required certifications;
iii. Type of equipment furnished, including
capacity in relation to demand and working
condition, as well as back-up equipment and
spare parts;
iv. General grouting procedure;
v. Duct pressure test and repair procedures;
vi. Method to be used to control the rate of flow
within ducts;
vii. Theoretical grout volume calculations;
viii. Mixing and pumping procedures;
ix. Direction of grouting;
x. Sequence of use of the inlets and outlet pipes;
xi. Procedures for handling blockages; and
xii. Procedures for possible post grouting repair.
Before grouting operations begin, a joint meeting of
the Contractor, grouting crew and the Engineer shall
be conducted. At the meeting, the grouting operation
plan, required testing, corrective procedures, and any
other relevant issues shall be discussed.
i. Each duct shall be air pressure tested prior to
the installation of the prestressing steel into the
ducts. If leaks are indicated during the test, the
duct shall be repaired to eliminate the leakage
or minimize the consequences of the leakage.
ii. All ducts shall be clean and free of deleterious
materials that would impair bonding or
interfere with grouting procedures.
iii. Ducts with concrete walls (cored ducts) shall be
flushed to ensure that the concrete is
thoroughly wetted. Metal ducts shall be flushed
if necessary to remove deleterious material.
iv. Water used for flushing ducts may contain
slack lime (calcium hydroxide) or quicklime
(calcium oxide) in the amount of 0.012 kg/l.
v. After flushing, all water shall be blown out of
the duct with oil-free compressed air.
i. The grouting equipment shall include a high-
speed shear mixer capable of continuous
mechanical mixing which will produce a grout
free of lumps and undispersed cement, a grout
pump, and stand-by flushing equipment with
water supply. The equipment shall be able to
pump the mixed grout in a manner which will
comply with all requirements.
ii. The equipment shall be as per ASTM LRFD
Bridge Construction Specification Article
10.11.3.
i. Water shall be added to the mixer first,
followed by cement grout.
ii. Grout shall be mixed in accordance with the
manufacturer's instructions using a colloidal
mixer to obtain homogeneous mixture. A
fluidity test shall be performed on the mixed
grout prior to beginning the injection process.
Target flow rates as a function of mixer type
used and ambient temperatures shall be
obtained from the grout manufacturer. The
♦ 5-37 ♦
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 grouting process shall not be started until the
proper grout properties have been obtained. Property Test Value Test Method
iii. Mixing shall be of such duration as to obtain a Max. 0.08% by
uniform, thoroughly blended grout, without Total Chloride weight of ASTM
Ions cementitious C1152/C1152M
excessive temperature increase or loss of
material
expansive properties of the admixture. The Fine Aggregate Max. Size ≤ No. ASTM C 33
grout shall be continuously agitated until it is (if utilized) 50 Sieve
pumped. Volume
0.0% to+0.2% at ASTM C 1090*
iv. Water shall not be added to increase grout Change at 28
24 h and 28 days
days
flowability which has been decreased by
≤2.0% for up to 3
delayed use of the grout. Expansion ASTM C 940
h
8 Injection of Grout: Compressive
i. All grout vents shall be opened before grouting Strength ASTM C 942
≥6 ksi
28 day (average
starts. Injection and ejection vents with
of 3 cubes)
positive shut-offs shall be provided. Grout shall
Initial Set of Min. 3 h ASTM C 953
be allowed to flow from the first injection vent
Grout Max. 12 h
until any residual flushing water or entrapped
Fluidity Test**
air has been removed prior to closing that vent.
Efflux Time
Remaining vents shall be closed in sequence in from Flow Min 11 s
the same manner. A continuous flow of grout ASTM C 939
Cone Max. 30 s or
at a rate between 10 000 mm and 15 000 mm ASTM C
a) Immediately Min. 9 s
939***
of duct per minute shall be maintained. after Mixing Max. 20 s
ASTM C 939
b) 30 min after Max. 30 s or
ii. The pumping pressure at the injection vent ASTM C
Mixing with Max. 30 s
should not exceed 1.0 MPa. Normal operations 939***
Remixing
shall be performed at approximately 0.5 MPa. for 30 s
If the actual grouting pressure exceeds the ASTM C
Bleeding at 3 h Max. 0.0%
maximum allowed, the injection vent shall be 940****
closed and the grout shall be injected at the Permeability at Max. 2500 AASHTO T 277
next vent that has been, or is ready to be 28 days coulombs at 30 (ASTM C 1202)
closed, as long as a one-way flow is volts for 6 h
maintained. Grout shall not be injected into a Table 5.4.3.1 Grout Properties for
succeeding vent from which grout has not yet Volume Change at 28 Days
flowed. Table 5.4.3-1 Notes
*Modify ASTM C 1090 to include verification at both
Iii Grout shall be pumped through the duct and
24 h and 28 days.
continuously wasted at the ejection vent until
no visible slugs of water or air are ejected. A **Adjustments to flow rates will be achieved by strict
fluidity test shall be performed on each tendon compliance with the manufacturer’s
recommendations.
in accordance with paragraph 5.4.3.7 (7)
measuring the grout fluidity from the discharge ***Grout fluidity shall meet either the standard ASTM
outlet. The measured grout efflux time shall C 939 flow cone test or the modified test described
not be faster than the efflux time measured at herein. Modify the ASTM C 939 test by filling the cone
the inlet or the minimum efflux time to the top instead of to the standard level. The efflux
time is the time to fill a 1.0 liter container placed
established in Table 5.4.3.1. If the grout efflux
directly under the flow cone.
time is not acceptable, additional grout shall be
discharged from the discharge outlet. Grout ****Modify ASTM C 940 to conform with the wick
efflux time shall be tested. This cycle shall be induced bleed test described below:
continued until acceptable grout fluidity is a) Condition dry ingredients, mixing water,
achieved. To ensure that the tendon remains prestressing strand and test apparatus overnight
filled with grout, the ejection and injection at 21 to 25 deg. C.
vents shall be closed in sequence, respectively, b) Insert 800 milliliters of mixed conditioned grout
with conditioned water into the 1000 milliliters
under pressure when the tendon duct is
graduated cylinder. Mark the level of the top of
completely filled with grout. The positive shut- the grout.
offs at the injection and ejection vents shall not c) Wrap the strand with 50 mm wide duct or
be removed or vents opened until the grout electrical tape at each end prior to cutting to
has set. avoid splaying of the wires when it is cut.
iv. The maximum allowable ambient temperature
to start grouting is 32 degrees C.

♦ 5-38 ♦
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 Degrease (with acetone or hexane solvent) and
wire brush to remove any surface rust on the
strand before temperature conditioning. Insert
completely a 500 mm length of conditioned,
cleaned, ASTM A 416/A 416M seven wire strand
12.7 mm diameter into the 1000 milliliter
graduated cylinder. Center and fasten the strand
so it remains essentially parallel to the vertical
axis of the cylinder (possibly using a centralizer).
Mark the level of the top of the grout.
d) Store the mixed grout at the temperature range
listed above in (a).
e) Measure the level of the bleed water every 15 min
for the first hour and hourly afterward for 2 h.
f) Calculate the bleed water, if any, at the end of the
3 h test period and the resulting expansion per
the procedures outlined in ASTM C 940, with the
quantity of bleed water expressed as a percent of
the initial grout volume. Note if the bleed water
remains above or below the top of the grout.
9 Vertical Grouting: In lieu of a positive shut-off,
vertical or near vertical tendon ducts for grouting shall
terminate in reservoirs at the upper-most point. The
reservoir shall have sufficient capacity to store excess
grout bleed water. Visible grout level shall be maintained
in the reservoirs. The reservoirs shall be maintained until
the grout has set. Grout shall be injected at a rate of 5000
mm of duct per minute.
10 Post-Grouting Inspection: Vacuum grouting shall be
used to fill any voids that expose strands discovered in the
grouting process. Where possible, all anchorages and
high-point vents shall be drilled and probed 48 hours after
grouting, until the Engineer is assured that no bleed water
or subsidence (settlement) voids exist. After the Engineer
is assured that voids do not exist, only one or two
anchorages per span shall be drilled and probed to ensure
quality grouting. Any voids discovered should be filled
immediately with the approved grout.
11 Finishing:
i. Valves, caps and vent pipes shall not be
removed or opened until the grout has set.
ii. The ends of vents shall be removed at least 25
mm below the concrete surface after the grout
has set.
iii. The void shall be filled with epoxy grout. All
miscellaneous material used for sealing grout
caps shall be removed before carrying out
further work to protect end anchorages.
12 Protection of End Anchorages: Permanent grout caps
constructed from either stainless steel or polymer shall be
specified. The following requirements apply:
i. Within seven days upon completion of the
grouting, the anchorage of post-tensioning
bars and tendons shall be protected as
indicated in the contract documents. The
application of the elastomeric coating may be
delayed up to 90 days after grouting. Plastic or
stainless steel threaded caps shall be used to
plug all grout inlets/outlets. A sand-filled epoxy
grout suitable for machinery base plate shall
be used to construct all pour-backs located at
anchorages of expansion joints or other areas
exposed to the elements.
ii. All laitance, grease, curing compounds, surface
treatments, coatings, and oils shall be removed
by grit blasting or water blasting using a
minimum 70.0 MPa nozzle pressure. The
surface shall be flushed with water and blown
dry. Surfaces shall be clean, sound, and
without any standing water. In case of dispute,
ACl 503 shall be followed for substrate testing
and a minimum of 1.2 MPa tension (pull-off
value) be developed.
iii. Epoxy shall be mixed and applied as
manufacturer's current standard technical
guidelines. All pour-backs shall be in leak proof
forms creating neat lines. The pumping of
epoxy grout shall be permitted for proper
installation. Forms shall be constructed to
maintain a liquid head to insure intimate
contact with the concrete surface. Vents shall
be used as needed to provide for the escape of
air to insure complete filling of the forms.
iv. The exposed surfaces of pour-backs or grout
caps, except on transverse tendons, shall be
coated with an elastomeric coating system
having a thickness of 760 to 1140 μm. Concrete,
grout caps or other substrates shall be
structurally sound, clean, and dry. Concrete
shall be a minimum of 28 days old. Laitance,
grease, curing compounds, surface treatments,
coatings, and oils shall be removed by grit
blasting or water blasting using a minimum
70.0 MPa nozzle pressure to establish the
anchor pattern. Surfaces shall be blown with
compressed air to remove the dust or water.
v. A 600 x 1200-mm concrete test block shall be
constructed with a similar surface texture to
the surfaces to be coated and a vertical face
shall be coated with the elastomeric coating
system chosen. The number of coats required
to achieve a coating thickness between 760 to
1140 μm without runs and drips shall be
determined. The elastomeric coating shall be
mixed and applied as per Manufacturer's
current standard technical specifications. Spray
or roller application may be permitted; spray
application is preferred. Coatings shall be
applied using approved and experienced
personnel with a minimum of 3 years
experience applying similar polyurethane
systems. Credentials of these persons shall be
submitted to the Engineer for review and
consideration for approval.
5.4.4 Method of Measurement
1 Concrete shall be measured under the provisions of
Section 5.1.
♦ 5-39 ♦
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2 Non-prestressed reinforcing steel shall be measured iv. Plant, equipment and labor for all stressing and
under the provisions of Section 5.2 . grouting operations, including making good all
3 Prestressing steel shall be measured by the weight in anchorage pockets as shown on the Drawings
metric tonnes for each size and quality of wire, strands or or as directed by the Engineer.
bar furnished, installed, completed and accepted. The v. All testing required in the Specifications.
weight shall be calculated based on the nominal mass of
each diameter wire, strand or bar as stated in the 5.4.6 Items in the Bill of Quantities
standards listed in Paragraph 5.4.21.3.
i Prestressing wires
4 In post-tensioning work, the prestressing steel shall
(state size and type) t.
be measured in t based on the actual length between the
ii Prestressing strands
outermost surfaces of the anchorages except where
(state size and type) t.
couplers are used in which case, the prestressing steel
shall be assumed to be continuous, without any flares, iii Prestressing bars
through the coupler. (state size and type) t.
5 In pre-tension work, the prestressing steel shall be
measured in t based on the actual length between the 5.5 Concrete Bridges and Erection
outermost faces of the member. Procedures
6 Items not measured: Measurement of prestressed
concrete is restricted to the items stated in items 1, 2 and 3 5.5.1 Description
above. No separate measurement is made for any other
5.5.1.1 Scope
component or work.
i. Cable ducts, duct couplers, grout tubes and 1 This Sub-section describes requirements for erection
steel chairs for the correct duct/tendon location of concrete bridge structures and decks in conformity with
are not measured for payment. the lines, grades and dimensions shown on the Drawings
ii. Anchor blocks for use in pre-tension work are and in accordance with the Specifications. These
not measured for payment. requirements are additional to the requirements for
concrete work generally as specified in the preceding Sub-
iii. Prestressing steel used in connection with
sections of this Section
temporary works is not measured for payment
even if such steel is left permanently in the 5.5.1.2 References
member.
1 American Association of State Highway and
iv. Epoxy bonding agent used in precast
Transportation Officials (AASHTO):
segmental construction shall not be measured
for payment. AASHTO 2008 AASHTO LRFD Bridge Construction
Specifications, 2nd Edition, 2004, 2008
v. Shear keys and location dowels used in precast
Interim Revisions.
segmental construction shall not be measured
for payment. AASHTO 2008 AASHTO LRFD Bridge Design
specifications, 3rd Edition, 2004, 2008
vi. Prestressing steel and anchorages used for
Interim Revisions.
applying temporary prestress to glued
segments shall not be measured for payment. AASHTO 1999 Guide Specifications for Design and
Construction of Segmental Concrete
vii. Anchorages and couplers shall not be
Bridges, 2nd Edition.
measured for payment.
2 Fédération Internationale de la Précontrainte (FIP)
5.4.5 Basis of Payment FIP Proposal for a Standard for Acceptance
Tests and Verification of Epoxy Agents
1 The amount of completed and accepted work for Segmental Construction.
measured as provided for above shall be paid at the rates
in the Bill of Quantities. These rates shall be full
5.5.2 Materials
compensation for the provision of materials, equipment,
labor, tools, testing and other items necessary for proper 1 Materials shall conform to the relevant requirements
completion of the Work. The rates shall include: of the following Sub-sections of the Specification:
i. Items not measured as described in Item 5.4.4 - Concrete Sub-section 5.1 Concrete
(6). Materials and
ii. Cement, water and additive used in making the Mixes
grout. - Reinforcing Steel Sub-section 5.2 Reinforcing
iii. All prestressing equipment and its calibration. Steel

♦ 5-40 ♦
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- Pre-stressing Sub-section 5.4 Pre-stressed
Concrete
Structures
5.5.3 Construction Requirements
5.5.3.1 Balanced Cantilever Construction with In-Situ
Concrete
1 General:
i. This work consists of installing temporary
bearings, casting concrete units in-situ and
setting the superstructure on permanent
bearings. The Contractor shall submit
complete details and descriptions of all
methods, arrangements and equipment which
he intends to adopt, for approval before
construction work is started.
ii. The construction method statement shall
include casting of units, method of the tie-
down of superstructure during cantilever
construction, method of application of all
temporary forces to be used for adjusting
horizontal and vertical alignment and to place
the structure on permanent bearings, details of
work plans and safety measures. It shall also
include control methods to ensure the accuracy
of alignments of the constructed superstructure.
iii. Work equipment includes all machinery,
devices, labor and material which are to be
used for construction but which will not
become a permanent part of the completed
superstructure. Construction equipment and
other loads shall not be placed upon any part
of the superstructure at any stage of
construction other than that which specifically
meets the requirements of total working load
3 Casting Procedures:
per unit, or has the approval of the Engineer.
This includes the post-tensioning, jointing,
jacking, grouting equipment, any other
equipment whatsoever, workmen and
materials of any kind.
iv. Unbalanced Load: During construction the
cantilever may be unbalanced by only one unit
at any time and be consistent with the holding-
down method adopted. In addition to the
unbalanced load due to one unit, 0.5 kN/m2
load is permissible anywhere on the cantilever.
This load includes workmen, miscellaneous
equipment and stored materials. The
Contractor shall take care to ensure that this
allowable load is not exceeded.
2 Construction Schedule:
i. The Contractor shall submit a construction
schedule showing the order of every phase and
stage of erection and construction of the
superstructure. The Contractor shall prepare a
table of elevations and alignments required at
each stage of construction at the check points
listed below, or an alternative of his choice and
submit the same for the Engineer's approval.
The check points are:
- One of the lowest corners at the top surface
of any temporary bearing pad which is to
be used as datum during construction.
- All four corners of the top slabs of the pier
units to establish grade and top levels.
- Two points on the longitudinal center line
of each pier unit, one on each end to
establish alignment.
- One point on the longitudinal center line,
and at least on one corner of each unit
along every joint between cast-in-place
units to establish elevations and
alignments at every stage of construction.
ii. The alignment and elevations of the cantilever
shall be checked by the Contractor and the
Engineer independently within 1 hour of
sunrise on each day that the units are to be
cast. The measurements made by the Engineer
and the Contractor shall agree to within 5 mm.
iii. The temporary bearing pads at the piers shall
be carefully placed. The top surface of these
pads must have the correct elevations,
alignments and slopes as required by the
working drawings and as established by the
procedure described above. Shims may be
used underneath the pads to accomplish
accuracy. The Contractor shall check
elevations and alignment of the structure at
every stage of construction and shall maintain
a record of all these checks and of all
adjustments and corrections made.
i. Casting of the units shall not begin until
approval of the shop drawings, calculations
and the post-tensioning system has been given.
ii. Sequence. The units shall be match cast
beginning with each pier unit. After the pier
unit is cast all units on either side of the pier
unit may be cast in order so long as match
casting is maintained.
iii. Care shall be taken in the set-up of each unit.
All materials to be encased within the concrete
of the segment shall be properly positioned
and supported. Before any concrete is placed,
the set up will be inspected and checked by the
Engineer. All ducts shall be located within
3mm of the location given on approved
drawings. The top surface of the units shall be
free of depressions or high spots.
iv. Forms shall not be removed until the concrete
has achieved the specified compressive
strength has been proved by test cylinders
made and cured in the same manner as the
♦ 5-41 ♦
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 unit. Care shall be taken in removing the forms
to prevent spalling and chipping of the
concrete.
4 Tolerances:
i. Formwork for box girder segments must satisfy
the following tolerances:
- Web thickness, +10 mm or -5 mm.
- Thickness of bottom slab +5 mm, but 0
reduction in depth.
- Thickness of top slab +5 mm, but 0
reduction in depth.
- Overall width of unit, ±5 mm.
- Overall depth of unit, ±5 mm.
- Length of match cast unit, ±10 mm, but not
cumulative and a maximum of 50 mm per
span.
- Diaphragm dimensions, +10 mm or -5 mm.
- Grade at top and bottom flanges, ±3.
ii. After erection, final post-tensioning, final
corrections and adjustments are completed
and the structure has been placed on its
permanent bearings, the superstructure shall
conform to the grade and alignment shown on
the Drawings with due consideration for creep
and superimposed load and dead load
deflections within a tolerance of ± 5 mm
horizontally and ± 10 mm vertically.
5.5.3.2 Glued Precast Segmental Construction
1 Where bridge decks are precast in segments and
assembled in position for glueing and stressing, the
Contractor shall satisfy the Engineer that his proposed
construction method will achieve the required standard of
workmanship and finish. The Contractor shall submit
details for approval of all his forms, falsework, precasting
factory and his method of lifting, transporting, assembling,
supporting, threading cables, glueing and stressing the
precast units before commencement of any work.
2 Epoxy Adhesive:
i. The epoxy resin adhesive shall be supplied by
an approved manufacturer.
ii. It shall be made up and packaged by approved
formulators and to specifications agreed by the
Engineer.
iii. The material shall be supplied in accurately
measured packs with the pack containing the
hardener clearly distinguished by both size and
labelling. The pack containing the resin shall
be large enough to permit the addition of the
hardener. Resin and hardener shall be
pigmented with dissimilar colours to indicate
when even mixing has been completely
attained and to produce an even gray colour to
match the concrete.
♦ 5-42 ♦
iv. Each batch of resin mixed shall be tested for
setting by compression and shear tests as
described below. No permanent prestress
shall be applied to a joint until the epoxy has
achieved the required strength. Should this
test show that the resin is not setting the joint
shall be broken and the resin removed. Set
resin shall be removed by grit blasting. Further
tests may be requested by the Engineer at
various times to ensure that the material as
mixed is complying with the Specification.
v. All the instructions of the manufacturer and/or
the formulator shall be submitted to the
Engineer for agreement. Such agreed
instructions shall be adhered to in all respects.
vi. The supplier shall carry out a program of
testing as described in FIP "Proposal for a
standard for acceptance tests and verification
of epoxy bonding agents for segmental
construction", after consultation with the
Engineer on the range of temperatures and
work cycles that are to be considered in the
tests. The Engineer may require the tests to be
witnessed either in person or by an approved
independent authority.
3 Surface Preparation: The interface of the units shall
be lightly grit blasted before erection to remove laitance.
Before applying the epoxy the interfaces must be clean
and free from laitance or any bond breaking material. Any
oil or grease which may be harmful shall be removed.
The surface shall have no free moisture.
4 Application of Epoxy: Application shall begin
immediately after a batch has been mixed. Application
shall be to both interfaces to a total nominal thickness of 2
mm with a spatula or by hand. No epoxy may be applied
within 25mm of any duct.
5 Preliminary Prestress: Immediately after the
interfaces are coated with epoxy, the unit shall be brought
into position and the preliminary prestress applied. This
preliminary prestress is to be just sufficient to start
squeezing epoxy resin out of the joint. The amount of
prestress required will depend on the formulation of resin
chosen by the Contractor. If this operation is not
completed within the life time of the first batch of epoxy to
be applied, the units shall be moved apart. All the epoxy
on both interfaces shall be removed with spatulas and an
approved solvent. No epoxy may be applied to the joint
until 24 hours after a solvent has been used. The life time
shall be reckoned from the end of the pot life unless the
manufacturer's instructions direct otherwise. All excess
epoxy shall be cleaned off from the outer faces of the
webs and the soffit in such a way as not to smear the
concrete face.
6 Records of Joining: The Contractor shall keep a
record of each joint with the following details:
i. Joint Number
ii. Date and Time of jointing
copy 249
 iii. Batch number of resin and hardener
iv. Weather conditions (temperature and
humidity) continuously recorded
v. Results of tests.
7 Tolerances: These shall be similar to those
prescribed for balanced cantilever construction.
5.5.3.3 Precast Beam and slab Construction
1 Manufacture of Prestressed Beams:
i. The details of method of manufacture shall be
approved by the Engineer before work is
started. No changes shall subsequently be
made without the consent of the Engineer.
ii. The Contractor shall inform the Engineer in
advance of the date of commencement of
manufacture and the dates when tensioning of
tendons, casting of members and transfer of
stress will be undertaken for the first time for
each type of beam.
iii. The Contractor shall submit to the Engineer,
not more than 7 days after the transfer of
stress, a certificate showing the force and
strain in the tendons immediately after they
were anchored, the strength and age of the test
cylinders cast in accordance with this
Specification, and the minimum age in hours
of the concrete at the time stress was applied
to the members. Copies of all 28 day cylinder
test results relating to the work shall be kept so
that the identity of those who stressed the
tendons, cast the concrete and transferred the
stress, on any member or line of members, can
be traced.
iv. Where the Engineer requires tests to be carried
out on beams, the beams to which these tests
related, shall not be dispatched to Site until the
tests have been satisfactorily completed.
2 Storage and Handling of Prestressed Members:
Members shall be firmly supported at such bearing
positions as will ensure that the stresses induced in them
are always less than the permissible design stresses.
Members shall be lifted or supported only at the points
specified and shall be handled and placed without impact.
3 Tolerance in Precast Members:
i. Dimensional variations shall not exceed the
tolerances given below:
- Length ±12 mm
- Width and depth ± 6 mm
- Bow in the vertical plane +15 mm or -0 mm
- Bow in the horizontal plane ±12 mm
- Difference between longest and
shortest dimensions (check for
squareness of beam) in any plane 6 mm
- Twist (measured by the deviation
of any corner from the plane
containing the other 3 corners) 6 mm
- Flatness (the maximum deviation
from a 1.5 meter straight-edge
placed in any position on
nominally plane surface) 6 mm
- Cover to reinforcement +5 or -0 mm
- Prestressing tendons 3 mm in any direction
- Dowel holes 3 mm in any direction
4 Composite Slab Construction:
i. Where in-situ concrete deck is cast to act
compositely with precast beams, the beams
shall be installed to correct line and level,
starting from the outermost beam and working
inwards progressively. When the beams are
laid side by side just before erection the
difference in soffit level between adjacent
beams shall nowhere exceed 6 mm. Where
permanent soffit shutters are used, they shall
be to the approval of the Engineer and they
shall be fixed securely so that there is no
movement or grout loss during deck
concreting.
ii. The in-situ concrete deck over any one span
shall be poured in one continuous operation
and shall be placed in such a sequence that the
advancing edge of the freshly deposited
concrete over the full width of deck or between
longitudinal construction joints is
approximately parallel to the deck supports.
Lateral displacement of beams shall be
prevented during the placing of in-situ concrete.
iii. The width of the in-situ deck shall be within
+25 mm of that specified. On curved bridge
deck, the in-situ deck may be in a series of
straights such that the width is within +25 mm
of that specified.
5.5.3.4 In-Situ Construction
1 Where bridge decks are constructed in-situ, the
details of all forms and falsework shall first be approved
by the Engineer. Dimensional variations shall not exceed
the following tolerances:
- Length ± 12 mm
- Width ± 10 mm
- Thickness ± 6 mm
- Levels + 10 mm or -0 mm
- Void Location 6 mm in any direction
- Cover to reinforcement + 5 mm or -0 mm
- Prestressing tendons 5 mm in any direction
5.5.4 Method of Measurement, Basis of
Payment and Items in the Bills of
Quantities
1 Concrete bridge construction is measured and
identified in the Bill of Quantities in accordance with
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Clause 5.1.7. Measurement and basis of payment will be in 2 Finishes to floors and walls, including tiles, plaster
accordance with the stipulations for the corresponding paint and special finishes shall be as described in the
items in Sub-sections 5.1, 5.2 and 5.4. No direct payment Special Specification.
will be made for the stipulations of this Sub-section 5.5,
which work is considered to be subsidiary to the 5.6.3 Construction Requirements
requirements of Sub-sections 5.1, 5.2 and 5.4. The rates
and prices for the relevant items of Sub-sections 5.1, 5.2 5.6.3.1 Excavation
and 5.4 shall be deemed to include for all the stipulations
1 The Contractor shall provide the Engineer with
of this Sub-section 5.5. detailed written proposals of construction methods of
temporary and permanent works for the underpass
5.6 Vehicular and Pedestrian excavation. Details of ground water lowering, excavation
Underpasses and Animal support and support of adjacent existing structures shall
Crossings be accompanied by relevant shop drawings and
calculations. The work shall not proceed until the
Engineer has given approval to these construction
5.6.1 Description
proposals together with the relevant construction program
5.6.1.1 Scope for these works. Such approval, when given, shall not
relieve the Contractor of his responsibility for the
1 This Sub-section specifies the requirements for
correctness, safety and adequacy of such proposal.
concrete underpasses and animal crossings. These
2 Excavation and earthwork shall comply with the
requirements are additional to the requirements for
requirements of Section 2.
concrete generally, as described in the preceding Sub-
sections of this Section. 3 The Contractor shall comply with arrangements to
maintain the flow of pedestrian and vehicular traffic as
5.6.1.2 References stated in Section 1 of the Specification and as detailed on
the Drawings or as instructed by the Engineer. The
1 The relevant stipulations of the following Sections or
Contractor's attention is specifically drawn to his
Sub-sections of this Specification shall apply to this Sub-
responsibilities regarding the safety of such traffic near to
section.
open excavations for the works and the operation of heavy
Section 2 Earthworks plant and equipment and the provision and maintenance
Section 5 Concrete and Concrete Structures of adequate fences and barriers.
Section 6 Structural Steel and Other Metalwork 4 The Contractor shall protect and support existing
Section 8 Drainage statutory services during the excavation works as stated in
Section 1 and Section 18 of the Specification and co-
Section 10 Piling
operate with all statutory services to ensure efficiency of
Section 12 Sidewalks, Paved Areas and Curbs diversion of such services where necessary. In the event
Section 15 Road Lighting and Electrical that services are uncovered during excavation that have
Installations not been previously located on Drawings, the Engineer's
attention shall be drawn to the matter without delay.
5.6.2 Materials 5 Particular care shall be taken by the Contractor to
1 Materials shall conform to the relevant requirements minimize noise, dust and vibration caused by excavation
of the following Sections and Sub-sections of the operations especially where such nuisances prove
Specification: hazardous to existing structures.

Piles Section 10 6 Where ground water lowering operations prove

necessary the phasing of pumping operations and their
Concrete Sub-section 5.1
termination on completion of the underpass structure
Reinforcing Steel Sub-section 5.2 shall be approved by the Engineer.
Structural Steel and Other Metal Section 6 7 Where the Drawings show the use of piles or
Backfilling Sub-section 2.7 diaphragm walls to support the underpass structure or
Road Pavement Sections 3, 4 retain the subsoil the Contractor shall submit to the
Engineer for his approval a detailed method statement
Concrete Pavement Sub-section 5.7
and work program for this work together with the names
Waterproofing Sub-section 5.10 of any specialist firms he intends to use for this work.
Pipe culverts Sub-section 8.1
Drainage Section 8
Sidewalks, Paved Areas Section 12
Electrical Installations Section 15

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5.6.3.2 Structural Concrete
1 The Contractor shall provide the Engineer with
detailed written proposals for the formwork design of all
major parts of the underpass structure together with
proposals for transporting, placing and curing concrete
and sizes of pours. The works shall not proceed until the
Engineer has given approval to these proposals; such
approval when given shall not relieve the Contractor of his
responsibility for the efficacy of such proposals.
2 The structural concrete work shall generally comply
with the relevant requirements of the following sections:
Section 5.1 Concrete Materials and Mixes
Section 5.2 Reinforcing Steel
Section 5.3 Reinforced Concrete Structures
Section 5.4 Prestressed Concrete Structures
5.6.3.3 Concrete Piles
1 The reinforced concrete construction of piling works
shown as the Drawings to support the underpass structure
or retain the subsoil shall comply with the relevant
requirements of Section 10.
5.6.3.4 Waterproofing
1 The waterproofing of the underpass structure shall
be generally carried out in compliance with Section 5.10
"Waterproofing for Structures".
2 Where membrane materials are specified on the
Drawings for special use, such as P.V.C. membranes, the
manufacturer's instructions for storage, handling and
installation of such membranes shall be strictly complied
with. Where special details of junctions of such
membranes with walls and piles are necessary, drawings
shall be submitted to the Engineer for approval before
work commences.
3 Tucks and seals for waterproofing shall be provided
at points of discontinuity such as edges, expansion joints
and rainwater drains. Sharp internal and external edges
shall be chamfered with minimum 40mm x 40mm fillets.
The waterproofing membrane shall be protected from
damage during the execution of the work.
4 Where the Drawings show the use of waterstops in
concrete walls and slabs at construction joints and
expansion joints the Contractor shall supply samples of
waterstop material for approval and provide details of
waterstop assembly for approval.
5 The standard of acceptance of waterproofing shall be
that there shall be no damp patches or visible leaks on the
inside face of walls, roof or floor of the underpass
structure.
5.6.3.5 Concrete Pavement Construction
1 Concrete pavement construction shall be in
accordance with all relevant requirements of Section 5.7
“Concrete Pavement”.
5.6.3.6 Bituminous Pavement Construction
1 Bituminous pavement construction shall be in
accordance with all relevant requirements of Section 4
“Bituminous Pavement”.
2 Drainage works shall be constructed in accordance
with all relevant requirements of Sub-Section 8.4
“Drainage of Structures”.
5.6.3.7 Electrical Works
1 The installation of lighting and electrical works for
shall be in accordance with details shown on the Drawings
and the general requirements of Section 15 "Electrical
Installations".
5.6.4 Method of Measurement
1 Excavation, backfilling, piling, concrete,
reinforcement, road pavement, sidewalks and paved areas,
drainage, ducts, waterproofing of concrete and electrical
work shall be measured in accordance with the relevant
Sections of this Specification.
2 Floor and wall finishes shall be measured in
accordance with the Special Specification for the
particular work.
5.6.5 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities,
which rate shall be full compensation for supplying
materials, transporting and placing, labor, equipment,
tools and other items necessary for the proper completion
of the work.
5.6.6 Items in the Bill of Quantities
All work in underpasses and animal crossings is
separately identified in the Bill of Quantities and the
relevant items, as stated in the respective Sections of the
Specification are included.
5.7 Cement Concrete Pavement
5.7.1 Description
1 This Sub-section specifies the requirements for
cement concrete pavement, with or without reinforcement,
on a prepared base all as and where shown on the
Drawings. These requirements are additional to the
requirements for concrete generally contained in the
preceding Sub-sections of this Section
5.7.2 Materials
1 Cementitious Materials: Portland cement alone or in
combination with one or more of blended hydraulic
cement, expansive hydraulic cement, fly ash and other
pozzolans, ground granulated blast-furnace slag, and silica
fume.
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2 Base Course: Cement treated base course or throughout the work, unless otherwise accepted by
aggregate base course placed beneath the concrete Engineer.
pavement. 2 Portland Cement: ASTM C 150, Type I. In particular
cases, where the design requires the use of Sulfate
5.7.2.1 Forms
Resistant Cement (SRC), the Contractor shall submit to the
1 Form Materials: Plywood, metal, metal-framed Engineer’s approval an SRC material complying with the
plywood, or other approved panel-type materials to requirements of ASTM C 150, Type II.
provide full-depth, continuous, straight, smooth exposed 3 Aggregate: ASTM C33 or BS EN 12620, shall consist
surfaces. Use flexible or curved forms for curves of a of crushed stone, crushed or uncrushed gravel, or natural
radius 30 m or less. sand. The aggregate shall be composed of sound, tough,
2 Form-Release Agent: Commercially formulated durable particles and shall meet the requirements for
form-release agent that will not bond with, stain, or deleterious substances given in ASTM C33 or BS EN 12620.
adversely affect concrete surfaces and will not impair The aggregate in any size group shall not contain more
subsequent treatment of concrete surfaces. than 8 percent by weight of flat or elongated pieces when
tested in accordance with ASTM D4791. A flat or
5.7.2.2 Steel Reinforcement elongated particle is one having a ratio between the
1 Reinforcement Bars: ASTM A 615, Grade 60, maximum and the minimum dimensions of a
deformed. circumscribing rectangular prism exceeding 5 to 1.
Uniformly graded, from a single source, with coarse
2 Plain Steel Wire: ASTM A 82, cold-drawn steel.
aggregate as follows:
3 Welded Deformed Steel Wire fabric: ASTM A497.
4 Fine Aggregate: Conform to the requirements of
4 Joint Dowel Bars: Plain steel bars, ASTM A 615, ASTM C33 (Table 5.7.2.1) or BS EN 12620.
Grade 60. Cut bars true to length with ends square and
free of burrs. Sieve Designation Percentage by Weight
5 Dowel Bars: High tensile plain steel bars conforming (square openings) Passing Sieves
to BS 4449, ASTM A615, ASTM A616, or ASTM A617, and 3/8 in (9.5 mm) 100
shall be free from burring or other deformation restricting No. 4 (4.75 mm) 95-100
slippage in the concrete. Before delivery to the
No. 8 (2.36 mm) 80-100
construction site, a minimum of two-thirds of the length of
each dowel bar shall be painted with one coat of zinc- No. 16 (1.18 mm) 50- 85
chromate. If plastic or epoxy-coated steel dowels are used, No. 30 (600 micro-m) 25- 60
no zinc-chromate coating is required, except when No. 50 (300 micro-m) 10- 30
specified for a particular situation on the contract plans. No. 100 (150 micro-m) 2- 10
Coated dowels shall conform to the requirements given in
No. 200 (75 micro-m) 0- 3
AASHTO M254.
6 Tie Bars: ASTM A 615M, Grade 60, deformed. Table 5.7.2.1: Gradation for Fine Aggregate ASTM C33

7 Sleeves: Metal, of an approved design to cover 50 1 Coarse Aggregate: Conform to the requirements of
mm to 75 mm of the dowel, with a closed end and with a ASTM C33 (Table 5.7.2.2) or BS EN 12620.
suitable stop to hold the end of the bar at least 25 mm
from the closed end of the sleeve. Sleeves shall be of Sieve Designation Percentage by Weight
such design that they will not collapse during construction. (square openings) Passing Sieves
in (mm) 19 mm – 2.36 mm
8 Hook Bolts: ASTM F 568M, Property Class 4.6,
internally and externally threaded. Design hook-bolt joint 1 (25) 100
assembly to hold coupling against pavement form and in 3/4 (19) 90 - 100
position during concreting operations, and to permit
1/2 (12.5) -
removal without damage to concrete or hook bolt.
3/8 (9.5) 20 - 55
9 Bar Supports: Bolsters, chairs, spacers, and other
devices for spacing, supporting, and fastening No. 4 (4.75) 0 – 10
reinforcement bars, welded wire fabric, and dowels in
No. 8 (2.36) 0–5
place. Use wire bar type supports complying to CRSI's
"Manual of Standard Practice". Table 5.7.2.2: Gradation for Coarse Aggregate ASTM C33
10 Epoxy Repair Coating: Liquid two-part epoxy repair The percentage of wear shall be no more than 30% when
coating, compatible with epoxy coating on reinforcement. tested in accordance with ASTM C131.

5.7.2.3 Concrete Materials 6 Water: Water used in mixing or curing shall be as

clean and free of oil, salt, acid, alkali, sugar, vegetable, or
1 General: Use the same brand and type of other substances injurious to the finished product as
cementitious material from the same manufacturer possible. Water will be tested in accordance with the

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requirements of AASHTOT26, ASTM C94. Water known to cellulosic fiber, or ASTM D 1752 for cork or self-expanding
be of potable quality may be used without testing. cork.
2 Joint filler shall be furnished in a single piece for the
5.7.2.4 Admixtures
full depth and width required for the joint, unless
1 General: Admixtures certified by manufacturer to otherwise specified by Engineer. When the use of more
contain not more than 0.1 percent water-soluble chloride than one piece is authorized for a joint, the abutting ends
ions by mass of cement and to be compatible with other shall be fastened securely and held accurately to shape by
admixtures. stapling or other positive fastening means satisfactory to
2 Approval Process: The use of any material added to Engineer.
the concrete mix shall be approved by Engineer. Submit 3 Joint sealer shall: meet the requirements of Sub-
certificates indicating that the material to be furnished section 5.8 of the Specification and shall be of the type(s)
meets all of the requirements indicated below. In addition, specified on drawings.
the Engineer may require the submittal of complete test 4 Dowels: Galvanized steel, to the dimensions shown
data from an approved laboratory showing that the on drawings.
material to be furnished meets all of the requirements of
5 Bonding Agent: ASTM C 1059, Type II, non-re-
the cited specifications. Subsequent tests will be made of
dispersible, acrylic emulsion or styrene butadiene.
samples taken by Engineer from the supply of the material
being furnished or proposed for use on the work to 5.7.2.7 Concrete Mixes
determine whether the admixture is uniform in quality
with that approved. 1 Prepare design mixes, proportioned according to ACI
211.1 and ACI 301, for each type and strength of normal-
3 Chemical Admixtures: Water reducing, set-retarding,
weight concrete determined by either laboratory trial
and set-accelerating admixtures shall meet the
mixes or field experience.
requirements of ASTM C494.
2 Use a qualified independent testing agency for
i. Water-Reducing Admixture: ASTM C 494,
preparing and reporting proposed mix designs for the trial
Type A. batch method. Do not use Employer’s field quality-control
ii. High-Range, Water-Reducing Admixture: testing agency as the independent testing agency.
ASTM C 494, Type F. 3 Proportion mixes to provide concrete with the
iii. Water-Reducing and Accelerating Admixture: following properties using test specimens prepared in
ASTM C 494, Type E. accordance with ASTM C31 and tested with ASTM C78:
iv. Water-Reducing and Retarding Admixture: i. Flexural Strength (28 Days): 4.6 MPa
ASTM C 494, Type D. ii. Compressive Strength (28 Days): 35 MPA.
5.7.2.5 Curing Materials iii. The minimum cementitious material content
shall be 300 kg. per cubic meter. The ratio of
1 Absorptive Cover: AASHTO M 182, Class 2, burlap water to cementitious material, including free
cloth made from jute or kenaf, weighing approximately. surface moisture on the aggregates but not
305 g/sq.m. dry. including moisture absorbed by the aggregates
2 Moisture-Retaining Cover: ASTM C 171, shall not be more than 0.50 by weight.
polyethylene film or white burlap-polyethylene sheet. 4 Slump Limit:
3 Water: Potable. i. The mix determined shall be workable concrete
4 Evaporation Retarder: Waterborne, monomolecular having a slump for side-form concrete between
film forming, manufactured for application to fresh 25 mm and 50 mm as determined by ASTM
concrete. C143.
5 Clear Solvent-Borne Liquid-Membrane-Forming ii. Slump Limit for Concrete Containing High-
Curing Compound: ASTM C 309, Type 1, Class B. Range Water-Reducing Admixture: Not more
6 Clear Waterborne Membrane-Forming Curing than 200 mm after adding admixture to plant-
Compound: ASTM C 309, Type 1, Class B. or site-verified, 50- to 75-mm slump.

7 White Waterborne Membrane-Forming Curing
Compound: ASTM C 309, Type 2, Class B.
5.7.2.6 Related Materials
1 Pre-molded joint filler shall conform to the
requirements of ASTM D1751 and shall be punched to
admit the dowels where called for on the plans.
Expansion and isolation joint-filler strips shall conform to
the requirements of ASTM D 1751 for asphalt-saturated
iii. Absorption and permeability tests on hardened
concrete shall be carried out in accordance
with ASTM C642.
5 Chemical Admixtures: Water-reducing and set-
controlling admixtures shall be added to the mix in the
manner recommended by the manufacturer and in the
amount necessary to comply with the specification
requirements. Tests shall be conducted on trial mixes,
during the mix design, in accordance with ASTM C494.

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6 Slip-form Construction: A high degree of uniformity
in the plastic concrete is required. Some edge slump of
the wet concrete behind the side form on the paving
machine will occur, even with low slump concrete. This
may continue, though very slowly, until initial set has
taken place.
5.7.2.8 Concrete Mixing
1 Ready-Mixed Concrete: Comply with requirements
and with ASTM C 94 and ASTM C 1116. Discharge of the
concrete shall be completed within a maximum of 1½
hours, or before the drum has revolved 300 revolutions,
whichever comes first. Mixing time shall be measured
from the time all materials, except water, are emptied into
the drum. However, when air temperature is between 30
deg. C and 32 deg. C, reduce mixing and delivery time
from 1½ hours to 75 minutes; and when air temperature is
above 32 deg. C, reduce mixing and delivery time to 60
minutes.
i. The minimum required revolutions of the
mixing speed for transit mixed concrete may
be reduced to not less than that recommended
by the mixer manufacturer.
ii. The number of revolutions recommended by
the mixer manufacturer shall be indicated on
the manufacturer's serial plate attached to the
mixer.
2 Concrete:
i. Concrete may be mixed at the work site
location in a central mix plant approved by the
Engineer and shall be transported in truck
mixers. The mixer shall be of an approved
type and capacity.
ii. Furnish test data acceptable to Engineer
verifying that the model of the mixer will
produce uniform concrete conforming to the
provisions of ASTM C 94 at the reduced
number of revolutions shown on the serial
plate.
3 When mixed at the work site or in a central mixing
plant, the mixing time shall not be less than 50 seconds
nor more than 90 seconds. Mixing time ends when the
discharge chute opens. Transfer time in multiple drum
mixers is included in mixing time. The contents of an
individual mixer drum shall be removed before a
succeeding batch is emptied therein.
4 Mixer:
i. The mixer shall be operated at the drum speed
recommended by the manufacturer as stated
nameplate on the mixer. Any concrete mixed
less than the specified time shall be discarded
at Contractor’s own expense.
ii. The volume of concrete mixed per batch shall
not exceed the mixer's nominal capacity, as
shown on the manufacturer's standard rating
plate on the mixer.
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iii. An overload up to 10 percent above the mixer's
nominal capacity may be permitted provided
concrete test data for segregation and uniform
consistency are satisfactory, and provided no
spillage of concrete takes place.
5 Batch: Constituents shall be charged into the drum so
that a portion of the mixing water enters in advance of the
cement and aggregates. The flow of water shall be
uniform, and all water shall be in the drum by the end of
the first 15 seconds of the mixing period. The throat of the
drum shall be kept free of such accumulations as may
restrict the free flow of materials into the drum.
6 Mixed Concrete:
i. Central mixing plant concrete shall be
transported in truck mixers, truck agitators, or
non- agitating trucks. Non-agitating trucks are
allowed to be used only when the location of
the mixing plant is very close to the site and to
the approval of the Engineer.
ii. The time elapsing from the time water is added
to the mix until the concrete is deposited in
place at the work site shall not exceed 30
minutes when the concrete is hauled in non-
agitating trucks, nor 45 minutes when the
concrete is hauled in truck mixers or truck
agitators. All these operations must be
performed within 45 minutes after the initial
mixing operations and the water-cement ratio
must not be exceeded.
iii. Admixtures for increasing the workability or for
accelerating the set will be permitted only
when specified for in the contract.
5.7.2.9 Limitations of Mixing:
1 No concrete shall be mixed, placed, or finished when
the natural light is insufficient, unless an adequate and
approved artificial lighting system is operated.
2 During periods of hot weather when the maximum
daily air temperature exceeds 30 deg. C, the following
precautions shall be taken: the forms and/or the
underlying material shall be sprinkled with water
immediately before placing the concrete. The concrete
shall be placed at the coolest temperature practicable, and
in no case shall the temperature of the concrete when
placed exceed 32 deg, C. The aggregates and/or mixing
water shall be cooled as necessary to maintain the
concrete temperature at or not more than the specified
max. Refer to ACI 305 R-77 for Hot Weather Concreting.
5.7.3 Construction Requirements
5.7.3.1 Preparation
1 Proceed with pavement layers only after
nonconforming conditions have been corrected and
subgrade is ready to receive pavement.
2 Remove loose material from compacted sub-base
surface immediately before placing concrete.
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5.7.3.2 Edge Forms and Screed Construction
1 Set, brace, and secure edge forms, bulkheads, and
intermediate screed guides for paving to required lines,
grades, and elevations. Install forms to allow continuous
progress of work and so that forms can remain in place at
least 24 hours after concrete placement.
2 Forms shall be securely set so that they can
withstand impacts and vibration of consolidating and
finishing equipment without visible spring or settlement.
Extend flange braces on the base outward for not less
than two thirds of the height of the form. Remove bent,
twisted or broken forms, and forms with damaged top
surfaces. Use repaired forms only with inspection and
approval. Built-up forms will not be allowed, unless
specifically approved. The top faces of forms are not to
vary from a true plane by more than 3 mm in 3m. The
upstanding leg shall be perpendicular to the base and is
not to vary horizontally from true alignment by more than
6 mm at any point. The ends of abutting sections lock
together tightly for secure setting. Local defects, such as
kinks in steel forms, will not be allowed.
3 Setting: Forms shall be set ahead of concrete
placement and staked into place with at least three pins
for each 3 m section. A pin shall be placed at each side of
every joint. Form sections shall be tightly locked and free
from movement in any direction. Excessive settlement or
springing from operation of the finishing machine will not
be allowed. Forms shall be cleaned and oiled before
concrete placement. The alignment and grade elevations
of the forms shall be checked, and corrections made
immediately before placing concrete. Reset and recheck
forms when they have been disturbed, or when the grade
has become unstable.
4 Clean forms after each use and coat with form
release agent as required, to ensure separation from
concrete without damage.
5 Removal: Do not remove forms until the concrete
has set for at least 12 hours, unless otherwise approved or
where auxiliary forms are used temporarily in widened
areas. Remove forms carefully to avoid damaging the
pavement, and after removal, the side of the slab shall be
cured by the method specified in the current specification.
5.7.3.3 Steel Reinforcement
1 General: Comply with CRSI's ‘Manual of Standard
Practice’ for fabricating reinforcement and with
recommendations in CRSI's "Placing Reinforcing Bars" for
placing and supporting reinforcement.
5.7.3.4 Placement of Reinforcement
1 Reinforced Concrete Pavement: Comply with
Concrete Reinforcing Steel Institute's recommended
practice for ‘Placing Reinforcing Bars’, for details and
methods of reinforcement placement and supports, and as
herein specified:
i. At the time concrete is placed the reinforcing
bars shall be free of mud, oil or other organic
matter that may adversely affect or reduce
bond. Reinforcing steel with rust, mill scale, or
a combination of both will be considered
satisfactory, provided the minimum
dimensions, weight, and tensile properties of a
hand wire-brushed test specimen are not less
than the applicable ASTM specification
requirements.
ii. Accurately position, support, and secure
reinforcement against displacement by
formwork, construction, or concrete placement
operations. Locate and support reinforcing
bars by metal chairs, runners, bolsters, spacers,
and hangers, as required.
iii. Arrange, space, and securely tie bars and bar
supports to hold reinforcement in position
during concrete placement operations. Set wire
ties so ends are directed into concrete, not
toward exposed concrete surfaces.
iv. Install welded wire fabric in as long lengths as
practicable. Lap adjoining pieces at least one
full mesh and lace splices with wire. Offset end
laps in adjacent widths to prevent continuous
laps in either direction.
5.7.3.5 Joints
1 General: Form construction, expansion, and
contraction joints and tool edgings true to line with faces
perpendicular to surface plane of concrete. Construct
transverse joints at right angles to centerline, unless
otherwise indicated. When joining existing pavement,
place transverse joints to align with previously placed
joints, unless otherwise indicated.
2 Construction Joints: Set construction joints at side
and end terminations of pavement and at locations where
pavement operations are stopped for more than one-half
hour, unless pavement terminates at isolation joints.
3 Expansion Joints: Form expansion joints of
preformed joint-filler strips abutting concrete curbs, catch
basins, manholes, inlets, structures, walks, other fixed
objects, and where indicated.
i. Locate expansion joints at intervals indicated
on drawings.
ii. Extend joint fillers full width and depth of joint.
iii. Terminate joint filler not less than 12 mm or
more than 25 mm below finished surface if
joint sealant is required.
iv. Place top of joint filler flush with finished
concrete surface if joint sealant is not indicated.
v. Furnish joint fillers in one-piece lengths.
Where more than one length is required, lace
or clip joint-filler sections together.
vi. Protect top edge of joint filler during concrete
placement with metal, plastic, or other
temporary preformed cap. Remove protective
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 cap after concrete has been placed on both
sides of joint.
4 Longitudinal and Transverse Joints: Construct as
indicated on the Drawings and in accordance with the
following requirements:
i. All joints shall be constructed true to line with
their faces perpendicular to the surface of the
pavement.
ii. Joints shall not vary more than 12mm from a
true line or from their designated position.
iii. The vertical surface of the pavement adjacent
to all expansion joints shall be finished to a
true plane and edged to a radius of 6mm or as
shown on the plans.
iv. The surface across the joints shall be tested
with a 3m straightedge as the joints are
finished and any irregularities in excess of
6mm shall be corrected before the concrete has
hardened.
v. Transverse joints shall be at right angles to the
centerline of the pavement and shall extend the
full width of the slab.
vi. The transverse joints in succeeding lanes shall
be placed in line with similar joints in the first
lane. All joints shall be so prepared, finished,
or cut to provide a groove of the width and
depth shown on the plans.
5 Slip-Form Construction: Transverse joints with
dowels shall be carefully placed to ensure the dowels are
accurately placed and not disturbed during concrete
placement.
i. Transverse dowels will require use of an
apparatus to firmly hold the dowels
perpendicular to the joint and parallel to the
slab surface.
ii. During the concrete placement operation, it is
advisable to place plastic concrete directly on
the dowel assembly immediately prior to
passage of the paver to help maintaining dowel
alignment.
6 Tie Bars: Deformed bars shall be fixed in longitudinal
joints as shown on the Drawings.
i. Tie bars shall be placed at right angles to the
centerline of the concrete slab and shall be
spaced at intervals shown on Drawings.
ii. Tie bars shall be held in position parallel to the
pavement surface and midway between the
surfaces of the slab.
iii. When tie bars extend into an unpaved lane,
they may be bent at right angles against the
form at longitudinal construction joints, unless
threaded bolt or other assembled tie bars are
specified.
iv. Tie bars shall not be painted, greased, or
enclosed in sleeves.
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7 Dowel Bars: Dowel bars or other load-transfer units
of an approved type shall be placed across transverse or
other joints in the manner as specified on the Drawings.
i. They shall be of the dimensions and spacing as
shown and held rigidly in the middle of the
slab depth in the proper horizontal and vertical
alignment by an approved assembly device left
permanently in place.
ii. The dowel or load-transfer and joint devices
shall be rigid enough to permit complete
assembly as a unit ready to be lifted and placed
into position.
iii. A metal, or other type dowel expansion cap or
sleeve shall be furnished for each dowel bar
used with expansion joints.
iv. These caps shall be substantial enough to
prevent collapse and shall be placed on the
ends of the dowels as shown on the Drawings.
v. The caps or sleeves shall fit the dowel bar
tightly and the closed end shall be watertight.
8 Fix dowel bars and support assemblies at joints
where indicated. Lubricate or asphalt-coat one-half of
dowel length to prevent concrete bonding to one side of
joint.
9 Joints Installation:
i. The top of an assembled joint device shall be
set at the proper distance below the pavement
surface and the elevation shall be checked.
Such devices shall be set to the required
position and line and shall be securely held in
place by stakes or other means during the
pouring and finishing of the concrete. The pre-
molded joint material shall be placed and held
in a vertical position; if constructed in sections,
there shall be no offsets between adjacent
units. Dowel bars shall be checked for exact
position and alignment as soon as the joint
device is staked in place, and the device shall
be tested to determine whether it is firmly
supported. The maximum permissible
tolerance on dowel bar alignment in each plane,
horizontal and vertical, shall not exceed 2
percent or 6mm per 300 mm of a dowel bar.
The most effective way to obtain proper
alignment is with well-fabricated dowel baskets
and dowel assemblies.
ii. When joints in concrete pavements are sawed,
the joints shall be cut as shown on the
Drawings. The circular cutter shall be capable
of cutting a groove in a straight line and shall
produce a slot at least 3mm wide and to the
depth shown on the plans. When shown on the
plans or required by the specifications, the top
portion of the slot groove shall be widened by
means of a second shallower cut or by suitable
and approved beveling to provide adequate
space for joint sealers. Sawing of the joints
copy 249
 shall commence as soon as the concrete has
hardened sufficiently to permit cutting without
chipping, spalling, or tearing. Sawing shall be
carried on both during the day and night as
required. The joints shall be sawed at the
required spacing consecutively in sequence of
the concrete placement, unless otherwise
approved by Engineer.
10 Contraction Joints: Form weakened-plane
contraction joints, sectioning concrete into areas as
indicated. Construct contraction joints for a depth equal to
at least one-fourth of the concrete thickness, as follows:
i. Grooved Joints: Form contraction joints after
initial floating by grooving and finishing each
edge of joint with groover tool to the radius
shown on drawings. Repeat grooving of
contraction joints after applying surface
finishes. Eliminate groover marks on concrete
surfaces.
ii. Sawed Joints: Form contraction joints with
power saws equipped with shatterproof
abrasive or diamond-rimmed blades. Cut
joints into concrete to the width shown on
drawings, when cutting action will not tear,
abrade, or otherwise damage surface and
before developing random contraction cracks.
11 Longitudinal Joints:
i. Construction type: longitudinal construction
joints necessary for lane construction shall be
formed against suitable side forms as indicated
in the plans. Wooden forms may be used
under special conditions, when approved by
Engineer. Where butt-type joints with dowels
are designated, the dowels for this type shall
be painted and greased. The edges of the joint
shall be finished with a grooving tool or edging
tool, and a space or slot shall be formed along
the joint of the dimensions, as indicated, to
receive the joint sealing material. Longitudinal
construction joints shall be sawed to provide a
groove at the top conforming to the details and
dimensions indicated on the plans. Provisions
shall be made for the installation of tie bars as
noted on the plans.
ii. Contraction or weakened - plane type:
longitudinal groove-formed or sawed joints in
the top of the slab shall be formed where
indicated on the Drawings. The groove shall
be formed in the plastic concrete with suitable
tools or material to obtain the width and depth
specified, or it shall be sawed with approved
equipment in the hardened concrete to the
dimensions required. When the groove is
formed in plastic concrete, it shall be true to
line with not more than 6mm variation in 3m; it
shall be uniform in width and depth; and the
sides of the groove shall be finished even and
smooth with an edging tool. If an insert
material is used, the installation and edge
finish shall be according to the manufacturer's
instructions. The sawed groove shall be
straight and of uniform width and depth. In
either case, the groove shall be clean cut so
that spalling will be avoided at intersections
with transverse joints. Tie bars shall be
installed across these joints where indicated on
the plans.
iii. Expansion type: longitudinal joints shall be
informed as indicated on the Drawings. The
pre-molded filler, of the thickness shown shall
extend for the full depth and width of the slab
at the joint, except for space for sealant at the
top of the slab. The filler shall be securely
staked or fastened into position perpendicular
to the proposed finished surface. A metal cap
shall be provided to protect the top edge of the
filler and to permit the concrete to be placed
and finished. After the concrete has been
placed and struck off, the cap shall be carefully
withdrawn leaving the space over the pre-
molded filler. The edge of the joint shall be
finished and tooled while the concrete is still
plastic.
12 Transverse Joints:
i. Expansion Type:
- Transverse expansion joints shall be
installed at the locations and spacing as
shown on the plans. The joints shall be
installed at right angles to the centerline
and perpendicular to the surface of the
pavement. The joints shall be formed and
finished to ensure complete separation of
the slabs. Joint filler shall be of a pre-
molded type as specified and shown on the
Drawings and shall extend the full width of
the pavement strip.
- All concrete shall be cleaned from the top
of the joint material. Before the pavement
is opened to traffic, it shall be swept clean
and filled with approved joint sealing
material.
- All devices used for the fixing expansion
joints shall be approved by the Engineer.
They shall be easily removable without
disturbing the concrete and held in proper
transverse and vertical alignment.
Immediately after forms are removed, any
concrete bridging the joint space at the
ends shall be removed for the full width
and depth of the joint.
- When specified, expansion joints shall be
equipped with dowels of the dimensions
and at the spacing and location indicated
on the Drawings. The dowels shall be
firmly supported in place and accurately
aligned parallel to the subgrade and the
♦ 5-51 ♦
copy 249
 centerline of the pavement by means of a
dowel assembly, which will remain in the
pavement and will ensure that the dowels
are not displaced during construction.
ii. Transverse contraction joints, weakened-plane
joints, or both, shall be formed at the locations
and spacing as shown on the Drawings by
forming a groove or cleft in the top of the slab
while the concrete is still plastic or by sawing a
groove into the concrete surface after the
concrete has hardened in the same manner as
specified. Dowel bar assemblies shall be
installed as shown on the Drawings.
iii. Transverse construction joints shall be formed
at the end of each day's placing operations and
at any other points within a paving lane when
concrete placement is interrupted for more
than 30 minutes or it appears that the concrete
will obtain its initial set before fresh concrete is
placed. Construction joints planned in advance
shall be located at a contraction or expansion
joint where possible but they shall not be
located within 2500 mm of a regular spaced
transverse joint. If the pouring of the concrete
is stopped, causing a joint to fall within this
limit, it shall not be formed, and the fresh
placed concrete shall be removed back to the
2500 mm limit.
13 Edging: Tool edges of pavement, gutters, curbs, and
joints in concrete after initial floating with an edging tool
to the radius shown on drawings. Repeat tooling of edges
after applying surface finishes. Eliminate tool marks on
concrete surfaces.
5.7.3.6 Conditioning of Underlying Course, Slip-Form
Construction
1 The base course on which the pavement will be
placed shall extend approximately 900 mm beyond the
paving machine track, or wider if required, to support the
paver without any noticeable deformation.
2 If damage occurs to the base course, it shall be relaid
for the full depth or the damaged areas filled with concrete
integral with the pavement. If traffic is allowed to use the
prepared grade, the grade shall be checked and corrected
immediately before the placement of concrete.
3 The prepared grade shall be well moistened with
water, without saturating, immediately ahead of concrete
placement to prevent rapid loss of moisture from concrete.
5.7.3.7 Conditioning of Underlying Course, Side-Form
Construction
1 The prepared grade shall be well moistened with
water, without saturating, immediately ahead of concrete
placement to prevent rapid loss of moisture from the
concrete.
♦ 5-52 ♦
2 If damage occurs to the base course, it shall be relaid
for the full depth, or the damaged areas filled with
concrete integral with the pavement.
3 A multiple-pin template weighing not less than 454
kg. per 6 m or other approved template shall be provided
and operated on the forms immediately in advance of the
placing of the concrete. The template shall be propelled
only by hand and not attached to a tractor or other power
unit. Templates shall be adjustable so that they may be
set and maintained at the correct contour of the
underlying course. The adjustment and operation of the
template shall be such as to provide an accurate re-test of
the grade before placing the concrete thereon. All excess
material shall be removed. Low areas may be filled with
concrete integral with the pavement.
5.7.3.8 Handling, Measuring, and Batching Material
1 Batch plant site: layout, equipment, and provisions
for transporting material shall assure a continuous supply
of material to the work.
2 Stockpiles: Build up stockpiles in layers of not more
than 900 mm in thickness. Each layer shall be completely
in place before beginning the next layer and shall not be
allowed to "cone" down over the next lower layer.
Aggregates from different sources and of different grading
shall not be stockpiled together. Improperly placed
stockpiles will not be accepted by Engineer.
3 Aggregates: Handle from stockpiles or other sources
to the batching plant in such manner to secure the
specified grading of the material. Aggregates that have
become segregated or mixed with earth or foreign
material shall not be used. All aggregates produced or
handled by hydraulic methods, and washed aggregates,
shall be stockpiled or binned for draining at least 12 hours
before being batched.
4 Cement: Store in weather tight structures with raised
floors or in suitable silos. Different consignments of
bagged cement shall be used separately and in the order
of delivery. Cement manufactured more than twelve
months prior to proposed use on site shall not be used. If
cement becomes partially set or contains lumps of caked
cement, it shall be rejected. Cement salvaged from
discarded or used bags shall not be used.
5 Aggregate: Fine and coarse aggregate shall be
separately weighed into hoppers in the respective
amounts approved by Engineer in the job mix. Cement
shall be measured by weight. Separate scales and hopper,
with a device to positively indicate the complete discharge
of the batch of cement into the batch box or container,
shall be used for weighing the cement.
6 When required by the contract or when permitted,
batching plants shall be equipped to proportion
aggregates and bulk cement, by weight, automatically
using interlocked proportioning devices of an approved
type.
7 Water shall be measured either by volume or by
weight accurately measured to within plus or minus 1
copy 249
percent of required amounts. Unless the water is to be
weighed, the water-measuring equipment shall include an
auxiliary tank from which the measuring tank shall be
filled. The measuring tank shall be equipped with an
outside tap and valve to provide for checking the setting,
unless other means are provided for readily and
accurately determining the amount of water in the tank.
The volume of the auxiliary tank shall be at least equal to
that of the measuring tank
8 Methods and equipment for adding air-entraining
agent or other admixtures to the batch, when required,
shall be approved by Engineer. All admixtures shall be
measured into the mixer with an accuracy of plus or
minus 3 percent.
5.7.3.9 Concrete Protection and Curing
1 General: Protect concrete against loss of moisture
and rapid temperature changes for at least seven days
from beginning of the curing operation. Unhardened
concrete shall be protected from rain and flowing water.
All equipment needed for adequate curing and protection
of the concrete shall be on hand, ready to use before
concrete placement begins. A standby water truck
capable of dispensing a fine spray of water shall be
continuously available during paving operations to keep
the concrete moist until the curing compound has been
applied. Provide protection as necessary to prevent
cracking of the pavement due to temperature changes
during the curing period.
2 Membrane Curing: Apply a uniform coating of white
pigmented-type membrane curing compound to the entire
exposed surface of the concrete by means of an approved
automatic spraying machine as soon as free water has
disappeared from the finished surface. Coat formed
surfaces immediately after the forms are removed and in
no case longer than one hour after removal of forms. Do
not allow concrete to dry before application of the
membrane. If any drying has occurred, moisten the
surface of the concrete with a fine spray of water and
apply curing compound as soon as the free water
disappears. The spraying machine shall be self-propelled
and shall ride on the side forms, or previously constructed
pavement straddling the newly paved lane. The machine
shall have one or more spraying nozzles that can be
controlled and operated to completely and uniformly
cover the pavement surface with the required amount of
curing compound. The curing compound shall be
thoroughly and continuously mechanically agitated in the
drum used for the spraying operation throughout the full
depth of the drum during application. Air agitation may
be used only to supplement mechanical agitation. Provide
sufficient spraying pressure to produce a fine spray to
cover the surface thoroughly and completely with a
uniform film. Maintain spray equipment in good
mechanical condition, and provide adequate wind guard
to the spray nozzle. Apply curing compound with an
overlapping coverage that will give a two-coat application
at a coverage rate of not more than 0.1 Liter per/sq.m. for
each coat or as recommended by the manufacturer. The
application of curing compound by hand-operated
pressure sprayers will be permitted only on small widths
or shapes of slabs as approved, and on concrete surfaces
exposed by removal of forms. When application is made
by hand-operated sprayer, apply the second coat in a
direction approximately at right angles to the direction of
the first coat. The compound shall form a uniform,
continuous, cohesive film that will not check, crack or peel,
and is free of pinholes and other discontinuities. Apply an
additional coat, if pinholes, abrasions or other
discontinuities exist, to the affected areas within 30
minutes. Re-spray concrete surfaces that are subjected to
heavy rainfall or abrasive wind-blown sand within three
hours after the curing compound has been applied. Re-
spray areas where the curing membrane is damaged by
subsequent construction operations within the curing
period.
i. Precautions shall be taken to ensure that
concrete is properly cured at sawed joints, but
that no curing compound enters the joints.
Tightly seal top of joint opening and joint
groove at exposed edges before concrete
adjacent to the joint is re-sprayed. Seal joint
groove by using method that will prevent loss
of moisture from the joint during the specified
curing period.
ii. Provide approved standby facilities for curing
concrete pavement at an accessible location at
the jobsite for use in the event of failure of the
spraying equipment, or other conditions that
might prevent correct application of curing
compound at the proper time.
iii. Protect concrete surfaces to which curing
compounds have been applied from pedestrian
and vehicular traffic and from any other
possible damage to the continuity of the
membrane, during the curing period except as
required for joint-sawing operations and
surface testing.
3 Protection: Protect pavement and its appurtenances
from damage caused by traffic. The Engineer will decide
when the pavement may be cleaned and opened to traffic,
but not earlier than 14 days after concrete placing. Protect
freshly placed concrete from premature drying and
excessive cold or hot temperatures. Comply with the
recommendations of ACI 306R for cold weather protection
and ACI 305R for hot weather protection during curing.
5.7.3.10 Concrete Placement
1 Inspection: Before placing concrete, inspect and
complete formwork installation, reinforcement steel, and
items to be embedded or cast in. Notify other trades to
permit installation of their work.
2 Moisten subbase to provide a uniform dampened
condition at the time concrete is placed. Do not place
concrete around manholes or other structures until they
are at the required finish elevation and alignment.
♦ 5-53 ♦
copy 249
3 Comply with requirements and with
recommendations in ACI 304R for measuring, mixing,
transporting, and placing concrete.
4 Do not add water to concrete during delivery, at Site,
or during placement.
5 Deposit and spread concrete in a continuous
operation between transverse joints. Do not push or drag
concrete into place or use vibrators to move concrete into
place.
6 Consolidate concrete by mechanical vibrating
equipment supplemented by hand-spading, rodding, or
tamping. Use equipment and procedures to consolidate
concrete according to recommendations in ACI 309R.
Consolidate concrete along face of forms and adjacent to
transverse joints with an internal vibrator. Keep vibrator
away from joint assemblies, reinforcement, or side forms.
Use only square-faced shovels for hand-spreading and
consolidation. Consolidate with care to prevent
dislocating reinforcement, dowels, and joint devices.
7 Following the placing of the concrete, it shall be
struck off to conform to the cross section shown on the
Drawings and to level such that when the concrete is
properly consolidated and finished, the surface of the
pavement shall be at the level shown on the Drawings.
8 Screed pavement surfaces with a straightedge and
strike off. Commence initial floating using bull floats or
darbies to form an open textured and uniform surface
plane before excess moisture or bleed water appears on
the surface. Do not further disturb concrete surfaces
before beginning finishing operations or spreading dry-
shake surface treatments.
9 Side Form Method:
i. The concrete shall be deposited on the
moistened grade to require as little re-handling
as possible. Unless truck mixers, truck agitators,
or non agitating hauling equipment are
equipped with means for discharge of concrete
without segregation of the materials, the
concrete shall be unloaded into an approved
spreading device and mechanically spread on
the grade to prevent segregation of the
materials. Placing shall be continuous between
transverse joints without the use of
intermediate bulkheads. Necessary hand
spreading shall be done with shovels - not
rakes. Workmen shall not be allowed to walk in
the freshly mixed concrete with boots or shoes
coated with earth or foreign substances.
ii. When concrete is to be placed adjoining a
previously constructed lane of pavement and
when mechanical equipment will be operated
upon the existing lane of pavement, the
concrete shall be at least 7 days old and at a
flexural strength approved by Engineer.
iii. Concrete shall be thoroughly consolidated
against and along the faces of all forms and
along the full length and on both sides of all
♦ 5-54 ♦
joint assemblies by means of vibrators inserted
in the concrete. Vibrators shall not be
permitted to come in contact with a joint
assembly, the grade, or a side form. In no case
shall the vibrator be operated longer than 15
seconds in any one location, nor shall the
vibrators be used to move the concrete.
iv. Concrete shall be deposited as near to
expansion and contraction joints as possible
without disturbing them but shall not be
dumped from the discharge bucket or hopper
onto a joint assembly unless the hopper is well
centered on the joint assembly.
v. Should any concrete materials fall on or be
worked into the surface of a completed slab,
they shall be removed immediately by
approved methods.
10 Slip-Form Method:
i. The concrete shall be placed with an approved
crawler-mounted, slip-form paver designed to
spread, consolidate, and shape the freshly
placed concrete in one complete pass of the
machine so that a minimum of hand finishing
will be necessary to provide a dense and
homogeneous pavement in conformance with
requirements of the plans and specifications.
The concrete should be placed directly on top
of the joint assemblies to prevent them from
moving when the paver moves over them. Side
forms and finishing screeds shall be adjustable
to the extent required to produce the specified
pavement edge and surface tolerance. The side
forms shall be of dimensions, shape, and
strength to support the concrete laterally for a
sufficient length of time so that no appreciable
edge slumping will occur. Final finishing shall
be accomplished while the concrete is still in
the plastic state.
ii. In the event that slumping or sloughing occurs
behind the paver or if there are any other
structural or surface defects, which, in the
opinion of the Engineer, cannot be corrected
within permissible tolerances, the Engineer
may halt paving operations until proper
adjustment of the equipment or procedures
have been made. In the event that satisfactory
pavement procedures are not achieved after
more than 600 m of single lane paving, the
balance of the work shall be completed with
the use of standard metal forms and the
formed method of placing and curing.
11 Slip-Form Pavers: When automatic machine
placement is used for pavement, submit revised mix
design and laboratory test results that meet or exceed
requirements. Produce pavement to required thickness,
lines, grades, finish, and jointing as required for formed
pavement. Compact subbase and prepare subgrade of
copy 249
sufficient width to prevent displacement of paver machine
during operations.
12 When adjoining pavement lanes are placed in
separate pours, do not operate equipment on concrete
until pavement has attained 85 percent of its 28-day
compressive strength.
13 Hot-Weather Placement: Place concrete according to
recommendations in ACI 305R and as follows when hot-
weather conditions exist:
i. Cool ingredients before mixing to maintain
concrete temperature at time of placement
below 32 deg. C. Chilled mixing water or
chopped ice may be used to control
temperature, provided water equivalent of ice
is calculated to total amount of mixing water.
Using liquid nitrogen to cool concrete is
Contractor's option.
ii. Cover reinforcement steel with water-soaked
burlap so steel temperature will not exceed
ambient air temperature immediately before
embedding in concrete.
iii. Fog-spray forms, reinforcement steel, and / or
stabilized base just before placing concrete.
Keep aggregate base moisture uniform without
standing water, soft spots, or dry areas.
iv. Concreting shall not be permitted when the
rate of evaporation exceed 1.0 kg./sq.m./h. (ACI
305R "Hot Weather Concreting"). The rate of
evaporation can be estimated from Fig. 2.1.5 of
ACI 305R with the prevailing temperature,
relative humidity, and wind speed. The
evaporation rate can also be determined more
accurately by evaporating water from a cake
pan having an area of approximately 1 ft2
(0.093 sq.m.). The pan is filled with water and
the mass determined every 15 to 20 min to
determine .the evaporation rate, which is equal
to the loss of water mass from the pan. A
balance of at least 2500 g capacity is
satisfactory.
v. No concreting shall take place when the
ambient temperature exceeds 40 deg. C.
5.7.3.11 Concrete Finishing
1 General: Wetting of concrete surfaces during
screeding, initial floating, or finishing operations is
prohibited.
2 Float Finish: Begin the second floating operation
when bleed-water sheen has disappeared and the
concrete surface has stiffened sufficiently to permit
operations. Float surface with power-driven floats, or by
hand floating if area is small or inaccessible to power units.
Finish surfaces to true planes. Cut down high spots, and
fill low spots. Refloat surface immediately to uniform
granular texture.
5.7.3.12 Final Strike-Off, Consolidation and Finishing
1 Sequence: The sequence of operations shall be the
strike-off and consolidation, floating and removal of
laitance, straight edging, and final surface finish. The
addition of superficial water to the surface of the concrete
to assist in finishing operations generally will not be
permitted. If the application of water to the surface is
permitted, it shall be applied as a fog spray by means of
approved spray equipment.
2 Strike-Off of Concrete: Following the placing of the
concrete, it shall be struck off to conform to the cross
section shown on the plans and to an elevation such that
when the concrete is properly consolidated and finished,
the surface of the pavement shall be at the elevation
shown on the plans.
3 Finishing at Joints:
i. Concrete adjacent to joints shall be compacted
or firmly placed without voids or segregation
against the joint material; it shall be firmly
placed without voids or segregation under and
around all load-transfer devices, joint assembly
units, and other features designed to extend
into the pavement.
ii. Concrete adjacent to joints shall be
mechanically vibrated. After the concrete has
been placed and vibrated adjacent to the joints,
the finishing machine shall be operated in a
manner to avoid damage or misalignment of
joints.
iii. If uninterrupted operations of the finishing
machine, to, over, and beyond the joints, cause
segregation of concrete, damage to, or
misalignment of the joints, the finishing
machine shall be stopped when the screed is
approximately 200mm from the joint.
iv. Segregated concrete shall be removed from
the front of and off the joint, the screed shall be
lifted and set directly on top of the joint, and
the forward motion of the finishing machine
shall be resumed. Thereafter, the finishing
machine may be run over the joint without
lifting the screed, provided there is no
segregated concrete immediately between the
joint and the screed or on top of the joint.
4 Machine Finishing:
i. The concrete shall be spread as soon as it is
placed, and it shall be struck off and screeded
by an approved finishing machine. The
machine shall go over each area as many times
and at such intervals as necessary to give the
proper consolidation and to leave a surface of
uniform texture.
ii. Excessive operation over a given area shall be
avoided. When side forms are used, the tops
of the forms shall be kept clean by an effective
device attached to the machine, and the travel
♦ 5-55 ♦
copy 249
 of the machine on the forms shall be
maintained true without lift, wobbling, or other
variation tending to affect the precision finish.
During the first pass of the finishing machine, a
uniform ridge of concrete shall be maintained
ahead of the front screed for its entire length.
iii. When in operation, the screed shall be moved
forward with a combined longitudinal and
transverse shearing motion, always moving in
the direction in which the work is progressing,
and so manipulated that neither end is raised
from the side forms during the striking-off
process. If necessary, this shall be repeated
until the surface is of uniform texture, true to
grade and cross section, and free from porous
areas.
5 Hand Finishing: Hand finishing methods will not be
permitted, except under the following conditions:
i. In the event of breakdown of the mechanical
equipment, hand methods may be used to
finish the concrete already deposited on the
grade;
ii. In areas of narrow widths or of irregular
dimensions where operation of the mechanical
equipment is impractical.
Concrete, as soon as placed, shall be struck off and
screeded. An approved portable screed shall be used. A
second screed shall be provided for striking off the bottom
layer of concrete when reinforcement is used.
The screed for the surface shall be at least 600 mm longer
than the maximum width of the slab to be struck off. It
shall be of approved design, sufficiently rigid to retain its
shape, and shall be constructed either of metal or of other
suitable material covered with metal. Consolidation shall
be attained by the use of a suitable vibrator.
6 Floating: After the concrete has been struck off and
consolidated, it shall be further smoothed, trued, and
consolidated by means of a longitudinal float, using
approved hand or machine methods.
7 Straight-Edge Testing and Surface Correction:
i. After the pavement has been struck off and
consolidated and while the concrete is still
plastic, it shall be tested for trueness with a
4.8m straightedge. Furnish and use an
accurate 4.8m straightedge swung from
handles 900 mm longer than one-half the width
of the slab.
ii. The straightedge shall be held in contact with
the surface in successive positions parallel to
the centerline and the whole area gone over
from one side of the slab to the other, as
necessary. Advancing shall be in successive
stages of not more than one-half the length of
the straightedge. Any excess water and
laitance shall be removed from the surface of
the pavement.
♦ 5-56 ♦
iii. Any depressions shall be immediately filled
with freshly mixed concrete, struck off,
consolidated, and refinished. High areas shall
be cut down and refinished.
iv. Special attention shall be given to assure that
the surface across joints meets the
requirements for smoothness. Straightedge
testing and surface corrections shall continue
until the entire surface is found to be free from
observable departures from the straightedge
and until the slab conforms to the required
grade and cross section.
v. The use of long-handled wood floats shall be
confined to a minimum; they may be used only
in emergencies and in areas not accessible to
finishing equipment.
5.7.3.13 Surface Texture
1 Brush or Broom Finish:
i. A brush or broom finish shall be formed on all
newly constructed concrete pavements when
the water sheen has practically disappeared,
using mechanical texturing equipment.
ii. The equipment shall operate transversely
across the pavement surface, providing
corrugations that are uniform in appearance
and approximately 2 mm in depth.
iii. The equipment must not tear or unduly
roughen the pavement surface during the
operation. Any imperfections resulting from
the texturing operation shall be corrected.
5.7.3.14 Skid Resistant Surfaces
1 Wire Combing: A skid resistant surface shall be
provided by wire combing in plastic concrete. The wire
combing technique shall use steel combs or tines of
various dimensions to form groove-like texture in the
plastic concrete pavement and shall provide grooves that
are approximately 3 mm by 3 mm spaced 13 mm center-
to-center.
5.7.3.15 Surface Test
1 As soon as the concrete has hardened sufficiently,
the pavement surface shall be tested with a 4.8 m
straightedge or other specified device. Areas in a slab
showing high spots of more than 6 mm but not exceeding
12 mm in 4.8 m shall be marked and immediately ground
down with an approved grinding machine to l within the
tolerance of 6 mm or less. Where the departure from
correct cross section exceeds 12 mm, the pavement shall
be removed and replaced when so directed by Engineer.
2 Any area or section so removed, shall not be less
than 3 m in length, nor less than the full width of the lane
involved. When it is necessary to remove and replace a
section of pavement, any remaining portion of the slab
adjacent to the joints that is less than 3 m in length shall
also be removed and replaced.
copy 249
5.7.3.16 Removing Forms
1 Unless otherwise specified, forms shall not be
removed from freshly placed concrete until it has set for at
least 12 hours, except where auxiliary forms are used
temporarily in widened areas. Forms shall be removed
carefully to avoid damage to the pavement. After the
forms have been removed, the sides of the slab shall be
cured. Major honeycombed areas shall be considered as
defective work and shall be removed and replaced. Any
area or section so removed shall not be less than 3 m in
length nor less than the full width of the lane involved.
When it is necessary to remove and replace a section of
pavement, any remaining portion of the slab adjacent to
the joints that is less than 3 m in length shall also be
removed and replaced.
5.7.3.17 Sealing Joints
1 The joints in the pavement shall be sealed as shown
on Drawings and as specified in Sub-Section 5.8.
5.7.3.18 Opening to Traffic
1 The Engineer shall decide when the pavement shall
be opened to traffic. The pavement will not be opened to
traffic until test specimens molded and cured in
accordance with ASTM C31 have attained the specified
flexural strength when tested in accordance with ASTM
C78, unless otherwise acceptable to Engineer.
5.7.3.19 Pavement Tolerance
1 Comply with tolerances of ACI 117 and as follows:
i. Level: Plus 6 mm, no minus.
ii. Thickness: Plus 9 mm, minus 6 mm.
iii. Surface: Gap below 3-m long, unleveled
straightedge not to exceed +6 mm.
iv. Lateral Alignment and Spacing of Tie Bars and
Dowels: +/-25 mm.
v. Vertical Alignment of Tie Bars and Dowels:
+/-6 mm.
vi. Alignment of Tie-Bar End Relative to Line
Perpendicular to Pavement Edge: +/-13 mm.
vii. Alignment of Dowel-Bar End Relative to Line
Perpendicular to Pavement Edge: Length of
dowel +/-6 mm per 300 mm.
viii. Joint Spacing: +/-75 mm.
ix. Contraction Joint Depth: Plus 6 mm, no minus.
x. Joint Width: Plus 3 mm, no minus.
2 Surface Roughness: The International Roughness
Index (IRI) for roads shall be complied with on all concrete
finished surfaces. The acceptable range of IRI test results
shall vary between 0 and 1.5 mm/m for highways and
primary roads and between 0 and 3.0 mm/m for secondary,
tertiary and other access roads. Adopt contact type test
instruments for test stretches not exceeding 400 m in
length and non-contact test instruments (optical or sonic)
for stretches exceeding 400 m in length. The Contractor
shall submit for the Engineer’s approval the appropriate
testing instrument(s) and test methodology for the surface
roughness test.
3 Tolerances. The following tolerances are applicable:
i. Lateral deviation from established alignment of
the pavement edge shall not exceed plus or
minus 30 mm in any lane.
ii. Vertical deviation from established grade shall
not exceed plus or minus 12 mm at any point.
iii. Surface smoothness deviations shall not
exceed 6 mm from a 4.8 m straightedge placed
in any direction, including placement along and
spanning any pavement joint or edge.
5.7.3.20 Pavement Marking
1 Do not apply pavement marking paint until layout,
colors and placement have been verified by the Engineer.
2 Allow concrete pavement to harden and gain
strength for 28 days and be dry before starting pavement
marking.
3 Sweep and clean surface to eliminate loose material
and dust.
5.7.3.21 Field Quality Control
1 Slump: Minimum one test at point of discharge for
each day's pour of concrete. Additional tests when
concrete consistency seems to have changed.
2 Concrete Temperature: Test hourly when air
temperature is 4 deg C and below, and when 27 deg C and
above, and each time a set of flexural test beams are
made.
3 Flexural Strength:
i. Flexural test beams shall be made for each
day's pour exceeding 4 cu.m, plus additional
sets for each 40 cu.m. over and above the first
20 cu.m. Each group of test beams shall be
molded from the same batch of concrete and
shall consist of a sufficient number of
specimens to provide two flexural strength
tests at each test age. The specimens shall be
made in accordance with ASTM C31. At the
start of paving operations and when the
aggregate source, aggregate characteristics, or
mix design is changed, additional groups of
test beams may be required until Engineer is
satisfied that the concrete mix complies with
the strength requirements of these
specifications. Test ages shall be 7 days and
28 days.
ii. The flexural strength of the concrete shall meet
the following requirements:
- The average of any 4 consecutive strength
tests, tested at the end of 28 days, shall be
equal to or greater than the specified
flexural strength;
♦ 5-57 ♦
copy 249
 - Not more than 20 percent of the beams
tested at the end of 28 days shall have a
flexural strength less than the specified
strength;
- No specimen shall have a flexural strength
less than 90% of the specified flexural
strength.
iii. Specimens, which are obviously defective,
shall not be considered in the determination of
the strength. When it appears that the test
specimens will fail to conform to the
requirements for strength, Engineer shall have
the right to order changes in the concrete mix
sufficient to increase the strength to meet the
requirements. When a satisfactory relationship
between 7-days and 28-day strengths has been
established and approved, the 7-day test
results may be used as an indication of the 28-
day strengths. However, the 7-day test results
will not replace the results of the 28-day tests if
the 28-day results fall below the requirements.
4 Testing Agency: Engage a qualified independent
testing and inspection agency to sample materials,
perform tests, and submit test reports during concrete
placement according to requirements specified in this
Clause.
5 Testing Services: Testing shall be performed
according to the following requirements:
i. Sampling Fresh Concrete: Representative
samples of fresh concrete shall be obtained
according to ASTM C 172, except modified for
slump to comply with ASTM C 94.
ii. Slump: ASTM C 143; one test at point of
placement for each flexural and/or
compressive-strength test, but not less than
one test for each day's pour of each type of
concrete. Additional tests will be required
when concrete consistency changes.
iii. Concrete Temperature: ASTM C 1064; one test
hourly when air temperature is 4 deg C and
below and when 27 deg C and above, and one
test for each set of flexural and/or compressive-
strength specimens.
iv. Compression Test Specimens: ASTM C 31/C
31M; one set of four standard cylinders for
each compressive-strength test, unless
otherwise indicated. Cylinders shall be molded
and stored for laboratory-cured test specimens
unless field-cured test specimens are required.
v. Compressive-Strength Tests: ASTM C 39; one
set for each day's pour of each concrete class
exceeding 4 cu.m., but less than 19 cu.m., plus
one set for each additional 38 cu.m. One
specimen shall be tested at 7 days and two
specimens at 28 days; one specimen shall be
retained in reserve for later testing if required.
♦ 5-58 ♦
vi. When frequency of testing will provide fewer
than five compressive-strength tests for a given
class of concrete, testing shall be conducted
from at least five randomly selected batches or
from each batch if fewer than five are used.
vii. When strength of field-cured cylinders is less
than 85 percent of companion laboratory-cured
cylinders, current operations shall be evaluated
and corrective procedures shall be provided for
protecting and curing in-place concrete.
viii. Strength level of concrete will be considered
satisfactory if averages of sets of three
consecutive compressive-strength test results
equal or exceed specified compressive strength
and no individual compressive-strength test
result falls below specified compressive
strength by more than 3.4 MPa.
6 Test results shall be reported in writing to Engineer,
concrete manufacturer, and Contractor within 24 hours of
testing. Reports of compressive-strength tests shall
contain Project identification name and number, date of
concrete placement, name of concrete testing agency,
concrete type and class, location of concrete batch in
pavement, design compressive strength at 28 days,
concrete mix proportions and materials, compressive
breaking strength, and type of break for both 7- and 28-
day tests.
7 Nondestructive Testing: Impact hammer, sonoscope,
or other nondestructive device may be permitted by
Engineer but will not be used as the sole basis for
approval or rejection.
8 Additional Tests: Testing agency shall make
additional tests of the concrete when test results indicate
slump, air entrainment, concrete strengths, or other
requirements have not been met, as directed by Engineer.
Testing agency may conduct tests to determine adequacy
of concrete by cored cylinders complying with ASTM C 42,
or by other methods as directed.
5.7.3.22 Repairs and Protection
1 Remove and replace concrete pavement that is
broken, damaged, or defective, or does not meet
requirements in the Specification
2 Drill test cores where directed by Engineer when
necessary to determine magnitude of cracks or defective
areas. Fill core holes in satisfactory pavement areas with
Portland cement concrete bonded to pavement with epoxy
adhesive.
3 Protect concrete from damage. Exclude traffic from
pavement for at least 14 days after placement. When
construction traffic is permitted, maintain pavement as
clean as possible by removing surface stains and spillage
of materials as they occur.
4 Maintain concrete pavement free from stains,
discoloration, dirt, and other foreign material. Sweep
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concrete pavement not more than two days before date the joint shall be removed and replaced at the Contractor's
scheduled for Substantial Completion inspections. expense.

5.7.3.23 Determination of Concrete Thickness

5.7.4 Method of Measurement
1 Thickness of concrete pavement shall be determined
1 Unreinforced concrete pavement shall be measured
by average caliper measurement of cores taken from in cubic meters computed as the paved area multiplied by
sections of the pavement as stated in Item 2 below,
the executed slab thickness as approved by the Engineer.
rounded upwards taken to the nearest mm.
2 Reinforced concrete pavement shall be measured in
2 Pavement sections shall consist of each 300 lin.m.
cubic meters of the paved area multiplied by the executed
length in each paver lane. The last section in each lane
slab thickness (as approved by the Engineer) and shall
shall be 300 m plus the fractional part of 300 m remaining. include the same items detailed in Item 1 of Clause 5.7.4
Other areas such as intersections, entrances, ramps, etc
above plus the reinforcement steel material furnished,
shall be measured as one section each and the thickness
spliced, jointed and placed all as shown on the
of each shall be determined separately. Small irregular Contractor’s shop drawings that are approved by the
unit areas may be included as part of another section,
Engineer.
3 One core shall be taken from each section by the
3 The rates in the Bill of Quantities shall be deemed to
Contractor at approved locations and in the presence of
include furnishing of all associated concrete and joint
the Engineer. When the measurement of the core from component materials, preparation of bases, concrete
any pavement section is not deficient by more than 5 mm
mixing, placing, compacting, finishing and curing, as well
from the specified thickness, the core will be deemed to be
as all joint sawing, cutting and cleaning operations,
of the specified thickness as shown on the Drawings. drilling and installing dowels and deformed tie bars and
4 When the measurement of the core from any other joint accessories, and all tests, all as detailed on
pavement section is deficient by more than 5 mm but not Drawings and in the Specifications.
more than 20 mm, 2 additional cores spaced at not less
than 100 mm shall be taken and used together with the 5.7.5 Basis of Payment
first core to determine the average thickness of such
section. 1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
5 When the measurement of the core from any
unit rates for the various items in the Bill of Quantities,
pavement section is less than the specified thickness by
which rate shall be full compensation for supplying
more than 20 mm, the average thickness of such section
materials, transporting and placing, for labor, equipment,
shall be determined by taking additional cores at not less
tools and other items necessary for the proper completion
than 5 m intervals parallel to the centerline in each
of the work.
direction from the affected location until, in each direction,
a core is taken which is not deficient by more than 20 mm.
Exploratory cores for deficient thickness will not be used
5.7.6 Items in the Bill of Quantities
in average thickness determinations. i. Unreinforced Cement Concrete
6 Where the average thickness of concrete pavement is Pavement (cu.m.)
deficient by more than 5 mm but not more than 20 mm ii. Reinforced Cement Concrete
adjustments shall be made in the area measurements as Pavement (cu.m.)
shown in Table 5.7.3.1.

Deficiency in Thickness as Proportion of Area 5.8 Joint Sealers for Concrete

Determined by Cores (mm) Measured for Payment Pavement
0.0 to 5.0 100%
5.1 to 10.0 90% 5.8.1 Description
10.1 to 15.0 75%
1 This Sub-section describes joint sealers for concrete
15.1 to 20.0 50%
pavement as shown on Drawings.
> 20.0 0%
Table 5.7.3.1: Concrete Thickness Deficiency 5.8.2 Materials
7 When the pavement is more than 20 mm deficient in 5.8.2.1 Materials, General
thickness, the Contractor shall remove such deficient areas
and replace them with concrete pavement of the specified 1 Compatibility: Provide joint sealers, joint fillers and
quality and thickness, all at his own expense. other related materials that are compatible with one
another and with joint substrates under conditions of
8 When the limits of a deficient area to be removed
service and application, as demonstrated by sealant
and replaced are within 3 m of an expansion, contraction
manufacturer based on testing and field experience.
or construction joint, the entire concrete pavement up to

♦ 5-59 ♦
copy 249
5.8.2.2 Elastomeric Hot-Poured Joint Sealants
1 ASTM D 3569 - Joint Sealants, Hot-Poured,
Elastomeric, Jet-Fuel-Resistant type, for Portland Cement
Concrete Pavements.
5.8.2.3 Joint Sealant Backing
1 General: Provide sealant backings of material and
type which are non-staining; are compatible with joint
substrates, sealants, primers and other joint fillers; and are
approved for applications indicated by sealant
manufacturer based on field experience and laboratory
testing.
2 Plastic Foam Joint Fillers: Preformed, compressible,
resilient, non-waxing, non-extruding strips of flexible, non-
gassing plastic foam of material indicated below;
nonabsorbent to water and gas; and of size, shape and
density to control sealant depth and otherwise contribute
to producing optimum sealant performance.
3 Bond-Breaker Tape: Polyethylene tape or other
plastic tape as recommended by sealant manufacturer for
preventing sealant from adhering to rigid, inflexible joint
filler materials or joint surfaces at back of joint where such
adhesion would result in sealant failure. Provide self-
adhesive tape where applicable.
5.8.2.4 Miscellaneous Materials
1 Primer: Provide type recommended by joint sealer
manufacturer where required for adhesion of sealant to
joint substrates indicated, as determined from
preconstruction joint sealer substrate tests and field tests.
2 Cleaners for Nonporous Surfaces: Provide non-
staining, chemical cleaners of type which are acceptable to
manufacturers of sealants and sealant backing materials,
which are not harmful to substrates and adjacent
nonporous materials, and which do not leave oily residues
or otherwise have a detrimental effect on sealant adhesion
or in-service performance.
3 Masking Tape: Provide non-staining, nonabsorbent
type compatible with joint sealants and to surfaces
adjacent to joints.
5.8.3 Construction Requirements
5.8.3.1 Examination
1 Examine joints for compliance with requirements for
joint configuration, installation tolerances and other
conditions affecting joint sealer performance. Do not
proceed with installation of joint sealers until
unsatisfactory conditions have been corrected.
5.8.3.2 Preparation
1 Surface Cleaning of Joints: Clean out joints
immediately before installing joint sealers to comply with
recommendations of joint sealer manufacturers and the
following requirements:
♦ 5-60 ♦
i. Remove all foreign material from joint
substrates which could interfere with adhesion
of joint sealer, including dust; paints, except for
permanent, protective coatings tested and
approved for sealant adhesion and
compatibility by sealant manufacturer; old joint
sealers; oil; grease; waterproofing; water
repellants; water and surface dirt.
ii. Remove laitance and form release agents from
concrete.
2 Joint Priming: Prime joint substrates where
indicated or where recommended by joint sealer
manufacturer based on preconstruction joint sealer-
substrate tests or prior experience. Apply primer to
comply with joint sealer manufacturer's recommendations.
Confine primers to areas of joint sealer bond, do not allow
spillage or migration onto adjoining surfaces.
3 Masking Tape: Use masking tape where required to
prevent contact of sealant with adjoining surfaces which
otherwise would be permanently stained or damaged by
such contact or by cleaning methods required to remove
sealant smears. Remove tape immediately after tooling
without disturbing joint seal.
5.8.3.3 Installation of Joint Sealers
1 General: Comply with joint sealer manufacturers'
printed installation instructions applicable to products and
applications indicated, except where more stringent
requirements apply.
2 Hot poured Sealants:
i. The joint sealant shall be applied solid,
uniformly from bottom to top and shall be
filled without formation of entrapped air or
voids. A backing material shall be placed as
shown on the plans and shall be non-adhesive
to the concrete or the sealant material. The
heating kettle shall be an indirect heating type,
constructed as a double boiler. A positive
temperature control and mechanical agitation
shall be provided. The sealant shall not be
heated to more than 11°C below the safe
heating temperature. The safe heating
temperature can be obtained from the
manufacturer's shipping container. A direct
connecting pressure type extruding device with
nozzles shaped for insertion into the joint shall
be provided. Any sealant spilled on the surface
of the pavement shall be removed immediately.
ii. Backup materials and bond breakers shall be
compatible with the sealant, shall not adhere to
the sealant, shall be compressible without
extruding the sealant, and shall recover to
maintain contact with the joint faces when the
joint is open.
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5.8.3.4 Cleaning
1 Clean off excess sealants or sealant smears adjacent
to joints as work progresses by methods and with
cleaning materials approved by manufacturers of joint
sealers and of products in which joints occur.
5.8.3.5 Protection
1 Protect joint sealers during and after curing period
from contact with contaminating substances or from
damage resulting from construction operations or other
causes so that they are without deterioration or damage at
time of Substantial Completion. If, despite such protection,
damage or deterioration occurs, cut out and remove
damaged or deteriorated joint sealers immediately and
reseal joints with new materials to produce joint sealer
installations with repaired areas indistinguishable from
original work.
5.8.4 Method of Measurement, Basis of
Payment and Bill of Quantities
1 No separate measurement is made for joint sealers
and no items are included in the Bill of Quantities. The
work is considered as subsidiary to the concrete pavement
and its cost is deemed to be included under payment for
concrete pavement items as measured under Clauses 5.7.4,
5.7.5 and 5.7.6.
5.9 Reinforced Concrete Box Culverts
and Headwalls, Wingwalls, Cut-
Off Walls and Aprons
5.9.1 Description
1 This Sub-section describes the requirements for
construction of reinforced concrete box culverts, in-situ or
precast, and headwalls, wing walls, cut-off walls and
aprons for box and pipe culverts, including earthworks,
structural concrete and all other ancillary items necessary
for the completion of the structures to the lines, grades
and dimensions as shown on the Drawings. These
requirements are additional to the requirements of
preceding Sections of the Specification.
5.9.2 Materials
1 Materials shall conform to the relevant requirements
of the following Sub-sections of the Specification:
- Concrete Sub-section 5.1
“Concrete Materials and Mixes”
- Reinforcing Steel Sub-section 5.2
“Reinforcing Steel”
2 Concrete classes shall be those prescribed on the
relevant Drawings.
3 Backfill shall be as specified in Section 2 “Earthwork”.
5.9.3 Construction Requirements
1 Construction work shall comply with the relevant
requirements of the following sections:
Section 2 Earthwork
Sub-section 5.2 Reinforcing Steel
Sub-section 5.3 Reinforced Concrete Structures.
2 Box culverts, headwalls, wing walls, cut-off walls and
aprons shall be to the lines and levels shown on the
Drawings. Unless otherwise shown, culverts shall have a
constant fall of 1:100 along their centerline.
3 Box culverts shall be constructed in sections such
that expansion joints are located at intervals which shall
be so spaced as to prevent the box culvert from behaving
as a long beam unless such structural action has been
allowed for in the design. Unless shown on the Drawings
or directed by the Engineer, the spacing of expansion
joints shall be no greater than 35 meters.
4 Unless otherwise indicated, expansion joints shall
also be used at the culvert ends where the culvert meets
the wing walls and apron slabs.
5 Where box culverts are located in road embankments,
the embankments shall first be constructed in accordance
with Paragraph 2.5.3.4 "Embankment Construction". The
compacted embankments shall then be excavated in
trenches for the culverts. This requirement may be
dispensed with by a written permission from the Engineer
to so do. Where a culvert is to be constructed under a
high embankment, this requirement may be relaxed or
dispensed with provided the fill is designed to arch over
the culvert or the culvert is specially designed for an
increased surcharge load from the embankment.
Embankments may be constructed to within 1 m above
the culvert then construction carried out as above.
6 For culverts located below firm ground, the
excavation shall be carried out in trenches in accordance
with Section 2 “Earthwork”.
7 Backfilling and compaction shall be carried out in
layers not exceeding 150 mm compacted thickness and
the difference in the levels of backfill on either side of the
culvert shall at no time exceed 500 mm. Start backfilling
after having attained 75 percent of the culvert 28-day
concrete strength.
8 All concreting shall be carried out in dry conditions.
9 Unless otherwise shown on the Drawings or
instructed by the Engineer, the base slab of the box culvert
for its entire length shall first be completed before
proceeding with the walls and roof slab. The construction
joints in the walls shall be located at not less than 100 mm
above the top of the base slab. Unless shown otherwise
on the Drawings or directed by the Engineer, the walls and
roof slabs shall be concreted in one pour between
expansion joints.
10 Unless otherwise shown on the Drawings or
instructed by the Engineer, the cut-off wall shall be cast
against earth.
♦ 5-61 ♦
copy 249
11 Concrete placing, forms, finishing, curing and ASTM D 173 Specification for Bitumen-Saturated
jointing shall be done in accordance with Section 5.3 Cotton Fabrics Used in Roofing and
“Reinforced Concrete Structures”. Waterproofing (AASHTO M 117)
ASTM D 449 Specifications for Asphalt Used in
5.9.4 Method of Measurement Dampproofing, and Waterproofing
(AASHTO M 115)
1 The work shall be measured according to the
dimensions shown on the Drawings in accordance with ASTM D 450 Specification for Coal-Tar Pitch Used in
the rules for measurement stated in Sub-section 5.1 Roofing, Dampproofing, and
‘Concrete Materials and Mixes’ and Sub-section Waterproofing (AASHTO M 118)
5.2 ’Reinforcing Steel’. ASTM D 490 Specifications for Road Tar (AASHTO M
2 Where the Contractor uses precast units as an 52)
alternative, any extra material and quantity necessary
shall not be measured. 5.10.2 Materials
3 All other work such as excavation for the cut-off walls
5.10.2.1 Asphalt
formwork, construction and expansion joints and the like,
shall be included as subsidiary work whose costs are 1 Waterproofing asphalt shall conform to AASHTO M
deemed to be included in the rates and prices for concrete 115 (ASTM D 449); Type I for use below ground, and Type
and reinforcement. II for use above ground.
2 Primer for use with asphalt in waterproofing shall
5.9.5 Basis of Payment conform to AASHTO M 116 (ASTM D 41).
1 The amount of completed and accepted work, 5.10.2.2 Bitumen
measured as provided for above, shall be paid for at the
unit rates in the Bill of Quantities, which rates shall be full 1 Waterproofing bitumen shall conform to AASHTO M
compensation for supplying, curing, finishing concrete 118 (ASTM D 450); Type II unless otherwise specified.
and cutting, shaping and fixing reinforcing steel and for 2 Primer for use with coal-tar bitumen in dampproofing
labor, materials, equipment, tools and other items and waterproofing shall conform to AASHTO M 121
necessary for the proper completion of the works. (ASTM D 43). It shall be a distillate of coal-gas tar or coke-
oven tar.
5.9.6 Items in Bill of Quantities
5.10.2.3 Waterproofing Fabric
1 Reinforced concrete box culverts, head walls, wing
walls and cut-off walls are separately identified in the Bill 1 Waterproofing fabric shall conform to AASHTO M
of Quantities and the relevant items as stated in Sub- 117 (ASTM D 173).
sections 5.1 and 5.2 are included.
5.10.2.4 Self-Adhesive Polyethylene Sheet

5.10 Waterproofing for Structures 1 Flexible, preformed waterproof membrane

comprising strong, high-density polyethylene film with
5.10.1 Description self-adhesive rubber/bitumen compound, and having the
following minimum properties:
5.10.1.1 Scope - Total thickness : 1.5 mm
2
1 This Sub-section describes waterproofing membrane, - Weight : 1.6 kg/m
sand dampproofing courses to external concrete surfaces 2
- Tensile strength : 42 N/mm
in contact with earth and epoxy coating to internal
- Elongation : 210% long.; 160% trans.
surfaces of concrete walls, slabs, and beds, all as shown
on the Drawings or as directed by the Engineer. - Tear resistance : 340 N/mm long.; 310
N/mm trans.
5.10.1.2 References - Puncture resistance : 220 N 65 mm
1 American Society for Testing and Materials (ASTM):
5.10.2.5 Tar for Absorptive Treatment
ASTM D 41 Specification for Asphalt Primer Used in
Roofing, Dampproofing, and 1 Tar for absorptive treatment shall be a liquid water-
Waterproofing (AASHTO M 116) gas tar that conforms to the following requirements:

ASTM D 43 Specification for Coat Tar Primer Used - Specific gravity, 25ºC 1.030 to 1.100
in Roofing, Dampproofing, and - Specific viscosity at 40ºC (Engler),
Waterproofing (AASHTO M 121) not more than 3.0
- Total distillate, percent by
weight, to 300ºC, not more than 50.0

♦ 5-62 ♦
copy 249
 - Bitumen (soluble in carbon disulfide)
not less than, percent 98.0
- Water, not more than, percent 3.0
5.10.2.6 Tar Seal Coat
1 Tar seal coat shall conform to AASHTO M 52, Grade
RTCB-5 (ASTM D 490).
5.10.2.7 Proprietary Waterproofing Systems
1 Proprietary waterproofing systems shall be
bituminous membranes reinforced with layers of suitable
reinforcement, bituminous coated polythene sheet,
plasticized polyvinyl chloride sheet, other approved
membranes or applications of resinous reinforced
coatings. The type to be used shall be as indicated on the
Drawings and shall be chosen according to its location
and serviceability. The specific system shall be approved
after site trials, should the Engineer decide these to be
necessary.
5.10.2.8 Epoxy Coating System
1 An approved epoxy coating system shall be
furnished and applied to the internal concrete surfaces of
culverts and open channels as shown on the Drawings or
as directed by the Engineer. The thickness of the epoxy
coating shall be at least 400 microns in accordance with
the manufacturer's recommendations.
5.10.3 Construction Requirements
5.10.3.1 Surface Preparation
1 Waterproofing:
i. All concrete surfaces to be waterproofed shall
be reasonably smooth and free from
projections or holes which might cause
puncture of the membrane. The surface shall
be dry, so as to prevent the formation of steam
when the hot asphalt or tar is applied, and,
immediately before the application of the
waterproofing, the surface shall be thoroughly
cleaned of dust, projecting tying wire and loose
material.
ii. No waterproofing shall be done in wet weather,
nor when the temperature is below 4 degrees C,
without special authorization from the Engineer.
Should the surface of the concrete become
temporarily damp, it shall be covered with a 50
mm layer of hot sand, which shall be allowed
to remain in place from 1 to 2 hours, or long
enough to produce a warm and surface-dried
condition, after which the sand shall be swept
back, uncovering sufficient surface for
beginning work, and the operation repeated as
the work progresses.
2 Dampproofing: The surface to which the
dampproofing coating shall be applied shall be cleaned of
all loose and foreign material and dirt and shall be dry.
When necessary the Engineer may require the surface to
be scrubbed with water and a stiff brush, after which the
surface shall be allowed to dry before application of the
primer.
5.10.3.2 Inspection, Delivery and Storage
1 All waterproofing materials shall be tested before
shipment. Unless otherwise ordered by the Engineer, they
shall be tested at the place of manufacture, and, when so
tested, a copy of the test results shall be sent to the
Engineer by the chemist or inspection bureau which has
been designated to make the tests, and each package shall
have affixed to it a label, seal, or other mark of
identification, showing that it has been tested and found
acceptable, and identifying the package with the
laboratory tests.
2 Factory inspection is preferred, but in lieu thereof
and/or addition thereof, the Engineer may order that
representative samples, properly identified, be sent to him
for test prior to shipment of the materials. After delivery
of the materials, representative check samples shall be
taken which shall determine the acceptability of the
materials.
3 All materials shall be delivered to the work in original
containers, plainly marked with the manufacturer's brand
or label.
4 Waterproofing and dampproofing material shall be
stored in a dry, protected place. Rolls of waterproofing
fabric and membranes shall not be stored on end.
5.10.3.3 Asphalt and Bitumen Waterproofing Fabric
1 Asphalt shall be heated to a temperature between
150 degrees C and 175 degrees C and tar for hot
application shall be heated to a temperature between 93
degrees C and 120 degrees C with frequent stirring to
avoid local overheating. The heating kettles shall be
equipped with thermometers.
2 In all cases, the waterproofing shall begin at the low
point of the surface to be waterproofed, so that water will
run over and not against or along the laps.
3 The first strip of fabric shall be of half-width; the
second shall be full-width, lapped the full-width of the first
sheet; and the third and each succeeding strip shall be full-
width and lapped so that there will be two layers of fabric
at all points with laps not less than 50 mm wide. All end
laps shall be at least 300 mm.
4 Beginning at the low point of the surface to be
waterproofed, a coating of primer shall be applied and
allowed to dry before the first coat of asphalt is applied.
The waterproofing shall then be applied as follows.
5 Beginning at the low point of the surface to be
waterproofed, a section about 500 mm wide and the full
length of the surface shall be mopped with the hot asphalt
or tar. Immediately following the mopping, the first strip
of fabric, or half-width, shall be rolled and pressed into
place so as to eliminate all air bubbles and obtain close
conformity with the surface. This strip and an adjacent
♦ 5-63 ♦
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section of the surface of a width equal to slightly more
than half of the width of the fabric being used shall then
be mopped with hot asphalt or tar, and a full width of the
fabric shall be rolled into this, completely covering the first
strip, and pressed into place as before. This second strip
and an adjacent section of the concrete surface shall then
be mopped with hot asphalt or tar and the third strip of
fabric "shingled" on so as to lap the first strip not less than
50 mm. This process shall be continued until the entire
surface is covered, each strip of fabric lapping at least 50
mm over the last strip. The entire surface shall then be
given a final mopping of hot asphalt or tar.
6 The completed waterproofing shall be a firmly
bonded membrane composed of two layers of fabric and
three moppings of asphalt or tar, together with a coating
of primer. Under no circumstances shall one layer of
fabric touch another layer at any point or touch the surface,
as there must be at least three complete moppings of
asphalt or tar.
7 In all cases the mopping on concrete shall cover the
surface so that no gray spots appear, and on cloth it shall
be sufficiently heavy to completely conceal the weave. On
horizontal surfaces not less than 49 liters of asphalt or tar
shall be used for each 10 square meter of finished work,
and on vertical surfaces not less than 61 liters shall be
used for each 10 square meter. The work shall be so
regulated that, at the close of a day's work, all cloth that is
laid shall have received the final mopping of asphalt or tar.
Special care shall be taken at all laps to see that they are
thoroughly sealed down.
8 At the edges of the membrane and at any points
where it is punctured by such appurtenances as drains or
pipes, suitable provisions shall be made to prevent water
from getting between the waterproofing and the
waterproofed surface.
9 All flashing at curbs and against girders, spandrel
walls, etc., shall be done with separate sheets lapping the
main membrane not less than 300 mm. Flashing shall be
closely sealed either with a metal counter-flashing or by
embedding the upper edges of the flashing in a groove
poured full of joint filler.
10 Joints which are essentially open joints but which are
not designed to provide for expansion shall first be
caulked with oakum and lead wool and then filled with hot
joint filler.
11 Expansion joints, both horizontal and vertical, shall
be provided with sheet copper or lead in "U" or "V" form in
accordance with approved details. After the membrane
has been placed, the joint shall be filled with hot joint filler.
The membrane shall be carried continuously across all
expansion joints.
12 At the ends of the structure the membrane shall be
carried well down on the abutments and suitable
provision made for all movement.
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5.10.3.4 Proprietary Waterproofing Membranes
1 Proprietary waterproofing membranes shall be
installed strictly in accordance with the manufacturer's
instructions and shall be laid so that no air is trapped
between it and the concrete surface or between successive
layers of sheeting.
2 Unless otherwise specified, joints between sheets
shall be lapped with end laps of at least 150 mm and side
laps of at least 100 mm. The joints shall be arranged so
that, at no points, are there more than three thicknesses of
sheeting and, as far as possible so that water will drain
away from the exposed edge.
5.10.3.5 Damage Patching of Waterproofing Fabrics
1 Care shall be taken to prevent injury to the finished
fabric membrane by workmen or wheelbarrows, or by
throwing any material on it. Any damage which may
occur shall be repaired by patching. Patches shall extend
at least 300 mm beyond the outermost damaged portion
and the second ply shall extend at least 75 mm beyond the
first.
2 Proprietary waterproofing membranes shall be
repaired according to the manufacturer's specifications
and as directed by the Engineer.
5.10.3.6 Dampproofing
1 Concrete, brick, or other surfaces to be protected by
dampproofing shall be thoroughly cleaned before the
primer is applied. The surfaces shall then be brush or
spray painted with two or more coats (as indicated on the
Drawings) of tar or asphalt for absorptive treatment.
Below ground not less than two coats shall be applied,
using 0.56 L/square meter of surface. On the well-primed
surface one application of tar or asphalt seal coat shall be
applied by brush, using 0.45 L/square meter.
2 Care shall be taken to confine all paints to the areas
to be waterproofed and to prevent disfigurement of any
other parts of the structure by dripping or spreading of the
tar or asphalt.
5.10.3.7 Protection of Waterproofing and Dampproofing
1 Waterproofing membranes and dampproofing
courses shall be covered by a protective layer which,
unless otherwise specified or shown on the Drawings,
shall be a 50 mm coat of mortar composed of one part
Portland cement and two parts sand, reinforced midway
between its top and bottom surfaces with wire netting of
150 mm mesh and No. 12 gauge, or an approved
equivalent. The top surface shall be troweled to a smooth,
hard finish and, where required, true to grade.
2 The protection course shall follow the waterproofing
so closely that the latter will not be exposed without
protection for more than 24 hours.
3 Unless otherwise shown on the Drawings or directed
by the Engineer, vertical faces waterproofed or
dampproofed shall be protected by a porous concrete
block wall of not less than 225 mm thickness. If approved
copy 249
by the Engineer, a proprietary synthetic sheeting may be
used as the protective layer in lieu of the porous concrete
block wall.
5.10.3.8 Testing
1 Unless otherwise agreed by the Engineer in writing,
at least one site trial application of the waterproofing
system shall be carried out to determine the suitability of
the surface preparation, method of application and
effectiveness of the protective layer. The size of
membrane laid shall be not less than 2.0 meters wide and
5.0 meters long.
5.10.4 Method of Measurement
construction in corrosive or marine environments or other
severe exposure conditions as shown on the Drawings.
2 The coating system shall be used for the protection
of reinforced concrete structures against carbonation or
chloride induced corrosion. Work includes, but not
necessarily limited to coating for:
- Piers, columns, frames and exposed surfaces
of abutments and retaining walls.
- Deck soffit and sides and other exposed
surfaces of deck.
- Precast concrete girders and other precast
concrete elements.
- Concrete parapets.

1 Waterproofing membrane shall be measured by the 5.11.1.2 Submittals

square meter of each type, furnished, laid, completed and
accepted.
2 Tar or bituminous painting to surfaces permanently
in contact with backfilled material shall be measured by
the square meter of surface area so painted.
3 Epoxy coating to internal surfaces of concrete shall
be measured by the square meter of the surface area so
coated.
4 Protection to waterproofing membrane and
dampproofing course shall not be measured for direct
payment but shall be deemed to be included in the rates
for waterproofing and dampproofing.
5 Site trials of waterproofing membranes shall not be
measured for direct payment but shall be deemed to be
included in the rates for waterproofing.
1 Proprietary special coating system for the protection
of exposed concrete surfaces shall be proposed by the
Contractor and shall be subject to the Engineer's approval.
Submittal shall include the details of the coating type and
coating manufacturer and a list of projects, executed in
environmental conditions similar to those experienced in
the project site, in which the same protective coating
system was successfully used.
2 The Contractor's submittal shall be accompanied by
the manufacturer's detailed product specifications
together with application instructions, and guarantee that
the product is suitable for use at the operating
temperatures in the Sultanate.
3 Trial Panels as specified in Paragraph 5.11.1.4 (1)
shall be provided.

5.10.5 Basis of Payment 5.11.1.3 Performance Requirements

1 The amount of completed and accepted Work
measured as provided for above will be paid at the unit
rates as specified in the Bill of Quantities, which unit rates
shall be full compensation for furnishing all materials,
labor, equipment, tools, supplies and all other items
necessary for the completion of the Work.
1 The coating system shall provide in-depth protection
against carbonation and chloride penetration while
permitting water vapor transmission from the concrete.
2 Final color shall be selected by the Engineer.
5.11.1.4 Quality Assurance

5.10.6 Items in the Bill of Qquantities
i Tar or bituminous paint
(State type, number of coats)
ii Membrane waterproofing
(State type, thickness)
iii Epoxy coating to internal
surfaces of concrete
(State type, thickness)
5.11 Protective Coating for Concrete
5.11.1 Description
5.11.1.1 Scope
1 This Sub-section describes protective coating on
exposed surfaces of reinforced and prestressed concrete
1 Trial Panels:
i. Prior to applying the system, trial applications
sq.m. shall be carried out on trial panels made by the
Contractor to the specified finishes. The trial
sq.m. shall demonstrate the method proposed for
applying the system, coverage, coating
thickness, color and final appearance of the
coating. Representatives of the coating
manufacturer shall be present at the trials and
sq.m.
the surface preparation and application of the
coating shall be carried out under their
direction. The Contractor shall, at his own
expense, coat as many panels as required by
the Engineer until a trial panel has been
accepted by the Engineer as satisfactory. The
coated panel, when accepted, will form the
standard against which the corresponding
coating in the works shall be judged. No

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 application of the coating in the works shall be 5.11.2.3 Topcoat
undertaken until trials have been completed to
1 The topcoat shall be a pure aliphatic acrylic resin,
the Engineer’s satisfaction.
decorative, high performance water based, pigmenting
ii. Trial panels shall be tested for permeability in coating. It shall have resistance to water, carbon dioxide
accordance with DIN 1048 and AASHTO T 277 and other air-borne acids and have the ability to allow
as defined in Paragraph 5.1.3.15 as a check on passage of water vapor from within the structure. The
the effectiveness of the coating. Acceptance of topcoat shall have elastomeric and flexural capabilities.
the coating shall be based on compliance with The color shall be selected by the Engineer.
the following acceptance limits. Based on this
result, the Engineer may reject the work or 5.11.2.4 Specifications
require additional coating.
1 The material employed for the coating shall comply
- DIN 1048 results for coated surfaces: one with the following requirements:
fifth of the limits for the unprotected
- Wet film thickness 650 microns
surfaces defined in Paragraph 5.1.3.15.
- Dry film thickness 400 microns
- AASHTO T 277 test results for coated
surfaces: charge passed should be less - Carbon dioxide diffusion
than 500 coulombs. resistance R value at 325μ
greater than 161
5.11.1.5 Testing m
1 Testing of the coating shall conform to the following: - Water vapor transmission greater than 13
g/m2.day
- Carbon dioxide diffusion resistance (R
value) - Chloride ion diffusion 3.63 x 10-10
Taywood Engineering Laboratories cm2/sec
- Water vapor transmission - Reduction in chloride ion
Taywood Engineering Laboratories penetration minimum 94 %
at 28 days
- Chloride ion diffusion
- Tear resistance 7.3 kN/mm2
Taywood Engineering Laboratories
- Crack bridgeability 1.5 mm
- Reduction in chloride ion penetration
BS 1881: Part 124 - Adhesion minimum 1.0
N/mm2
- Tear resistance
ASTM D624 - Reduction in water absorption minimum 82
(measured against a control % at 28 days
- Crack bridgeability concrete sample) when tested at a
BRE method water-cement
2 Where test methods are not specified, the procedure ratio 0.5
for establishing compliance with the specification
requirements shall be agreed with the Engineer. 5.11.3 Construction Requirements
5.11.3.1 General
5.11.2 Materials
1 The Contractor shall adhere strictly to the
5.11.2.1 General
manufacturer's recommendations regarding the use,
1 The coating system shall consist of a penetrating, storage, application and safety rules in respect of the
reactive primer and an acrylic topcoat system to minimize approved materials.
ingress of acidic gases, chlorides and water. 2 During storage, mixing and application, the
Contractor shall comply with the health and safety and
5.11.2.2 Primer
environmental protection recommendations of the
1 The primer shall be a low viscosity silane-siloxane manufacturer and governing authorities.
acrylic blend dissolved in a penetrating organic carrier.
5.11.3.2 Inspection of Concrete
The primer shall have the capability to penetrate and
produce a chemically bound hydrophobic barrier to 1 The Contractor shall not proceed with the surface
prevent the passage of chloride and sulfate ions. The finish or making good of concrete surfaces until he has
primer shall also be film forming to condition and stabilize received the Engineer’s permission to do so and he shall
the substrate prior to the application of the topcoat. The not apply cement slurry or mortar or any other coating to
primer shall be applied in full accordance with the the concrete surfaces from which the formwork has been
manufacturer’s instructions. struck until the Engineer has inspected and approved the
concrete.

♦ 5-66 ♦
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5.11.3.3 Surface Preparation
1 Before application, all surfaces must be dry and free
from oil, grease, loose particles, decayed matter, moss or
algae growth and general curing compounds.
2 All such contamination and laitance must be
removed by the use of sweep sand blasting, high pressure
jetting or equivalent mechanical means.
3 Before proceeding to apply the protective coatings,
all surfaces which are not to be coated, but which may be
affected by the application of the coating shall be fully
masked.
4 Blow holes and areas of pitting shall be made good
with a one part modified cementitious material and
allowed to cure in accordance with the manufacturer’s
recommendations. In particular, the application shall be in
accordance with the manufacturer’s recommendations,
with respect to the maximum application thickness.
5.11.3.4 Approval Prior to Coating Application
1 The Engineer’s approval must be obtained prior to
applying the coating system in the works. Before giving
the approval, the Engineer will need to be satisfied as to
the following:
i. All construction work in the immediate vicinity of
the structure to be coated has been completed.
ii. The surface preparation of the structure has
been completed.
iii. The whole of the structure can be coated in a
continuous operation.
iv. Adequate measures have been taken to protect
the property of third parties, including vehicles,
from coating splatters.
v. The weather conditions accord with the coating
manufacturer’s directions for coating application.
5.11.3.5 Application
1 The exposed concrete surfaces shall be conditioned
by the application of the penetrating hydrophobic primer.
The primer shall be allowed to dry in accordance with the
manufacturer’s requirements.
2 The Contractor shall then apply two coats of the
pigmented topcoat in accordance with the manufacturer’s
instructions. The finished coating shall be pinhole free.
The color and finish shall be agreed with the Engineer.
3 The coating shall be applied by spray, roller or brush
to achieve a finish acceptable to the Engineer.
5.11.4 Method of Measurement, Basis of
Payment and Bill of Quantities
1 No separate measurement is made for protective
coating and no items are included in the Bill of Quantities
for direct payment. The work is considered as subsidiary
work, the cost of which will be deemed to be included in
the unit rates for the relevant BOQ Items for concrete
described and measured for payment under the provisions
of Section 5.1 “Concrete Materials and Mixes”.
5.12 Bridge Load Testing
5.12.1 Description
1 All bridges shall be load tested unless otherwise
agreed by the Engineer.
2 The aim of the testing is not to measure the actual
factor of safety of the bridge but intended to verify the
design and construction of the bridge under normal
loading conditions. Measurements are, accordingly, meant
to give an order of magnitude and fine precision is not
required.
3 The date of conducting the load testing shall be fixed
by the Engineer and shall be at least 90 days after all
concrete structural elements are constructed. Load testing
may be carried out before or after opening the bridge for
traffic.
4 If the bridge is open to traffic before being load
tested, the Engineer may impose restrictions on highway
loading over the bridge until testing is satisfactorily
completed, such as banning the passage of heavy traffic
loading of the order of the Oman Special Truck, or any
other measures.
5 Load testing comprises:
i. Application of load as described in Clause 5.12.2.
ii. Detailed visual inspection before, during and
after the testing as described in Clause 5.12.3.
iii. Measurement of deflections and other quantities
as described in Clause 5.12.4.
6 If the Works include a number of similar bridges
testing may be limited as follows:
i. At least one bridge shall be tested for all the
tests specified in this Sub-Section.
ii. The other bridges may be subject only to testing
by static loads.
iii. The latter test may be further simplified by
reducing the number of tests. It is
recommended, however, to measure the
deflection at, at least, one point per span.
7 Bridges are considered similar when their
superstructures have the same design, same material
specifications and are constructed by the same contractor.
8 If the results of the load testing are unfavorable, and
leave some doubt as to the ability of the bridge to
withstand the loads it is supposed to carry, more elaborate
testing shall be considered, including non-destructive full-
scale testing.
5.12.2 Load Application
5.12.2.1 Composition of Applied Load
1 The applied load shall consist of a number of loaded
trucks sufficient to satisfy the requirements of this Clause.
2 The loads shall be applied in two types of tests: by
static loads and moving loads.
3 The loads shall be restricted to the carriageways and
no load is applied on the sidewalks.
♦ 5-67 ♦
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4 The stipulations of this Clause are set as minimum
requirements. In particular cases, when there is doubt
about the quality of the bridge, the Engineer may impose
more severe loads.
5.12.2.2 Testing by Static Load
3 After the completion of testing, a detailed visual
inspection shall also be carried out to all accessible parts
of the bridge.
4 Visual inspections shall be complemented with
photographs.

1 The loaded trucks shall be positioned on the 5.12.4 Measurements

carriageways and grouped together in the longitudinal
and transverse directions such that the straining actions
they develop are between 67 and 75 percent of the
maximum straining actions developed by all unfactored
loading cases.
2 The straining actions considered do not include any
load factor magnification.
3 The test starts by loading the bearings before
applying any loads on the spans in order to activate
immediately the bearing deformation, and then the
measured deflections will be significant.
4 Bridges with simply supported spans shall have the
loads applied independently on every span.
5 Bridges with continuous spans shall have the loads
applied independently on every span, then on every two
adjacent spans, with no loads on the others, to obtain the
maximum hogging (negative) bending moment over the
support. The latter loading shall be repeated for every
intermediate support.
6 The loads shall be applied gradually, one truck at a
time. After each load increment, there will be a
consolidation period of one hour, or as instructed by the
Engineer, during which no load is applied. Measurements
shall be recorded at the beginning and end of the loading
increment period and of the consolidation period.
7 Removal of the load shall also be done by equal
decrements with a consolidation period of one hour, or as
instructed by the Engineer. Measurements shall be
recorded at the beginning and end of the loading
decrement period and of the consolidation period.
5.12.2.3 Testing by Moving Load
1 Out of the loaded trucks used for static loading of the
bridge, a number shall be selected equal to the number of
traffic lanes. The selection shall consider those with the
heaviest axle loads. The trucks shall travel in one direction
along the whole length of the bridge at the largest
possible speed with due consideration of safety measures.
2 Measurements shall be recorded during passage of
the moving load.
1 As a minimum the deflections of each span and the
deformation of the bearings shall be measured.
2 Measurement of the deflections will be carried out by
topographic equipment or by deflectometers installed on
scaffoldings independent of the structure as instructed by
the Engineer.
3 If specified or instructed by the Engineer, additional
measurements may be requested such as the strains in
the steel reinforcement and/or concrete surface.
4 Digital recording of measurements by electronic
means is encouraged for important structures, particularly
for strain measurements and moving load testing. It may
be imposed by instruction of the Engineer.
5 The ambient temperature shall be recorded with
every measurement made.
6 A report shall be prepared by the Contractor
including the testing procedure, measurements,
interpretation and conclusion.
5.12.5 Method of Measurement
1 Load testing of the bridge shall be measured by the
number of bridges tested as instructed by the Engineer,
inclusive of all static load cases and moving load testing
and inclusive of the provision and operation of the loaded
trucks, measuring and recording equipment of any type
and their calibration, platforms and scaffoldings for visual
inspection and of accepted testing report.
5.12.6 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above shall be paid at the unit
rates in the Bill of Quantities. These rates shall be full
compensation for the provision of labor, materials,
equipment, tools and other items necessary for proper
completion of the Work.
5.12.7 Items in the Bill of Quantities
i Bridge loading test nr.

5.12.3 Visual Inspection

1 All parts of the structure that can be accessed by
platforms, scaffoldings or other means shall be visually
inspected jointly by the Engineer and the Contractor
before start of testing.
2 During static load testing, visual inspection shall also
be carried out in the consolidation periods at reasonable
at intervals.

♦ 5-68 ♦
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Ref. Title Page No.
6.1 Description 6-1
6.1.1 Summary 6-1
6.1.2 Definitions 6-1
6.1.3 Submittals 6-1
6.1.4 Quality Assurance 6-1
6.1.5 Delivery, Storage, and Handling 6-2
6.1.6 Coordination 6-2

6.2 Materials 6-2

6.2.1 Structural-Steel Materials and Steel
Railings 6-2
6.2.2 Bolts, Connectors, and Anchors 6-2
6.2.3 Grout 6-3
6.2.4 Fabrication 6-3
6.2.5 Shop Connections 6-4
6.2.6 Source Quality Control 6-4

6.3 Construction Requirements 6-4

6.3.1 Examination 6-4
6.3.2 Preparation 6-5
6.3.3 Erection 6-5
6.3.4 Orthotropic-Deck Super Structure 6-5
6.3.5 Field Connections 6-6
6.3.6 Field Quality Control 6-6

6.4 Method of Measurement 6-6

6.5 Basis of Payments 6-7
6.6 Items in the Bill of Quantities 6-7

copy 249
copy 249
6.1 Description
6.1.1 Summary
1 This Section describes:
i. Structural steel.
ii. Grout.
iii. Steel pipe and tube railings.
6.1.2 Definitions
1 Structural Steel: Elements of structural-steel frame,
as classified by AISC 303, ‘Code of Standard Practice for
Steel Buildings and Bridges.’
2 Seismic-Load-Resisting System (SLRS): Elements of
structural-steel frame shown on the Drawings, designated
as ‘SLRS’ or along grid lines designated as "SLRS" on
Drawings, including columns, beams, and braces and their
connections.
3 Heavy Sections: Rolled and built-up sections as
follows:
i. Shapes included in ASTM A 6/A 6M with
flanges thicker than 38 mm.
ii. Welded built-up members with plates thicker
than 50 mm.
iii. Column base plates thicker than 50 mm.
4 Protected Zone: Structural members or portions of
structural members indicated as ‘Protected Zone’ on
Drawings. Connections of structural and nonstructural
elements to protected zones are limited.
5 Demand Critical Welds: Those welds, the failure of
which would result in significant degradation of the
strength and stiffness of the Seismic-Load-Resisting
System and which are indicated as ‘Demand Critical’ or
‘Seismic Critical’ on Drawings.
6.1.3 Submittals
1 Product Data: Submit data for each type of product
specified or shown on the Drawings or as directed by the
Engineer.
2 LEED (Leadership in Energy and Environmental
Design) :Submit the following as directed by the Engineer
i. Product data for Credit MR 4.1
Credit MR 4.2. For products having recycled
content, include documentation indicating
percentages by weight of post-consumer and
pre-consumer recycled content and a statement
indicating costs for each product having recycled
content.
3 Shop Drawings: Submit shop drawings as required
by the specification and directed by the Engineer to show
fabrication of structural-steel components.
i. Include details of cuts, connections, splices,
camber, holes, and other pertinent data.
ii. Include embedment drawings.
iii. Indicate welds by standard AWS symbols,
distinguishing between shop and field welds,
and show size, length, and type of each weld.
Show backing bars that are to be removed and
supplemental fillet welds where backing bars are
to remain.
iv. Indicate type, size, and length of bolts,
distinguishing between shop and field bolts.
Identify pre-tensioned and slip-critical high-
strength bolted connections.
v. Identify members and connections of the
seismic-load-resisting system.
vi. Indicate locations and dimensions of protected
zones.
vii. Identify demand critical welds.
4 Welding Procedure Specifications (WPSs) and
Procedure Qualification Records (PQRs): Provide details
according to AWS D1.1/D1.1M, ‘Structural Welding Code -
Steel’ for each welded joint qualified by testing, including
the following:
i. Power source (constant current or constant
voltage).
ii. Electrode manufacturer and trade name, for
demand critical welds.
5 Qualification Data: Submit details for qualified
Installer, fabricator, professional engineer, and testing
agency.
6 Welding certificates.
7 Paint Compatibility Certificates: Submit certificates
from manufacturers of topcoats applied over shop primers,
certifying that shop primers are compatible with topcoats.
8 Mill test reports for structural steel, including
chemical and physical properties.
9 Product Test Reports: Submit reports for the
following:
i. Bolts, nuts, and washers including mechanical
properties and chemical analysis.
ii. Direct-tension indicators.
iii. Tension-control, high-strength bolt-nut-washer
assemblies.
iv. Shear stud connectors.
v. Shop primers.
vi. Non-shrink grout.
10 Source quality-control reports.
and
6.1.4 Quality Assurance
1 Fabricator Qualifications: A qualified fabricator who
participates in the AISC Quality Certification Program and
is designated an AISC-Certified Plant or approved by the
Engineer.
2 Installer Qualifications: A qualified installer who
participates in the AISC Quality Certification Program and
is designated an AISC-Certified Erector, Category ACSE or
approved by the Engineer.
3 Shop-Painting Applicators: Qualified according to
AISC's Sophisticated Paint Endorsement P1 or SSPC-QP 3,
"Standard Procedure for Evaluating Qualifications of Shop
Painting Applicators’ or approved by the Engineer.
♦ 6-1 ♦
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4 Welding Qualifications: Welding procedures and 6.2 Materials
personnel shall be qualified according to
AWS D1.1/D1.1M, ‘Structural Welding Code - Steel". 6.2.1 Structural-Steel Materials and Steel
i. Welders and welding operators performing work Railings
on bottom-flange, demand-critical welds shall 1 Recycled Content of Steel Products: Provide
pass the supplemental welder qualification products with an average recycled content so that the
testing, as required by AWS D1.8 or shall be post-consumer recycled content plus one-half of pre-
approved by the Client Authority. FCAW-S and consumer recycled content is not less than 25 percent.
FCAW-G shall be considered separate processes
2 W-Shapes shall comply, as appropriate, with
for welding personnel qualification.
ASTM A 992/A 992, ASTM A 572/A 572M Grade 5
5 Comply with applicable provisions of the following ASTM A 529/A 529M Grade 50, and ASTM A 913/
specifications and documents: A 913M, Grade 50.
i. AISC 303. 3 Channels, angles , M shapes and , S-shapes shall
ii. AISC 341 and AISC 341s1. comply, as appropriate, with ASTM A 36/A 36M,
iii. AISC 360. ASTM A 572/A 572M Grade 50, ASTM A 529/A 529M
iv. RCSC's "Specification for Structural Joints Using Grade 50 and ASTM A 913/A 913M Grade 50.
ASTM A 325 or A 490 Bolts."
4 Plate and bar shall comply, as appropriate with
6 Pre-installation Conference: Conduct conference at ASTM A 36/A 36M, ASTM A 572/A 572M Grade 50, and
Site. ASTM A 529/A 529M Grade 50.
7 Source Limitations: Obtain each type of railing or 5 Corrosion-resisting low-alloy structural-steel shapes,
similar product from single source, from single plates, and bars shall comply with ASTM A 588/A 588M,
manufacturer. Grade 50.
6 Cold-formed hollow structural sections shall comply
6.1.5 Delivery, Storage, and Handling
with ASTM A 500, Grade B or C, structural tubing.
1 Store materials to permit easy access for inspection
7 Corrosion-resisting cold-formed hollow structural
and identification. Keep steel members off ground and
sections shall comply with ASTM A 847/A 847M,
spaced by using pallets, dunnage, or other supports and
structural tubing.
spacers. Protect steel members and packaged materials
from corrosion and deterioration. 8 Steel Pipe shall comply with ASTM A 53/A 53M,
i. Do not store materials on a structure in a manner Type E or S, Grade B.
that might cause distortion, damage, or overload i. Weight Class: Standard.
to members or supporting structures. Repair or ii. Finish: Black except where indicated to be
replace damaged materials or structures as galvanized.
directed. 9 Steel castings shall comply with
2 Store fasteners in a protected place in sealed ASTM A 216/A 216M, Grade WCB with supplementary
containers with manufacturer's labels intact. requirement S11.
i. Fasteners may be repackaged only with the 10 Steel Forgings shall comply with
Engineer’s approval and under his supervision. ASTM A 668/A 668M.
ii. Clean and re-lubricate bolts and nuts that 11 Welding Electrodes shall comply with AWS
become dry or rusty before use. requirements.
iii. Comply with manufacturers' written
12 Woven-wire mesh shall be intermediate-crimp,
recommendations for cleaning and lubricating
diamond or square pattern, 50-mm woven-wire mesh,
ASTM F 1852 fasteners and for retesting
made from 3.5-mm nominal diameter wire complying with
fasteners after lubrication.
ASTM A 510M.

6.1.6 Coordination 6.2.2 Bolts, Connectors, and Anchors

1 Coordinate selection of shop primers with topcoats
1 High-Strength Bolts, Nuts, and Washers:
to be applied over them. Comply with paint and coating
ASTM A 325 (ASTM A 325M), Type 1, heavy-hex steel
manufacturers' recommendations to ensure that shop
structural bolts; ASTM A 563, Grade C, (ASTM A 563M,
primers and topcoats are compatible with one another.
Class 8S) heavy-hex carbon-steel nuts; and ASTM F 436
2 Coordinate installation of anchorage items to be (ASTM F 436M), Type 1, hardened carbon-steel washers;
embedded in or attached to other construction so as not to all with plain finish.
delay the work. Provide setting diagrams, sheet metal i. Direct-Tension Indicators: ASTM F 959,
templates, instructions, and directions for installation. Type 325 (ASTM F 959M, Type 8.8),
compressible-washer type with plain finish.
High-Strength Bolts, Nuts, and Washers: ASTM A 490
(ASTM A 490M), Type 1, heavy-hex steel structural bolts;

♦ 6-2 ♦
copy 249
ASTM A 563, Grade DH, (ASTM A 563M, Class 10S) 9 Eye Bolts and Nuts: Made from cold-finished carbon
heavy-hex carbon-steel nuts; and ASTM F 436 steel bars, ASTM A 108, Grade 1030.
(ASTM F 436M), Type 1, hardened carbon-steel washers 10 Sleeve Nuts: Made from cold-finished carbon steel
with plain finish. bars, ASTM A 108, Grade 1018.
i. Direct-Tension Indicators: ASTM F 959,
11 Structural Slide Bearings: Low-friction assemblies, of
Type 490 (ASTM F 959M, Type 10.9),
configuration indicated, that provide vertical transfer of
compressible-washer type with plain finish.
loads and allow horizontal movement perpendicular to
2 Zinc-Coated High-Strength Bolts, Nuts, and Washers: plane of expansion joint while resisting movement within
ASTM A 325 (ASTM A 325M), Type 1, heavy-hex steel plane of expansion joint.
structural bolts; ASTM A 563, Grade DH (ASTM A 563M, i. Manufacturers: Subject to compliance with work
Class 10S) heavy-hex carbon-steel nuts; and ASTM F 436 requirements.
(ASTM F 436M), Type 1, hardened carbon-steel washers. ii. Basis-of-Design Product: Subject to compliance
i. Finish: Hot-dip or mechanically deposited zinc with requirements, provide product indicated on
coating. Drawings or comparable product.
ii. Direct-Tension Indicators: ASTM F 959, iii. Mating Surfaces: PTFE and mirror-finished
Type 325 (ASTM F 959M, Type 8.8), stainless steel.
compressible-washer type with mechanically iv. Coefficient of Friction: Not more than 0.03.
deposited zinc coating v. Design Load: Not less than 41 MPa.
3 Tension-Control, High-Strength Bolt-Nut-Washer vi. Total Movement Capability: 50 mm.
Assemblies: ASTM F 1852, Type 1, heavy-hex head 12 Fasteners for Interconnecting Railing Components:
assemblies consisting of steel structural bolts with splined i. Provide concealed fasteners for interconnecting
ends, heavy-hex carbon-steel nuts, and hardened carbon- railing components and for attaching them to
steel washers. other work, unless otherwise indicated.
i. Finish: Mechanically deposited zinc coating. ii. Provide concealed fasteners for interconnecting
4 Shear Connectors: ASTM A 108, Grades 1015 railing components and for attaching them to
through 1020, headed-stud type, cold-finished carbon other work, unless exposed fasteners are
steel; AWS D1.1/D1.1M, Type B. unavoidable or are the standard fastening
method for railings indicated.
5 Unheaded Anchor Rods: ASTM F 1554, Grade 36 or
iii. Provide square or hex socket flat-head machine
ASTM F 1554, Grade 55, weldable
screws for exposed fasteners unless otherwise
i. Configuration: Hooked.
indicated.
ii. Nuts: ASTM A 563 (ASTM A 563M) heavy-hex
carbon steel.
6.2.3 Grout
iii. Plate Washers: ASTM A 36/A 36M carbon steel.
iv. Washers: ASTM F 436 (ASTM F 436M), Type 1, 1 Metallic, Shrinkage-Resistant Grout: ASTM C 1107,
hardened carbon steel. factory-packaged, metallic aggregate grout, mixed with
v. Finish: Hot-dip zinc coating, water to consistency suitable for application and a 30-
ASTM A 153/A 153M, Class C. minute working time.

6 Headed Anchor Rods: [ASTM F 1554, Grade 36] 2 Non-metallic, Shrinkage-Resistant Grout:
[ASTM F 1554, Grade 55, weldable] [ASTM A 354] ASTM C 1107, factory-packaged, nonmetallic aggregate
[ASTM A 449], straight. grout, noncorrosive and non-staining, mixed with water to
i. Nuts: ASTM A 563 (ASTM A 563M) heavy-hex consistency suitable for application and a 30-minute
carbon steel. working time.
ii. Plate Washers: ASTM A 36/A 36M carbon steel.
iii. Washers: ASTM F 436 (ASTM F 436M), Type 1, 6.2.4 Fabrication
hardened carbon steel. 1 Structural Steel: Fabricate and assemble in shop to
iv. Finish: Hot-dip zinc coating, greatest extent possible. Fabricate according to AISC's
ASTM A 153/A 153M, Class C. "Code of Standard Practice for Steel Buildings and
7 Threaded Rods: ASTM A 36/A 36M and Bridges" and AISC 360.
A 572/A 572M, Grade 50 (345). i. Camber structural-steel members where
i. Nuts: ASTM A 563 (ASTM A 563M) heavy-hex indicated.
carbon steel. ii. Fabricate beams with rolling camber up.
ii. Washers: [ASTM F 436 (ASTM F 436M), iii. Identify high-strength structural steel according
Type 1, hardened]. to ASTM A 6/A 6M and maintain markings until
iii. Finish: Hot-dip zinc coating, structural steel has been erected.
ASTM A 153/A 153M, Class C. iv. Mark and match-mark materials for field
assembly.
8 Clevises and Turnbuckles: Made from cold-finished
carbon steel bars, ASTM A 108, Grade 1035.

♦ 6-3 ♦
copy 249
 v. Complete structural-steel assemblies, including
welding of units, before starting shop-priming
operations.
2 Thermal Cutting: Perform thermal cutting by
machine to greatest extent possible
i. Plane thermally cut edges to be welded to
comply with requirements in AWS D1.1/D1.1M.
3 Bolt Holes: Cut, drill, or punch standard bolt holes
perpendicular to metal surfaces.
4 Finishing: Accurately finish ends of columns and
other members transmitting bearing loads.
5 Cleaning: Clean and prepare steel surfaces that are
to remain unpainted according to SSPC-SP 3, "Power Tool
Cleaning"
6 Shear Connectors: Prepare steel surfaces as
recommended by manufacturer of shear connectors. Use
automatic end welding of headed-stud shear connectors
according to AWS D1.1/D1.1M and manufacturer's written
instructions.
7 Holes: Form holes required for securing other work
to structural steel and for other work to pass through steel
framing members.
i. Cut, drill, or punch holes perpendicular to steel
surfaces. Do not thermally cut bolt holes or
enlarge holes by burning.
ii. Base plate holes: Cut, drill, mechanically thermal
cut, or punch holes perpendicular to steel
surfaces.
iii. Weld threaded nuts to framing and other
specialty items indicated to receive other work.
8 Steel pipe and tube railings:
i. Fabricate connections that will be exposed to
weather in a manner to exclude water. Provide
weep holes where water may accumulate.
ii. Connections: Fabricate railings with either
welded or non-welded connections unless
otherwise indicated.
iii. Connect members with concealed mechanical
fasteners and fittings.
iv. Form changes in direction by bends of radius
indicated or by inserting prefabricated elbow
fittings of radius indicated.
v. Close exposed ends of railing members with
prefabricated end fittings.
vi. Provide inserts and other anchorage devices for
connecting railings to concrete or masonry work.
Fabricate anchorage devices capable of
withstanding loads imposed by railings.
Coordinate anchorage devices with supporting
structure.
9 Galvanization: The minimum average thickness of
coating for all galvanized specimens shall conform to the
requirements of ASTM A 123/A 123M.
6.2.5 Shop Connections
1 High-Strength Bolts: Shop install high-strength bolts
according to RCSC's "Specification for Structural Joints
♦ 6-4 ♦
Using ASTM A 325 or A 490 Bolts" for type of bolt and
type of joint specified.
i. Joint Type: Slip critical.
2 Weld Connections: Comply with AWS D1.1/D1.1M
and AWS D1.8/D1.8M for tolerances, appearances,
welding procedure specifications, weld quality, and
methods used in correcting welding work.
i. Assemble and weld built-up sections by methods
that will maintain true alignment of axes without
exceeding tolerances in AISC 303 for mill
material.
6.2.6 Source Quality Control
1 Testing Agency: The Employer may engage an
independent testing and inspecting agency to perform
shop tests and inspections and prepare test reports.
i. Provide testing agency with access to places
where structural-steel work is being fabricated or
produced to perform tests and inspections.
2 Correct deficiencies in work that test reports and
inspections indicate does not comply with the
Specification or Drawings.
3 Bolted Connections: Shop-bolted connections will
be tested and inspected according to RCSC's
"Specification for Structural Joints Using ASTM A 325 or
A 490 Bolts."
4 Welded Connections: In addition to visual inspection,
shop-welded connections will be tested and inspected
according to AWS D1.1/D1.1M and the following
inspection procedures, at testing agency's option:
i. Liquid Penetrant Inspection: ASTM E 165.
ii. Magnetic Particle Inspection: ASTM E 709;
performed on root pass and on finished weld.
Cracks or zones of incomplete fusion or
penetration will not be accepted.
iii. Ultrasonic Inspection: ASTM E 164.
iv. Radiographic Inspection: ASTM E 94.
5 In addition to visual inspection, shop-welded shear
connectors will be tested and inspected according to
requirements in AWS D1.1/D1.1M for stud welding and as
follows:
i. Bend tests will be performed if visual inspections
reveal either a less-than-continuous 360-degree
flash or welding repairs to any shear connector.
ii. Tests will be conducted on additional shear
connectors if weld fracture occurs on shear
connectors already tested, according to
requirements in AWS D1.1/D1.1M.
6.3 Construction Requirements
6.3.1 Examination
1 Verify, with steel erector present, elevations of
concrete- and masonry-bearing surfaces and locations of
anchor rods, bearing plates, and other embedments for
compliance with requirements.
copy 249
 i. Prepare a certified survey of bearing surfaces,
anchor rods, bearing plates, and other
embedment, showing dimensions, locations,
angles, and elevations.
2 Proceed with installation only after unsatisfactory
conditions have been corrected.
6.3.2 Preparation
1 Provide temporary shores, guys, braces, and other
supports during erection to keep structural steel secure,
plumb, and in alignment against temporary construction
loads and loads equal in intensity to design loads.
Remove temporary supports when permanent structural
steel, connections, and bracing are in place unless
otherwise indicated.
i. Do not remove temporary shoring supporting
composite deck construction until cast-in-place
concrete has attained its design compressive
strength.
6.3.3 Erection
1 Set structural steel accurately in locations and to
elevations indicated and according to AISC 303 and
AISC 360.
2 Base Bearing and Leveling Plates: Clean concrete-
and masonry-bearing surfaces of bond-reducing materials,
and roughen surfaces prior to setting plates. Clean
bottom surface of plates.
i. Set plates for structural members on wedges,
shims, or setting nuts as required.
ii. Weld plate washers to top of base plate.
iii. Snug-tighten anchor rods after supported
members have been positioned and plumbed.
Do not remove wedges or shims but, if
protruding, cut off flush with edge of plate
before packing with grout.
iv. Promptly pack grout solidly between bearing
surfaces and plates so no voids remain. Neatly
finish exposed surfaces; protect grout and allow
curing. Comply with manufacturer's written
installation instructions for shrinkage-resistant
grouts.
3 Maintain erection tolerances of structural steel and
steel railing within AISC's "Code of Standard Practice for
Steel Buildings and Bridges."
4 Align and adjust various members that form part of
complete frame or structure before permanently fastening.
Before assembly, clean bearing surfaces and other
surfaces that will be in permanent contact with members.
Perform necessary adjustments to compensate for
discrepancies in elevations and alignment.
i. Level and plumb individual members of structure.
ii. Make allowances for difference between
temperature at time of erection and mean
temperature when structure is completed and in
service.
5 Splice members only where indicated.
6 Do not use thermal cutting during erection unless
approved by Engineer. Finish thermally cut sections
within smoothness limits in AWS D1.1/D1.1M.
7 Do not enlarge unfair holes in members by burning
or using drift pins. Ream holes that must be enlarged to
admit bolts.
i. Shear Connectors: Prepare steel surfaces as
recommended by manufacturer of shear
connectors. Use automatic end welding of
headed-stud shear connectors according to
AWS D1.1/D1.1M and manufacturer's written
instructions.
6.3.4 Orthotropic-Deck Super Structure
1 Protection of Deck Plate after Sandblasting: If
sandblasting to a white metal, or an equivalent method, is
used to prepare the deck plate to receive a wearing
surface, a protective coating shall be applied to the plate
immediately after cleaning.
2 Dimensional Tolerance Limits:
i. Dimensional tolerance limits for orthotropic-deck
bridge members shall be applied to each
completed but unloaded member and shall be as
specified in the AWS Structural Welding Code
except as superseded hereinafter. The deviation
from detailed flatness, straightness, or curvature
at any point shall be the perpendicular distance
from that point to a template edge which has the
detailed straightness or curvature and which is in
contact with the element at two other points.
The term element as used herein refers to
individual panels, stiffeners, flanges, or other
pieces. The template edge may have any length
not exceeding the greatest dimension of the
element being examined and, for any panel, not
exceeding 1.5 times the least dimension of the
panel; it may be placed anywhere within the
boundaries of the element. The deviation shall
be measured between adjacent points of contact
of the template edge with the element; the
distance between these adjacent points of
contact shall be used in the formulas to establish
the tolerance limits for the segment being
measured whenever this distance is less than the
applicable dimension of the element specified for
the formula.
ii. The term panel as used in this paragraph means
a clear area of steel plate surface bounded by
stiffeners, webs, flanges, or plate edges and not
further subdivided into such elements. The
provisions of this paragraph apply to all panels
in the bridge; for plates stiffened on one side
only such as orthotropic-deck plates or flanges of
box girders, this includes the total clear width on
the side without stiffeners as well as the panels
between stiffeners on the side with stiffeners.
The maximum deviation from detailed flatness
or curvature of a panel shall not exceed 5 mm.
♦ 6-5 ♦
copy 249
 The maximum deviation from detailed
straightness or curvature in any direction
perpendicular to its length of a longitudinal
stiffener subject to calculated compressive stress,
including each orthotropic-deck rib, shall not
exceed L/480, where L = the length of the
stiffener or rib between cross members, webs, or
flanges, in millimeters.
iii. The maximum deviation from detailed
straightness or curvature in any direction
perpendicular to its length of a transverse web
stiffener or other stiffener not subject to
calculated compressive stress shall not exceed
L/240, where L = the length of the stiffener or rib
between cross members, webs, or flanges, in
millimeters.
6.3.5 Field Connections
1 High-Strength Bolts: Install high-strength bolts
according to RCSC's "Specification for Structural Joints
Using ASTM A 325 or A 490 Bolts" for type of bolt and
type of joint specified.
i. Joint Type: Slip critical.
2 Weld Connections: Comply with AWS D1.1/D1.1M
and AWS D1.8/D1.8M for tolerances, appearances,
welding procedure specifications, weld quality, and
methods used in correcting welding work.
i. Comply with AISC 303 and AISC 360 for bearing,
alignment, adequacy of temporary connections,
and removal of paint on surfaces adjacent to
field welds.
ii. Remove backing bars or runoff tabs, back gouge,
and grind steel smooth.
iii. Assemble and weld built-up sections by methods
that will maintain true alignment of axes without
exceeding tolerances in AISC's "Code of
Standard Practice for Steel Buildings and
Bridges" for mill material.
6.3.6 Field Quality Control
1 Testing Agency: The Employer may engage a
qualified independent testing and inspecting agency to
inspect field welds and high-strength bolted connections.
2 Bolted Connections: Bolted connections will be
tested and inspected according to RCSC's "Specification
for Structural Joints Using ASTM A 325 or A 490 Bolts."
3 Welded Connections: Field welds will be visually
inspected according to AWS D1.1/D1.1M.
i. In addition to visual inspection, field welds will
be tested and inspected according to
AWS D1.1/D1.1M and the following inspection
procedures, at testing agency's option:
- Liquid Penetrant Inspection: ASTM E 165.
- Magnetic Particle Inspection: ASTM E 709;
performed on root pass and on finished weld.
Cracks or zones of incomplete fusion or
penetration will not be accepted.
- Ultrasonic Inspection: ASTM E 164.
- Radiographic Inspection: ASTM E 94.
4 In addition to visual inspection, test and inspect field-
welded shear connectors according to requirements in
AWS D1.1/D1.1M for stud welding and as follows:
i. Perform bend tests if visual inspections reveal
either a less-than-continuous 360-degree flash or
welding repairs to any shear connector.
ii. Conduct tests on additional shear connectors if
weld fracture occurs on shear connectors already
tested, according to requirements in
AWS D1.1/D1.1M.
5 Correct deficiencies in work that test reports and
inspections indicate does not comply with the
Specification or Drawings.
6.4 Method of Measurement
1 Structural steel is measured by weight in tonnes.
Except for rolled steel sections and plates whose weights
are computed from nominal weight as paragraphs 2 and 3
below, the weight shall be calculated on the basis that 1.0
cu. meter weighs 7850 kg.
2 The weights of rolled shapes shall be computed on
the basis of their nominal weights per meter as shown on
the Drawings, or listed in the handbooks.
3 The weights of plates shall be computed on the basis
of the nominal weight for their width and thickness as
shown on the Drawings, plus an estimated overrun
computed as one-half the ‘Permissible Variation in
Thickness and Weight’ as tabulated in Specification,
‘General Requirements for Delivery of Rolled Steel Plates,
Shapes, Steel Piling, and Bars for Structural Use’,
AASHTO M 160.
4 The weight of castings shall be computed from the
dimensions shown on the approved shop drawings,
deducting for open holes. To this weight shall be added 5
percent allowance for fillets and over-run. Scale weights
may be substituted for computed weights in the case of
castings or of small complex parts for which accurate
computations of weight would be difficult.
5 The weight of temporary erection bolts, shop and
field paint, boxes, crates, and other containers used for
shipping, and materials used for supporting members
during transportation and erection, shall not be included
in the rate and is subsidiary to the rate of structural steel.
6 In computing pay weight on the basis of computed
net weight the following stipulations in addition to those
in the foregoing paragraphs shall apply:
i. The weight shall be computed on the basis of the
net finished dimensions of the parts as shown on
the approved shop drawing, deducting for copes,
cuts, clips, and all open holes, except bolt holes.
ii. The weight of heads, nuts, single washers, and
threaded stick-through of all high-tensile
strength shop bolts, both shop and field, shall be
included on the basis of the following weights:

♦ 6-6 ♦
copy 249
 Diameter of Bolt Weight per 100 bolts 6.5 Basis of Payments
mm kg
12 9.0 1 The prices for fabrication and erection of structural
16 14.4 steel and railings shall include all labor, materials,
19 23.8 equipment, transportation, and shop and field painting
22 36.5 necessary for the proper completion of the work in
25 53.0 accordance with the contract. The prices for fabrication
29 75.0 without erection shall include all labor and materials
32 96.4 necessary for the proper completion of the work.
35 127.3
38 154.5 6.6 Items in the Bill of Quantities
Table 6.4-1 Bolt Weights
1 Payment will be made under one or more of the
iii. The weight of weld metal shall be computed on following:
the basis of the theoretical volume from
dimensions of the welds. i. Structural Steel (grade) (t.)
7 In computing pay weight on the basis of computed
ii. Railings (Type) (height) (lin. m.)
gross weight, the following stipulations in addition to the
above shall apply.
i. The weight shall be calculated on the basis of
rectangular dimensions for all plates, and
ordered over-all lengths for all structural shapes;
except that (A) when parts can be economically
cut in multiples from material of larger
dimensions, the computed weight shall be that
of the material from which the parts are cut, and
(B) all material shall be ordered to produce as
little waste as practicable when cut and finished
by modern shop methods.
ii. No deductions from the computed weight of
rolled steel shall be made for the copes, clips,
sheared edges, punchings, borings, milling or
planning; or from the computed weight of
castings to allow for drillings or borings.
iii. The weight of weld metal shall be computed on
the basis of the theoretical volume of the
dimensions of the welds. To this weight shall be
added 50 percent allowance for overrun.
8 In computing pay weight on the basis of scale
weights, the pay quantity of structural steel will be the
shop scale weight of the fabricated members, which shall
be weighed on satisfactory scales in the presence of the
Inspector. If the shop paint has been applied to the
completed member when weighed, 0.4 percent of the
weight of the member shall be deducted from the scale
weight of the member to compensate for weight of shop
paint. The weight of field bolts shall be based on the
approved shipping list. No payment will be made for any
weight in excess of 1.5 percent above the computed net
weight of the whole item.
9 Steel railings are measured in lin. meters as the
actual length fixed in position according to type and
height, without differentiation for straight, curved, raking
and stepped railings The rates are deemed to include for
all accessories and fixings and finishes.

♦ 6-7 ♦
copy 249
copy 249
Ref. Title Page No. Ref. Title Page No.
7.1 Description 7-1 7.2.5.11  Brushing Properties  7‐3 
7.2.5.12  Spraying Properties  7‐3 
7.1.1  Summary  7‐1 
7.2.5.13  Drying Time  7‐3 
7.1.1.1  Description  7‐1 
7.2.6 Zinc Dust-Zinc Oxide Primer 7-4
7.2 Materials 7-1 7.2.6.1  Description  7‐4 
7.2.1 General 7-1 7.2.6.2  Zinc Oxide Vehicle  7‐4 
7.2.1.1  References and Warranties  7‐1  7.2.6.3  Zinc Dust-Zinc Oxide Mixed Primer  7‐4 
7.2.1.2  Composition and Mixing  7‐1  7.2.7 Aluminum Paint 7-5
7.2.1.3  Compatibility  7‐1  7.2.7.1  Description  7‐5 
7.2.1.4  Covering Qualities  7‐1  7.2.7.2  Proportions  7‐5 
7.2.1.5  Containers  7‐1  7.2.7.3  Mixing 7‐5 
7.2.1.6  Delivery  7‐1  7.2.8 Tinted Aluminum Paint 7-5
7.2.1.7  Storage and Handling  7‐1  7.2.8.1  Description  7‐5 
7.2.2 Pigments and Pastes 7-1 7.2.8.2  Proportions  7‐5 
7.2.3 Paint Oils, Thinners and Dryers 7-2 7.2.9 Basic Lead Silico-Chromate Maroon
7.2.4 Red Lead Paint 7-2 Field Coat 7-5
7.2.4.1  Description  7‐2  7.2.9.1  Description  7‐5 
7.2.4.2  Composition  7‐2  7.2.9.2  Composition  7‐5 
7.2.4.3  Weight per Liter  7‐2  7.2.9.3  Weight per Liter  7‐5 
7.2.4.4  Coarse Particles  7‐2  7.2.9.4  Coarse Particles  7‐5 
7.2.4.5  Consistency  7‐2  7.2.9.5  Consistency  7‐5 
7.2.4.6  Condition in Container  7‐2  7.2.9.6  Condition in Container  7‐5 
7.2.4.7  Skinning  7‐2  7.2.9.7  Skinning  7‐5 
7.2.4.8  Dilution Stability  7‐2  7.2.9.8  Dilution Stability  7‐5 
7.2.4.9  Brushing Properties  7‐2  7.2.9.9  Brushing Properties  7‐5 
7.2.4.10  Spraying Properties  7‐2  7.2.9.10  Spraying Properties  7‐6 
7.2.4.11  Drying Time  7‐3  7.2.9.11  Drying Time  7‐6 
7.2.4.12  Tinting  7‐3  7.2.10 Basic Lead Silico-Chromate Dark Green
7.2.5 Basic Lead Silico-Chromate Primer 7-3 Finish Coat 7-6
7.2.5.1  Description  7‐3  7.2.10.1  Description  7‐6 
7.2.5.2  Composition  7‐3  7.2.10.2  Composition  7‐6 
7.2.5.3  Weight per Liter  7‐3  7.2.10.3  Weight per Liter  7‐6 
7.2.5.4  Coarse Particles  7‐3  7.2.10.4  Coarse Particles  7‐6 
7.2.5.5  Consistency  7‐3  7.2.10.5  Consistency  7‐6 
7.2.5.6  Flash Point  7‐3  7.2.10.6  Color  7‐6 
7.2.5.7  Condition in Container  7‐3  7.2.10.7  Condition in Container  7‐6 
7.2.5.8  Skinning  7‐3  7.2.10.8  Skinning  7‐6
7.2.5.9  Dilution Stability  7‐3 7.2.10.9 Dilution Stability 7-6
7.2.5.10  Appearance  7‐3 7.2.10.10 Brushing Properties 7-6

copy 249
Ref. Title Page No. Ref. Title Page No.
7.2.10.11  Spraying Properties  7‐6  7.3.8 Painting Existing Structures 7-12
7.2.10.12  Drying Time  7‐6  7.3.9 Painting Steel Piling and Steel Pile
7.2.11 Zinc Dust Paint 7-7 Shells 7-13
7.2.11.1  Description  7‐7  7.3.10 Painting Steel Pile Enclosures
7.2.11.2  Requirements  7‐7  and Tubular Steel Piers 7-13
7.2.12 Gloss Enamel 7-7
7.4 Method of Measurement 7-13
7.2.12.1  Description  7‐7 
7.2.12.2  Requirements  7‐7 
7.5 Basis of Payments 7-13
7.2.13 Sampling and Testing 7-7 7.6 Items in the Bill of Quantities 7-13
7.2.14 Portland Cement Paint 7-7
7.2.14.1  Description  7‐7 
7.2.14.2  Composition  7‐7 
7.2.14.3  Colors  7‐7 
7.2.15 Polymer Latex Paint 7-8
7.2.15.1  Description  7‐8 
7.2.15.2  Composition  7‐8 
7.2.15.3  Colors  7‐8 
7.2.16 Polymer Paint 7-8
7.2.16.1  Description  7‐8 
7.2.16.2  Composition  7‐8 
7.2.16.3  Colors  7‐8 
7.2.17 Acrylic Emulsion Paint 7-8

7.3 Construction Requirements 7-8

7.3.1 General 7-8
7.3.2 Application 7-9
7.3.2.1  General  7‐9 
7.3.3 Concrete Surfaces 7-9
7.3.3.1 Preparation 7-9
7.3.3.2 Painting  7‐10 
7.3.4 Structural Steel ,Requirements 7-11
7.3.5 Shop Coat (Prime) 7-11
7.3.5.1 Shop Cleaning  7‐11 
7.3.5.2 Shop Painting  7‐11 
7.3.6 Field Coat 7-12
7.3.6.1 Field Cleaning  7‐12 
7.3.6.2 Field Painting  7‐12 
7.3.7 Bridge Railings and Guardrails 7-12
7.3.7.1 Bridge Railings  7‐12 
7.3.7.2 Guardrail  7‐12

copy 249
7.1 Description 7.2.1.4 Covering Qualities

1 All mixed paint shall have satisfactory protective and

7.1.1 Summary
7.1.1.1 Description
1 This Section describes painting to steel and concrete
structures and painting to railings and other metalwork.
2 The work described herein includes protective and
decorative painting to new and existing structures and
metalwork to meet the ambient conditions.
3 The paints, primers and ancillary products included
in this Section include a full range of products. The actual
products to be used for the particular project shall be as
specified in the Special Specification for each project or as
directed by the Engineer.
covering qualities. Mixed paint shall not run, streak, break
or sag when brushed on a clean one hundred fifty (150)
millimeters by two hundred fifty (250) millimeter glass
panel placed in a vertical position. The paint shall dry to a
smooth, uniform finish, free from roughness, grit,
unevenness and other surface imperfections.
7.2.1.5 Containers
1 Paint containers shall be sufficiently strong and
durable to withstand shipment and normal handling
procedures without damage. Paint containers shall be
equipped with lids which positively prevent the entrance
of air into the container.

7.2.1.6 Delivery
7.2 Materials
1 All paint shall be delivered to the site in original
7.2.1 General manufacturer's metal containers with labels which give
type, color, quantity, gross and tare, and paint ingredient
7.2.1.1 References and Warranties proportions of every item of the contents.

1 Where reference is made to specifications and 7.2.1.7 Storage and Handling

standards issued by named organizations, such
specifications and standards are hereby made a part of
this specification to the same extent as if fully set out
herein.
2 The paint manufacturer(s) shall supply evidence that
the proposed products have performed satisfactorily for a
minimum of five (5) years in conditions similar to those of
Oman as to ultraviolet light exposure and intensive
climatic conditions.
7.2.1.2 Composition and Mixing
1 All paints and painting products shall be stored and
protected and used in environmental conditions that
ensure that the paint is not affected by extremes of
temperature.
7.2.2 Pigments and Pastes
1 When specified in mixed paints, the following
pigments and pastes shall comply with the requirements
of the ASTM designations indicated below:

1 Paints shall be factory-mixed or in paste form. Mixing Pigments and Pastes ASTM
of dry pigment and a vehicle by the Contractor will not be Zinc Oxide D 79
permitted, except as specifically required by the White Lead, Basic Carbonate D 81
specifications. Mixed paints shall be mixed with a paddle White Lead, Basic Sulfate D 82
to a smooth and homogenous condition. Pigments and Red Lead, ninety-seven (97) percent D 83
insoluble ingredients shall be finely ground to a smooth Grade
uniform consistency Mixed paints or pastes which have Iron Oxide, Class II Type A D 84
hardened, thickened or otherwise deteriorated during Lampblack D 209
storage or shipment will not be accepted. Chrome Oxide Green D 263
2 Thinners for a particular type of paint must mix Titanium Dioxide, Type I D 476
readily with that type of paint. Carbon Black D 561
3 When paint is tinted, the tinting material shall be Magnesium Silicate Pigment D 605
thoroughly mixed into the paint to form an even, uniform Aluminum Pigments, Type II Class B D 962
shade. (except coarse particles may be two
(2) percent maximum)
7.2.1.3 Compatibility Copper Phtalocyanine Blue D 963
1 Finish paint for factory-primed items shall be of a Basic Lead Silico-Chromate D 1648
type compatible with the primer. Primers for unprimed Copper Phthalocyanine Green D 3021
items shall be as recommended by the manufacturer for Table 7.2.2-1: Specifications for Pigments and Paste
use with the finish paint.
2 Siliceous red iron oxide shall meet the following
2 Primers, sealers, undercoat and finishing coat paint
requirements:
shall be compatible in composition and color and, for any
one paint system, shall be the products of the same
manufacturer.

♦ 7-1 ♦
copy 249
 Total Iron Oxide, Eighty-five percent (85%) ii. Pigment: The extracted pigment shall conform
Calculated as Fe2O3 min. to the following by weight:
Coarse particles, on One percent (1%) True red lead Sixty-two and Five-tenths (62.5)
Number 325 mesh sieve maximum percent min.
Calcium Oxide Five-tenths percent (0.5%) Ferric oxide siliceous Twelve and Five-tenths (12.5)
max. matter and percent min.
Moisture and other Two percent (2%) max. remainder
volatile material Other oxides of lead
Water soluble matter One and five-tenths
Table 7.2.4-2: Composition of Pigment for Red Lead Paint
percent (1.5%) max.
Oil absorption Sixteen (16%) percent min. 7.2.4.3 Weight per Liter
Siliceous matter Balance
1 Red lead paint shall weigh not less than two (2)
Organic colors None Permitted
kilograms per liter.
Table 7.2.2-2: Requirements of Siliceous Red Iron Oxide
7.2.4.4 Coarse Particles
7.2.3 Paint Oils, Thinners and Dryers
1 Coarse particles and skins retained on a forty-five
1 When specified in mixed paints or vehicles the thousandths (0.045) millimeter (No. 325) sieve shall not
following paint liquids shall comply with the designations exceed one percent (1%) by weight based on pigment.
indicated below:
7.2.4.5 Consistency
Component ASTM
Turpentine, steam distilled D 13 1 Consistency shall be not less than seventy-three (73)
Pine Oil, Type 1 FSS LLL-P-400 nor more than eighty-six (86) Krebs Units (K.U.).
Raw linseed oil D 234 7.2.4.6 Condition in Container
Mineral spirits D 235
Mineral spirits, Grade 1 and Grade FSS TT-T-291 1 The paint shall be thoroughly ground and mixed; it
2 shall not be settled, caked or thickened to such a degree
Boiled linseed oil, Type 1 D 260 that it cannot be redispersed easily with a paddle to a
Dryers, liquid paint, Class B D 600 uniform and homogenous state.
Alkyd resin solutions, Type I, II and FSS TT-R-266 7.2.4.7 Skinning
III
Table 7.2.3-1: Specifications for Paint Liquids 1 Skinning shall be entirely absent from a sample that
has been stored forty-eight (48) hours in a dark place in a
7.2.4 Red Lead Paint three-quarters-filled tightly-closed container.

7.2.4.1 Description 7.2.4.8 Dilution Stability

1 Rapid-dry red lead paint shall consist only of lead 1 The paint shall remain stable and uniform after
pigment, iron oxide pigment, magnesium silicate pigment, reduction with mineral spirits in the proportions of eight
raw linseed oil, linseed oil modified alkyd resin, thinners (8) parts by volume of paint to one (1) part by volume of
and dryers. The paint shall not contain more than four- mineral spirits.
tenths (0.4) percent aluminum stearate to produce loose 7.2.4.9 Brushing Properties
suspension of the pigment during storage.
1 The paint, after thorough mixing, shall have
7.2.4.2 Composition satisfactory brushing and leveling properties and show no
1 Rapid-dry red lead paint shall conform to the running or sagging tendencies when brushed on a vertical
following composition by weight: steel surface.
i. Paint. 7.2.4.10 Spraying Properties
Pigment Sixty-six (66) percent min. 1 The paint, when thinned, shall spray satisfactorily,
Vehicle Thirty-four (34) percent max. show no tendency to orange-peel, sag, creep, or run, and
Non-volatile Fifty-six (56) percent min. shall show satisfactory spraying properties in all other
material in vehicle respects. The mineral spirits used as a reducer shall
Phthalic anhydride Fifteen (15) percent min. conform to FSS TT-T-281 Grade 1, and shall be tested and
based on vehicle approved prior to use.
solids
Water Five-tenths (0.5) percent max.
Table 7.2.4-1: Composition of Red Lead Paint

♦ 7-2 ♦
copy 249
7.2.4.11 Drying Time 7.2.5.5 Consistency

1 The paint shall be touch-dry in not more than four (4) 1 Consistency shall be not less than seventy (70) or
hours and dry-through in not more than sixteen (16) hours more than eighty-three (83) Krebs Units (K.U.).
when applied as in FSS Test Method, Standard Number
141, Method 4061. 7.2.5.6 Flash Point

1 The flash point shall be not less than thirty degrees

7.2.4.12 Tinting
1 When used for the shop (prime) and second coat,
sufficient black synthetic or magnetite iron oxides shall be
added to the second coat paint as a tinting agent for
identification of the coated surfaces.
Celsius (30 C) when tested in accordance with Federal Test
Method, Standard Number 141, Method 4293 using
Pensky-Martens Closed Cup Tester.
7.2.5.7 Condition in Container

1 The paint shall be thoroughly ground and mixed; it

7.2.5 Basic Lead Silico-Chromate Primer
7.2.5.1 Description
1 Primer shall be suitable for use as a structural metal,
shop or spot primer. It shall consist only of basic lead
silico-chromate, and red iron oxide eighty-five (85) percent,
linseed-soya oil modified alkyd resin, raw linseed oil,
thinners and dryers. The primer shall not contain more
than seven-tenths (0.7) percent pigment suspended agent.
The alkyd resin shall conform to FSS TT-R-266, Type III.
shall not be settled, caked or thickened to such a degree
that it cannot be dispersed easily with a paddle to a
uniform and homogenous state.
7.2.5.8 Skinning
1 Skinning shall be entirely absent from a sample that
has been stored forty-eight (48) hours in a dark place in a
three-quarters-filled tightly-closed container.
7.2.5.9 Dilution Stability

7.2.5.2 Composition 1 The paint shall remain stable and uniform after
reduction with mineral spirits in the proportions of eight
1 Basic lead silico-chromate primer shall conform to (8) parts by volume of paint to one (1) part by volume of
the following by weight: mineral spirits.
i. Paint:
7.2.5.10 Appearance
Pigment Fifty-seven (57) percent min.
Non-volatile material Fifty-two (52) percent min. 1 After a flow-out panel of the paint on one hundred
in vehicle (100) millimeters by three hundred (300) millimeter clean
Phthalic anhydride Fifteen (15) percent min. glass plate has dried in a nearly vertical position at room
based on vehicle temperature, it shall show no streaking or separation.
solids
7.2.5.11 Brushing Properties
Water Five-tenths (0.5) percent max.
Table 7.2.5-1: Composition of Basic Lead Silico-Chromate 1 The paint, after thorough mixing, shall have
Primer Paint satisfactory brushing and leveling properties and show no
running or sagging tendencies when brushed on a vertical
ii. Pigment: The extracted pigment shall conform steel surface at a spreading rate of twelve and three-tenths
to the following by weight: (12.3) square meters per liter.

Basic lead Silico- Ninety-three and two-tenths 7.2.5.12 Spraying Properties

chromate (93.2) percent minimum
Ferric oxide Four and eight-tenths (4.8) to 1 The paint, when thinned, shall spray satisfactorily,
five and eight-tenths (5.8) show no tendency to orange-peel, sag, creep, or run, and
percent shall show satisfactory spraying properties in all other
respects. The mineral spirits used as a reducer shall
Table 7.2.5-2: Composition of Pigment for Basic Lead
conform to FSS TT-T-291, Grade 1 and shall be tested and
Silico-Chromate Primer
approved prior to use.
7.2.5.3 Weight per Liter 7.2.5.13 Drying Time
1 Basic lead silico-chromate primer shall weigh not 1 The paint shall dry to a smooth uniform surface, free
less than one and six-tenths (1.6) kilograms per liter. from roughness, grit, unevenness, and other surface
7.2.5.4 Coarse Particles imperfections. The paint shall be touch-dry in not more
than four (4) hours and shall dry-through in not more than
1 Coarse particles and skins retained on a forty-five sixteen (16) hours when applied as in FSS Test Method,
thousandths (0.045) millimeter (No. 325) sieve shall not Standard Number 141, Method 4061.
exceed one (1) percent by weight based on pigment.

♦ 7-3 ♦
copy 249
7.2.6 Zinc Dust-Zinc Oxide Primer 2 Weight per Liter: Zinc dust-zinc oxide mixed primer
shall weigh not less than one and eight-tenths (1.8)
7.2.6.1 Description kilograms per liter.
1 Type II zinc dust-zinc oxide-phthalic alkyd resin 3 Coarse Particles: Coarse particles and skins retained
primer, conforming to FSS TT-P-641d Type II, shall be a on a forty-five thousandths (0.045) millimeter (No. 325)
ready-to-mix paint for use on galvanized metal surfaces, sieve shall not exceed four (4) percent by weight based on
with the zinc oxide mill-ground into the entire vehicle in pigment.
one (1) container and the dry zinc dust in a separate 4 Consistency: Consistency shall be not less than sixty-
container. The zinc dust shall show an analysis of not less seven (67) nor more than eight-six (86) Krebs Unit (K.U.).
than ninety-four percent (94%) metallic zinc by weight. The
5 Dilution Stability: The mixed primer shall remain
zinc oxide vehicle shall consist of zinc oxide and a vehicle
stable and uniform after reduction with mineral spirits in
containing long oil, linseed-modified alkyd resin of the air
the proportions of eight (8) parts by volume of paint to
drying type, petroleum or terpene thinners, dryers and
one (1) part by volume of mineral spirits. After standing
anti-skimming agents.
twenty-four (24) hours there shall be no curdling or
7.2.6.2 Zinc Oxide Vehicle precipitation on the vehicle.
6 Flexibility: After air-drying eighteen (18) hours,
1 Composition: Zinc oxide vehicle shall conform to the
baking for twenty-four (24) hours at one hundred five
following by weight:
degrees Celsius (105°C) and cooling to twenty-three
Zinc oxide in the extracted Ninety-eight (98) degrees Celsius (23°C), a film of the mixed primer applied
and ignited pigment percent min. to flat tin panel with a five-hundredths (0.05) millimeter
Non-volatile material in the Forty-three (43) percent Bird Film Applicator shall show no cracking after bending
vehicle min. double over a three (3) millimeter mandrel. This test shall
Phthalic anhydride based on Twenty-three(23) be conducted according to FSS Test Method Number 141,
vehicle solids percent min. Method 2012.
None 7 Adhesion: After air-drying for eighteen (18) hours,
Rosin or rosin derivatives
baking for three (3) hours at one hundred twenty-one
Table 7.2.6-1: Composition of Zinc Oxide Vehicle degrees Celsius (121°C), a film of the mixed primer
brushed on a clean new galvanized iron panel, seventy-
2 Condition in Container: The zinc oxide vehicle shall five (75) millimeters by one hundred fifty (150) millimeters,
be thoroughly ground and mixed. It shall not be settled, shall cut loose in the form of a ribbon without flaking or
caked, or thickened to such a degree that it cannot be otherwise loosening from the panel when tested with a
redispersed easily with a paddle to a uniform and knife blade.
homogenous state. It shall be readily incorporated with
8 Brushing Properties: The mixed primer, after
the zinc dust to form a smooth uniform paint of good
thorough mixing, shall have satisfactory brushing and
brushing consistency.
leveling properties and show no running or sagging
7.2.6.3 Zinc Dust-Zinc Oxide Mixed Primer tendencies when brushed on a vertical surface three
hundred (300) millimeters by six hundred (600) millimeters
1 Composition.: Zinc dust-zinc oxide mixed primer of smooth, clean, untreated galvanized iron.
shall conform to the following by weight when mixed in
9 Spraying Properties: The mixed primer when thinned
the proportions as submitted in the original containers:
with not more than one (1) part by volume of mineral
i. Primer.
spirits to eight (8) parts by volume of paint shall spray
Pigment Sixty-two (62) to sixty-five (65) percent satisfactorily, show no tendency to orange-peel, sag, creep,
Vehicle Thirty-five (35) to thirty-eight (38) percent or run, and shall show satisfactory spraying properties in
Water Three-tenths (0.3) percent max. all other respects.
Table 7.2.6-2: Composition of Zinc Dust-Zinc Oxide Mixed 10 Drying Time: The mixed primer shall be touch-dry in
Primer not less than thirty (30) minutes nor more than four (4)
hours and dry-hard in not more than eighteen (18) hours
ii. Pigment: The extracted pigment shall conform when applied as in FSS Test Method, Standard Number
to the following by weight: 141, Method 4061.

Metallic zinc Seventy-four (74) percent min.

Zinc oxide Eighteen (18) percent min
Metallic zinc plus zinc Ninety-seven (97) percent
oxide min.
Sulfide sulfur None
Table 7.2.6-3: Composition of Pigment for Zinc Dust-Zinc
Oxide Mixed Primer

♦ 7-4 ♦
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7.2.7 Aluminum Paint Pigment Fifty-nine and five tenth
(59.5) percent min.
7.2.7.1 Description
Vehicle Forty and five tenths (40.5)
1 Aluminum paint shall be composed of aluminum percent max.
paste and aluminum vehicle and shall conform to the Non-volatile material in Fifty two (52) percent min
requirements specified in AASHTO M 69, Type 1. The vehicle
paste and vehicle shall be delivered to the project Phthalic anhydride Fourteen and nine tenths
unmixed and in separate containers. (14.9) percent min.
Water Five tenths percent max.
7.2.7.2 Proportions
Table 7.2.9-1: Composition of Maroon Field Coat Paint
1 The mixed paint shall be prepared for use on the
ii. Pigment: The extracted pigment shall conform
project by combining the aluminum paste and aluminum
to the following by weight:
vehicle in the proportions of twenty-four hundredths (0.24)
kilogram paste per liter of vehicle. Basic lead silico- Sixty-six and five-tenths (66.5)
chromate percent minimum
7.2.7.3 Mixing
Siliceous red iron oxide Thirty-three (33) percent max.
1 The paste and vehicle shall be thoroughly mixed Table 7.2.9-2: Composition of Pigment for Maroon Field
before use. The quantity of paint mixed shall not be Coat Paint
greater than will be used within twenty-four (24) hours
after mixing. 7.2.9.3 Weight per Liter

1 Maroon field coat paint shall weigh not less than one
7.2.8 Tinted Aluminum Paint
and sixty-seven hundredths (1.67) kilograms per liter.
7.2.8.1 Description
7.2.9.4 Coarse Particles
1 Tinted aluminum paint shall consist of a mixture
1 Coarse particles and skins retained on a forty-five
containing aluminum paint that conforms to the
thousandths (0.0450) millimeter (No. 325) sieve shall not
requirements of Clause 7.2.7 and Prussian Blue Paste or
exceed one (1) percent by weight based on pigment.
Chrome Green paste, conforming to the requirements
specified in ASTM D 212 or D261. 7.2.9.5 Consistency

7.2.8.2 Proportions 1 Consistency shall be not less than seventy (70) or

1 Tinted aluminum paint shall be prepared by mixing
one (1) liter of aluminum paint meeting this specification
with between thirty (30) and forty-five (45) grams of either
Prussian Blue paste or Chrome Green paste in oil or
varnish.
7.2.9 Basic Lead Silico-Chromate Maroon
Field Coat
7.2.9.1 Description
1 This paint is intended for use as a field coat over a
properly primed surface. Hiding power shall be sufficient
to obtain a complete hiding when applied at normal
spreading rates and shall have a good contrast with the
primer coat. This paint shall consist only of basic lead
silico-chromate, siliceous red iron oxide, raw linseed oil,
linseed-soya oil modified alkyd resin, thinners, dryers, and
from five tenths (0.5) to seven-tenths (0.7) percent
suspending agent, based on the pigment, to insure soft
settlement of the pigment during storage. The alkyd resin
shall conform to FSS TT-R-266, Type III and the thinner to
FSS TT-T-291, Grade 2.
7.2.9.2 Composition
1 Maroon field coat paint shall conform to the
following composition by weight:
i. Paint:
more than eighty-two (82) Krebs Units (K.U.).
7.2.9.6 Condition in Container
1 The paint shall be thoroughly ground and mixed; it
shall not be settled, caked, or thickened to such a degree
that it cannot be redispersed easily with a paddle to a
uniform and homogenous state.
7.2.9.7 Skinning
1 Skinning shall be entirely absent from a sample that
has been stored forty-eight (48) hours in a dark place in a
three-quarters-filled tightly-closed container.
7.2.9.8 Dilution Stability
1 The paint shall remain stable and uniform after
reduction with mineral spirits in the proportions of eight
(8) parts by volume of paint to one (1) part by volume of
mineral spirits.
7.2.9.9 Brushing Properties
1 The paint, after through mixing, shall have
satisfactory brushing and leveling properties, and show no
running or sagging tendencies, when brushed on a
vertical steel surface.

♦ 7-5 ♦
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7.2.9.10 Spraying Properties 7.2.10.4 Coarse Particles

1 The paint, when thinned, shall spray satisfactorily,
show no tendency to orange-peel, sag, creep or run, and
shall show satisfactory spraying properties in all other
respects. The mineral spirits used as a reducer shall
conform to FSS TT-T-291 Grade 1, and shall be tested and
approved prior to use.
7.2.9.11 Drying Time
1 Coarse particles and skins retained on a forty-five
thousandths (0.045) millimeter (No. 325) sieve shall not
exceed one (1) percent by weight based on pigment.
7.2.10.5 Consistency
1 Consistency shall be not less than seventy-two (72)
nor more than eighty (80) Krebs Units (K.U.).

1 The paint shall be touch-dry in no more than four (4) 7.2.10.6 Color
hours and dry-through in not more than twenty-four (24) 1 Dark green finish coat paint color shall be as
hours. approved by the Engineer. The Contractor shall submit to
the Engineer, for approval, color chips of the paint
7.2.10 Basic Lead Silico-Chromate Dark proposed for the work.
Green Finish Coat
7.2.10.7 Condition in Container
7.2.10.1 Description
1 The paint shall be thoroughly ground and mixed; it
1 This paint is intended for use as a finish coat over a shall not be settled, caked, or thickened to such a degree
properly primed and field-coated surface. Dark green that it cannot be redispersed easily with a paddle to a
finish coat paint shall consist only of basic lead silico- uniform and homogenous state.
chromate, chromium oxide green, phthalocyanine green
and/or phthalocyanine blue, lampblack, soya oil modified 7.2.10.8 Skinning
alkyd resin, raw linseed oil, thinners, dryers and from six-
1 Skinning shall be entirely absent from a sample that
tenths (0.6) to seven-tenths (0.7) percent suspended agent,
has been stored forty-eight (48) hours in a dark place in a
based on the pigment, to insure soft settlement of the
three-quarters-filled tightly-closed container.
pigment during storage. The alkyd resin solution shall
conform to FSS TT-R-266, Type I, and the thinner shall 7.2.10.9 Dilution Stability
conform to FSS TTT-291, Grade 2.
1 The paint shall remain stable and uniform after
7.2.10.2 Composition reduction with mineral spirits in the proportions of eight
(8) parts by volume of paint to one (1) part by volume of
1 Dark green finish coat paint shall conform to the
mineral spirits.
following by weight:
i. Paint: 7.2.10.10 Brushing Properties
Pigment Forty-one (41) percent min. 1 The paint, after through mixing, shall have
Vehicle Fifty-nine (59) percent max. satisfactory brushing and leveling properties, and show no
Non-volatile material in Fifty-three (53) percent min. running or sagging tendencies when brushed on a vertical
vehicle steel surface.
Phthalic anhydride Twenty & five-tenths (20.5)
based on vehicle solids percent max. 7.2.10.11 Spraying Properties
Water Five-tenths (0.5) percent max. 1 The paint, when thinned, shall spray satisfactorily,
Table 7.2.10-1: Composition of Dark Green Finish Coat show no tendency to orange-peel, sag, creep or run, and
Paint shall show satisfactory spraying properties in all other
respects. The mineral spirits used as a reducer shall
ii. Pigment.: The extracted pigment shall conform conform to FSS TT-T-291 Grade 1, and shall be tested and
to the following by weight: approved prior to use.
Basic lead silico- Eighty-six (86) percent min.
7.2.10.12 Drying Time
chromate
Chromium oxide green Nine (9) percent min. 1 The paint shall be touch-dry in not less than twenty
Table 7.2.10-2: Composition of Pigment for Dark Green (20) minutes or more than four (4) hours and dry-through
in not more than twenty-four (24) hours.
Finish Coat Paint

7.2.10.3 Weight per Liter

1 Dark green finish coat paint shall weigh not less than
one and thirty-three hundredths (1.33) kilograms per liter.

♦ 7-6 ♦
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7.2.11 Zinc Dust Paint
7.2.11.1 Description
1 Zinc dust paint shall be a ready-mixed, high zinc dust
content paint suitable for repairing damaged spelter
coating on galvanized steel.
7.2.11.2 Requirements
1 The paint shall comply with all the requirements of
U.S. Military Specification MIL-P-21035 (Ships), Paint, High
Zinc Dust Content, Galvanizing Repair, dated August 23,
1957, with the following additions and exceptions:
i. The paint shall be supplied ready-mixed.
Material supplied in two (2) compartment cans
to be mixed on the job will not be accepted.
ii. Pigment content expressed as a weight percent
of total nonvolatile content may be a minimum
of ninety-two (92) instead of the ninety-four
(94) minimum required by the Military
Specification.
iii. Percent metallic zinc by analysis in the pigment
may be minimum of ninety-four (94) instead of
the ninety-seven and five-tenths (97.5)
minimum required by the Military Specification.
7.2.12 Gloss Enamel
7.2.12.1 Description
1 Gloss paint shall be a high-grade synthetic-type high
gloss enamel for use on exterior and interior metal. It shall
be highly weather-resistant and characterized by easy
brushing, good color and gloss retention, good drying and
flexibility, with freedom from after-tack.
7.2.12.2 Requirements
1 The paint shall conform to Federal Specification TT-
E-489, Class A, Air Drying. This enamel may be thinned
with Thinner; Federal Specification TT-T-291E, Type II,
Grade A (Mineral Spirits).
7.2.13 Sampling and Testing
1 All materials shall be accompanied by the
manufacturer's certificate of guarantee. The certificate
shall give the quantity of paint in the shipment and shall
identify the paint by order number, project location and
destination. Materials not accompanied by a certificate of
guarantee shall be sampled in the field and samples
submitted to an approved independent laboratory for
testing.
2 The Engineer will approve materials on the basis of
the certificates of guarantee and/or laboratory tests, but
reserves the right to resample and have retested any
materials used during the progress of the work. Should
the paint not conform to the specifications, it shall be
rejected, previous approval notwithstanding.
3 Materials and paints shall be analyzed or tested by
the methods specified in the ASTM, AASHTO, or FSS Test
Method Standard No. 141, for the material to be analyzed
or tested.
4 No paint or paint materials shall be used which have
not been approved by the Engineer. Paint or paint
materials for which samples and/or certificates of
guarantee of the same paint or paint materials have
previously been submitted to the Engineer and approved
thereby may be used if the additional shipments are
accompanied by the manufacturer's guarantee that the
product is equal in all respects to the previously approved
materials.
5 The required color, and, if applicable, texture of the
coating shall be as specified on the Drawings or as
directed by the Engineer and the coating shall be selected
by the Engineer on the basis of trial panels prepared by
the Contractor.
6 The Contractor shall supply manufacturer's samples,
specifications and chemical compositions of paint(s)
meeting the requirements of these specifications and
which correspond to the color and texture specified. A
minimum of five (5) samples per pay item shall be
provided, of which not more than three (3) shall be from
any one manufacturer. The Engineer shall select a
maximum of three (3) coatings per pay item for which trial
panels shall be constructed by the Contractor as specified
herein.
7.2.14 Portland Cement Paint
7.2.14.1 Description
1 Cement paint shall conform to the US Federal
Specification TTP- 0035(1) - Paint, Cementitious, Powder,
White and Colors and is intended for use on properly
prepared concrete surfaces; this paint shall not be applied
over old paint or other types of surfaces. Portland cement
paint is suitable for use on interior and exterior concrete
surfaces, below and above grade, under normal service
and climatic conditions. Where more stringent
requirements are anticipated, preference shall be given to
solvent based polymer paints, described below under
Clause 7.2.15.
7.2.14.2 Composition
1 Portland cement paint shall be a water-based
pigmented cement wash coating, having properties
similar to the concrete surface itself. Portland cement
paint shall be supplied as dry powder to be mixed with
water prior to using. After addition of water, thorough
mixing shall follow to obtain a creamy consistency to
facilitate a uniform application, and paint shall thereafter
be used within the time limits specified by the
manufacturer.
7.2.14.3 Colors
1 Portland cement paint colors shall be as shown
on the Drawings or as directed by the Engineer.
♦ 7-7 ♦
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7.2.15 Polymer Latex Paint
7.2.15.1 Description
1 Polymer latex paint shall conform to the US Federal
Specifications TT-P-0033 - Paint, Latex Base, Exterior, or
TT-P-96D - Paint Latex Base, for Exterior Surfaces and is
intended for use on properly prepared concrete surfaces,
not less than 3 weeks old, with normal, high or varying
moisture content, on masonry surfaces, and on other
types of old paints. Application over other types of paint is
subject to the manufacturer's written instructions and
limitations, and to the approval of the Engineer. Polymer
latex paint is suitable for use on interior and exterior
concrete and masonry surfaces, below and above grade,
under normal service and climatic conditions. Where more
stringent requirements are anticipated, preference shall be
given to solvent-based polymer paints, described under
Clause 7.2.16.
7.2.15.2 Composition
1 Polymer latex paint shall be a water-based dispersion
of pigments and polymeric film-forming materials. Film
formers may be butadiene-styrene, chlorinated rubber,
vinyl acetate or butyrate, or acrylic resins. Exterior grade
shall be used in all cases, with a flat or semi-gloss mildew-
resistant finish, as shown on the Drawings or as directed.
7.2.15.3 Colors
1 Polymer latex paint colors shall be as shown on the
Drawings or as directed by the Engineer.
7.2.16 Polymer Paint
7.2.16.1 Description
1 Polymer paint shall conform to the requirements of
the US Federal Specifications TT-P-1411A-Paint,
Copolymer Resin, Cementitious; TT-P-95CPaint, Rubber for
Swimming Pools and Other Concrete and Masonry
Surfaces; TT-P-97DPaint, Styrene-Butadiene Solvent Type,
White; TT-P-1181A(1)-Paint, Styrene-Acrylate Solvent
Types, Tints and Deep Tones; TT-C-545 D(1) - Coating :
Polyester-Epoxy (Two Component), High-Build, Gloss and
Semigloss, White and Tints; TT-C-1659A – Coatings :
Epoxy Emulsion, Two-Component Gloss and Semigloss;
TT-C-535B(1) - Coating, Epoxy, Two Component; TT-C-
542D - Coating, Polyurethane, Oil Free, Moisture Curing; or
MIL-C-22750C - Coating, Epoxy-Polyamide. Polymer paint
is intended for use on properly prepared interior or
exterior concrete and masonry surfaces, with low or
relatively stable moisture content, below and above grade,
under normal or adverse service conditions and normal,
humid or wet climatic conditions; and on certain types of
old paints, subject to the manufacturer's written
instructions/ limitations, to the approval of the Engineer,
and as herein specified.
♦ 7-8 ♦
7.2.16.2 Composition
1 Single-component polymer paints shall be
pigmented solvent-based solutions of resins, such as
chlorinated rubber, styrene butadiene and vinyl chloride-
vinyl acetate copolymers. Such ‘rubber-based’ paints shall
be of a formulation so as to possess a considerable degree
of flexibility and extensibility when applied to the specified
thickness, in order to maintain a continuous coating over
minor cracks which may exist or develop in the concrete
substrate.
2 The paint formulation shall have a potential to resist
soiling and be cleanable with commercial detergents.
Thermoplastic formulations and formulations soluble in
organic solvents shall not be approved for use on surfaces
that need to be cleaned with steam cleaning or strong
detergents and aggressive solvents.
3 Two-component polymer paints: One of the
components shall be a pigmented solution of a
compounded polymer, with or without solvent, such as
epoxy, urethane or polyester; the other component shall
contain a reactive chemical, the hardener. After mixing the
two components to the manufacturer's instructions,
application to the substrate and curing, the painted
surface shall be a hard, strong, chemical- and moisture-
resistant film with excellent adhesion to the protected,
properly prepared surface. The finished surface shall be
easy to clean, resistant to fungus and strong detergents,
and inert to heat and steam in order to be used as anti-
graffiti paint, when required. Two-component epoxy
formulations shall not be used on surfaces that are
exposed to sunlight. In such cases, two-component
exterior grade urethane formulations (aliphatic grades)
shall be approved for use.
7.2.16.3 Colors
1 Polymer paint colors shall be as shown on the
Drawings or as directed by the Engineer.
7.2.17 Acrylic Emulsion Paint
1 Acrylic emulsion paint shall comply in all respects
with the following Master Painters Institute Detailed
Performance Standards:
i. MPI #10 for flat paint,
ii. MPI #11 for semi-gloss, or
iii. MPI #119 for gloss.
2 The paint may be tinted by using ‘universal’ or ‘all
purpose’ concentrates.
7.3 Construction Requirements
7.3.1 General
1 Painting of steel and concrete structures and other
metal, concrete and masonry shall include proper cleaning
and preparation of the substrate surfaces; application,
protection, drying, and curing of the paint coatings;
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protection of pedestrian, vehicular or other traffic upon or
underneath or near the work; and protection of other
completed work against disfigurement by spatters,
splashes and smirches, of paint or of paint material.
7.3.2 Application
7.3.2.1 General
1 The paint shall be applied in accordance with the
following procedures:
i. Paint may be applied with brushes or by
spraying, except for aluminum paint, which
shall be applied by spraying. All spraying
equipment shall be subject to the Engineer's
approval. If work done by spraying is not
satisfactory to the Engineer, hand brushing will
be required,
ii. Paint shall be applied only when the air
temperature is at or above five degrees Celsius
(5oC.). It shall not be applied upon damp
surfaces or when the air is misty or otherwise
unsatisfactory for the work.
iii. Paint shall not be applied in the open on metal
or other surfaces that are too hot and which
will cause the paint to blister and produce a
porous paint film. Material painted under cover
shall remain under cover until dry and when
weather conditions permit its exposure in the
open.
iv. When brushes are used, the paint shall be
spread to produce a uniform even coating in
close contact with the substrate, or with
previously applied paint. To secure a
maximum thickness of paint film upon rivet
heads, the edges of plates, angles, or other
rolled shapes, these areas shall be ‘striped’ in
advance of the general painting, and shortly
afterwards shall be given a second or ‘wash’
coat when the general coat is applied. The
paint shall be well-worked into all joints and
open spaces.
v. Power spraying equipment shall apply the
paint in a fine, even spray, without the addition
of thinner. Paint, when applied with spray
equipment shall be immediately followed by
brushing, when necessary, to secure uniform
coverage and to eliminate wrinkling, blistering
and air holes.
vi. On all surfaces which are inaccessible for paint
brushes, the paint shall be applied with
sheepskin daubers specially constructed for the
purpose.
vii. Unless otherwise permitted or required by the
manufacturer's printed instructions, the
following shall apply:
- Water-based paints shall be applied
when the temperatures of the surfaces to
be painted and of the surrounding air are
between ten and thirty-two degrees
Celsius (10o- 32o C).
- Solvent-based paints shall be applied
when the temperatures of the surfaces to
be painted and of the surrounding air are
between seven and thirty-five degrees
Celsius (7o-35o C).
- Paint shall not be applied in fog, mist,
rain or when the relative humidity
exceeds eighty-five percent (85%).
Painting operations shall not start when
rain is anticipated to strike the painted
surface within twenty-four (24) hours of
application.
7.3.3 Concrete Surfaces
7.3.3.1 Preparation
1. Concrete surfaces to receive paint shall be prepared
to ensure complete adhesion of the coating material.
i. Preparation of concrete and masonry surfaces
shall comply with the requirements of this
Specification. Due to the continuous
development of new products, absolute
adherence to the paint manufacturer's
recommendations and written instructions is
critical for the proper performance of the work.
The Engineer may, at any time, require the
presence of the manufacturer's technical
representative on site, for as long as the
Engineer deems necessary, to ensure proper
execution of the work.
ii. The concrete and masonry surfaces shall not
be contaminated by chemicals, such as form
release agents or curing compounds that can
prevent good adhesion between the paint
material and the substrate. The surfaces shall
be newly exposed, free of loose, weak and
unsound materials. laitance, efflorescence,
inadequately cured concrete, and condensed
surface moisture are conditions objectionable
to paint application. The dryness or dampness
of the surface shall be compatible with the
paint type to be used as per the manufacturer's
instructions.
iii. Preparation of repaired concrete surfaces may
include chemical cleaning and mechanical
cleaning. Acid etching shall be employed only
at the recommendation of the paint
manufacturer and upon approval by the
Engineer, and shall be performed by crews
experienced in its use.
iv. Chemical cleaning shall be employed prior to
mechanical cleaning or acid etching when
removal of surface contaminants such as oil,
grease and dirt is required. Solutions of caustic
soda or tri-sodium phosphate may be used, as
well as proprietary detergents specially
formulated for use on concrete. Solvents shall
♦ 7-9 ♦
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 not be used for this purpose. The approved
detergent shall be applied with vigorous
scrubbing, followed by flushing with water to
remove all traces of both the detergent and the
contaminant.
v. Mechanical cleaning may include scarification
and grinding when small areas are involved.
For larger areas, wet sandblasting and,
preferably, high-pressure water jetting shall be
employed. Conventional dry sandblasting shall
not be permitted.
vi. Acid to be used for etching, when approved,
shall be a 10/90 maximum dilution ratio of
commercial grade phosphoric acid in water
solution, applied at a rate of one (1.0) liter per
square meter of surface to be prepared.
Hydrochloric acid solutions shall not be
permitted for this purpose. For small areas,
plastic sprinkling cans may be used for
dispensing the acid solution. Larger areas shall
be sprayed with low pressure automatic spray
equipment. Upon subsidy of the foaming
action of the acid (3 to 5 minutes) the entire
treated surface shall be thoroughly flushed
with water, while scrubbed with stiff bristle or
wire brushes to remove the salts formed on the
surface and to dislodge loose particles. The
adequacy of the flushing operation shall be
checked at several points within the cleaned
area by placing litmus or pH paper on the wet
surface to determine whether the acid has been
completely neutralized. Further flushing may
be necessary to ensure an absolutely
neutralized surface.
vii. When forced drying of wet surfaces is
necessary, as approved by the Engineer, heat
may be applied or dry, oil-free air may be
blown over the surface.
viii. Concrete and masonry surfaces to be painted
shall be tested for surface quality prior to
application of paint. Tests shall include
cleanliness, dryness and strength qualities of
the substrate as specified below.
ix. Cleanliness of Surface.
- Dusty condition: wipe the surface with a
dark cloth; if a white powder is on the
cloth, the surface is unsatisfactory.
- Oily condition: Sprinkle water on the
dried suspect surface; if the water
spreads out immediately instead of
standing as droplets, the surface is not
contaminated by oils.
- Acid condition: Use pH paper to
determine the acidity at the concrete
surface; a pH value below four (4) is
unacceptable.
x. Dryness of Surface: Unless otherwise specified
by the paint manufacturer, this test is
♦ 7-10 ♦
applicable only to solvent-based paints. Water-
based paints may be required to be applied on
damp surfaces to promote adhesion; however,
free-standing water on the surface to be
painted shall not be acceptable.
Moisture content is considered excessive on a
tested surface, if moisture collects at the bond
plane between the concrete and the paint
material before the paint has cured. Tape a one
and two tenths by one and two tenths (1.20 x
1.20) meters clear, polyethylene sheet to the
tested surface and determine the time required
for moisture to collect on the underside of the
sheet. Compare the time required for moisture
to collect, (1), with the time required for the
paint to cure, (2), as supplied by the paint
manufacturer. If (1) is greater than (2), the
surface is adequately dry.
xi. Strength of Surface, when laitance is present:
Unless otherwise specified by the paint
manufacturer, this test is applicable to water-
based paints and to two-component, solvent-
based paints.
Where loose powdery material is readily observed
following the scraping of the surface with a putty knife,
excessive laitance is present that could adversely affect
the adhesion of the paint. The paint manufacturer should
be consulted as to the intensity of mechanical cleaning
required.
7.3.3.2 Painting
1 Portland cement paint shall be applied to damp
surfaces without any free surface water. After application,
the paint shall be cured by keeping it moist for forty-eight
(48) to seventy-two (72) hours. For two-coat applications,
the second coat shall be applied within twenty-four (24)
hours from completion of the first coat. Dry film thickness
shall be not less than three hundred eighty (380) microns
per coat. One coat shall be applied, unless otherwise
shown on the plans.
2 Polymer latex paint shall be applied to damp
concrete surfaces, so water will not be absorbed from the
paint before it has a chance to properly cure, unless
otherwise specified by the manufacturer. When latex paint
does not properly adhere to chalky surfaces, the prior
application of a low viscosity penetrant primer will be
required, per the manufacturer's instructions. Any
embedded or adjacent steel work shall be coated with a
rust inhibitive primer as specified in this Section, before
application of any water-based paint. Dry film thickness
shall be not less than sixty-five (65) microns per coat. Two
coats shall be applied, excluding sealer or primer, unless
otherwise shown on the plans.
3 Polymer paint shall be applied to dry surfaces, unless
otherwise specifically permitted by the paint manufacturer
in writing. Two-component paints require the mixture of
the two components supplied as a kit, in the correct
proportions as per the manufacturer's instructions. To
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ensure a complete chemical reaction between the
hardener and the polymer, power stirrers shall be used for
thorough mixing. The paint shall be used after expiration
of the required induction period and within the expected
pot-life period of the mixed system, as specified by the
manufacturer. Should thinning or viscosity reduction be
necessary, only thinners recommended by the
manufacturer shall be used. Thinners shall be added only
after the two components are blended.
Dry film thickness shall be not less than forty (40) microns
per coat. A minimum of two coats shall be applied,
excluding primer, unless otherwise shown on the plans or
recommended by the paint manufacturer for the intended
purpose.
4 All finished coatings shall be uniform in color and
texture, free from runs, drops, ridges, waves, laps, etc.,
and shall match the color and texture of the approved
sample panel to the Engineer's satisfaction.
5 Should any coating, in the Engineer's opinion, be
non-uniform in color and/or texture or should there be
runs, drops, ridges, waves, laps, etc., in the coating, the
Contractor shall propose remedial works for the
Engineer's approval. Should the Contractor's proposals be
unacceptable, or should the remedial works result in an
unsatisfactory finish, the Engineer shall require the
Contractor to:
- Recoat the complete area affected; or
- Remove, to the extent possible, the coating
from the affected area and reapply the coating.
The Engineer shall notify the Contractor which option he
requires and, in the case of a re-coating being
unsatisfactory, the Engineer shall require the Contractor to
remove, to the extent possible, the re-coating and the
original coating and re-apply a new coating. All re-coating
works and removal and re-application of coatings shall be
at the Contractor's expense.
6 If the color of the coating departs from that of the
approved trial panel color to a degree which, in the
opinion of the Engineer, is unacceptable, the Contractor
shall stop application and shall demonstrate to the
Engineer's satisfaction that the coating formulation and/or
application method can be suitably adjusted to produce a
color matching that of the trial panel. If considered
necessary by the Engineer, the Contractor shall produce
additional trial panel(s) at his own expense to demonstrate
that a color match can be obtained.
7 If, in the opinion of the Engineer, a satisfactory color
match cannot be obtained, the Engineer, at his option,
may require the Contractor to remove, to the extent
possible, the unacceptable coating applied to the
permanent works and/or to apply an alternative coating.
Such an alternative coating will be selected by the
Engineer on the basis of the previously prepared trial
panels, except that where in the opinion of the Engineer
such trial panels are unacceptable, the Contractor shall
supply additional manufacturer's samples and trial panels
as the Engineer may require until a coating satisfactory to
the Engineer is obtained.
8 Acrylic emulsion paint for concrete shall be applied
in not less than two applications to produce a uniform
appearance. The paint shall be applied only when the
ambient temperature is 10 degree C or above. Painting
shall not be permitted when it can be anticipated that the
ambient temperature will drop below 10 degree C during
the application and drying of the paint.
7.3.4 Structural Steel Requirements
1 Unless otherwise specified on the Drawings, or in the
Special Specification, all new structural steel shall be
given three (3) coats of paint. The first coat shall be
applied immediately after shop fabrication is complete.
The second and third coats shall be applied after all
erection is complete, except that immediately following
the field riveting or bolting of members, the heads of field
rivets, bolts, and all abrasions of the shop coat due to
handling at the shop, shipment, erection, etc., and all field
erection marks shall be thoroughly covered with one (1)
coat of primer as specified for shop coat and permitted to
become thoroughly dry before the first field coat is applied.
2 All metal coated with impure or unauthorized paint
shall be thoroughly cleaned and repainted to the
satisfaction of the Engineer. Prime coats of paint shall be
at least four hundredths (0.04) millimeter thick when dry
and each intermediate and finish coat of paint shall be at
least three hundredths (0.03) millimeter thick when dry.
No portion of the paint films shall be less than these
specified thicknesses. The film thickness shall be not so
great that either the appearance or service life of the paint
will be detrimentally affected.
7.3.5 Shop Coat (Prime)
7.3.5.1 Shop Cleaning
1 All surfaces of metal to be painted shall be
thoroughly cleaned of rust, loose mill scale, dirt, oil or
grease, and all other foreign substances. The removal of
rust, scale and dirt shall generally be done by the use of
metal brushes, scrapers, chisels, hammers, sandblasting,
or other effective means. Oil and grease may be removed
by the use of gasoline or benzene. Bristle or wood fiber
brushes shall be used for removing loose dirt. Unless
cleaning is to be done by sandblasting, all weld areas,
before cleaning is done, shall be neutralized with a proper
chemical, after which they shall be thoroughly rinsed with
water. All cleaning shall conform to the requirements of
AASHTO Standard Specifications for Highway Bridges.
7.3.5.2 Shop Painting
1 Shop painting shall be done in accordance with the
following procedures:
i. When all fabrication work is complete and has
been accepted, all surfaces not painted before
assembling shall be given an approved shop
coat of paint. Steel members shall not be
♦ 7-11 ♦
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 loaded for shipment until thoroughly dry. No
painting shall be done after loading.
ii. Structural steel which is to be welded shall not
be painted before welding is complete. If it is to
be welded only in the fabricating shop and
subsequently erected by bolting, it shall receive
one (1) coat of paint after shop welding is
finished. Steel which is to be field welded shall
be given one (1) coat of boiled linseed oil or
other approved protected coating after shop
welding and shop fabrication are completed.
iii. Surfaces of metal to be in contact when
assembled shall not be painted. Surfaces of
field connections gusset plates of trusses and
areas of girders or plates where floor beam or
stringer connections are to come in contact
shall not be painted.
iv. With the exception of pins and pinholes in
bearings, unless otherwise shown in the
Drawings, all surfaces except those described
in Subparagraph iii, whether machine finished
or otherwise, shall be given the regular coat of
shop paint, and those parts inaccessible after
erection shall be given two (2) coats of field
paint. Pins and pinholes shall be coated, as
soon as practicable after being accepted, with a
hot mixture of white lead and tallow before
removal from the shop.
v. The composition used for coating machine
finished surfaces shall be mixed in the
following proportions:
- One and eight-tenths (1.8) kilograms of
pure tallow
- Nine-tenths (0.9) kilograms of pure white
lead
- Ninety-five hundredths (0.95) liters of
pure linseed oil
vi. Erection marks for field identification of
members shall be painted upon previously
painted surfaces.
7.3.6 Field Coat
7.3.6.1 Field Cleaning
1 When the erection work is complete, including all
riveting, bolting, welding, straightening of bent metal, etc.,
all adhering rust, scale, dirt, grease, or other foreign
matter shall be removed as specified under Paragraph
7.3.5.1, ‘Shop Cleaning’.
7.3.6.2 Field Painting
1 As soon as the field cleaning is done to the
satisfaction of the Engineer, the heads of field rivets and
bolts, welded surfaces, and any surface from which the
shop paint has worn off, or has otherwise become
defective, and all shipping and erection marks, shall be
touched up by covering with one (1) coat of the same type
♦ 7-12 ♦
of paint used in the shop, and allowed to become dry
before the first field coat is applied.
2 When the paint for ‘touching up’ coat has become
dry, the first and second field coats may be applied. In no
case shall a succeeding coat be applied until the previous
coat has dried through the full thickness of the paint film.
3 All small cracks and cavities which have not become
sealed by the first coat shall be filled with a paste mixture
of red lead and linseed oil before the second coat is
applied.
4 Contractor shall, take precautions to prevent dust
and dirt from coming in contact with freshly painted
surfaces or with surfaces before the paint is applied.
7.3.7 Bridge Railings and Guardrails
7.3.7.1 Bridge Railings
1 Metal bridge railing shall be painted as specified in
the Special Specification.
2 Aluminum hand rails shall not be painted except for
the portion of posts to be inserted in concrete which shall
first be painted with one (1) coat of zinc dust-zinc oxide
primer (Clause 7.2.6) to a point two (2) centimeters above
the concrete line. The aluminum hand rail after erection
shall be wiped with a rag saturated with lacquer thinner to
remove stains.
7.3.7.2 Guardrail
1 Guardrail posts and beams shall be painted if
specified in the Special Specifications. Under no
circumstances shall any paint other than zinc dust-zinc
oxide primer (Clause 7.2.6) be used for the shop or prime
coat on galvanized guardrails.
7.3.8 Painting Existing Structures
1 The painting of existing structures shall be done in
accordance with the following procedures:
i. Preparation shall include the removal of the
rust, scale, dead paint, dirt, grease or other
foreign matter from all parts of existing bridge
structures.
ii. The requirements and methods e for cleaning
and painting shall be the same as specified for
shop and field painting herein.
iii. All metal surfaces not in close contact with
other metal surfaces or truss members,
concrete, stone masonry, or other structure
materials shall be considered as exposed to
deterioration by rusting and shall be
thoroughly cleaned and given the number of
coats of designated paint stated in the Special
Specification.
iv. Unless otherwise stated, the metal shall be
given at least two (2) coats of paint.
v. When repainting with the same type of paint as
that on an existing surface, the surface shall be
thoroughly washed with commercial
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 detergents, or, where approved, with solvents, 3 Trial panels made by the Contractor to determine
to remove any dirt, chalk and grime suitability of surface preparation methods and of the
accumulation, along with dead paint. finished coating color and/or texture shall not be
vi. When repainting with a different type of paint measured for payment.
from that on an existing surface, the Contractor
shall ensure that the paint is compatible with 7.5 Basis of Payments
the existing paint.
vii. Loose paint, curled edges and blistered paint 1 Painting or repainting in whole or in part of existing
shall be removed before repainting. Light wet structure(s) shall rank for payment of the amount of
sandblasting, water-jet blasting, machine completed and accepted work as measured, at the unit
sanding, or paint strippers may be utilized. rate(s) bid per square meter as specified in the Bill of
viii. Filling of cracks and holes in the concrete shall Quantities.
be done in the same manner as for new 2 Unit rates shall be full compensation for furnishing
concrete. If the old paint has become partially all labor, transport, materials, equipment, tools, tackle,
removed, but that remaining is in good scaffolding and any other equipment, and for performing
condition, the bare areas shall be painted first, all surface preparation and cleaning and all other items
followed by two coats over all. If the old paint necessary for the proper completion of the work.
is blistered or peeling due to efflorescence, the
cause shall be investigated and the Engineer 7.6 Items in the Bill of Quantities
will instruct corrective measures or, the type of
paint may be changed.
1 Payment will be made under one or more of the
following:
7.3.9 Painting Steel Piling and Steel Pile
i Painting of existing concrete structure
Shells
(state type) (sq.m.)
1 Unless otherwise provided in the Drawings or ii Painting of existing steel structure
Special Specification, steel bearing piles, steel sheet piles, (state type) (sq.m.)
and steel pile shells need not be painted if they are to be iii Painting of existing railing
encased in concrete or other solid waterproof materials (state type) (lin.m.)
from six hundred (600) millimeters below the water line or
ground line to the tops of the piles.
2 When steel bearing piles, and steel pile shells are not
to be encased, or when provided in the plans, they shall
be painted in accordance with the requirements stated
hereinbefore, except that three (3) coats of shop paint
shall be applied from the tops of the piles to an elevation
three (3) meters below the water line or finished ground
line before driving, and then two (2) field coats of paint as
specified for structural steel shall be applied to each steel
bearing pile, or steel pile shell which extends above the
low water line or finished ground line after driving.

7.3.10 Painting Steel Pile Enclosures and

Tubular Steel Piers
1 The exterior surfaces of steel pile enclosures and
tubular steel piers shall be painted in accordance with the
requirements of Clause 7.3.8, Painting Existing Structures.

7.4 Method of Measurement

1 No separate measurement is made for painting of

new structures and miscellaneous metalwork, and piling
which work is considered subsidiary to other sections. The
rates stated in the Bill of Quantities for the work of the
relevant section shall be deemed to include for painting.
2 Painting of existing structures shall be measured in
square meters of the actual area painted..

♦ 7-13 ♦
copy 249
copy 249
Ref. Title Page No. Ref. Title Page No.
8.1 Pipe Culverts 8-1 8.2.2.4 uPVC Pipe 8-4
8.2.2.5 Polyethylene (PE) Gravity Pipe 8-4
8.1.1 General 8-1
8.2.2.6 GRP Pipes 8-4
8.1.1.1 Description 8-1
8.2.2.7 Vitrified Clay Pipes 8-5
8.1.1.2 Submittals 8-1
8.2.2.8 Joints for Concrete Beds and Pipe
8.1.1.3 Installation and Checking 8-1
Surrounds 8-5
8.1.2 Materials 8-1
8.2.2.9 Bitumen Emulsion 8-5
8.1.2.1 Delivery, Storage and Handling 8-1
8.2.2.10 Pumping Plant 8-5
8.1.2.2 Precast Reinforced Concrete Pipe 8-1
8.2.3 Construction Requirements 8-5
8.1.2.3 Unreinforced Concrete Pipe 8-1
8.2.3.1 Excavation, Bedding and Backfilling 8-5
8.1.2.4 Reinforced Concrete Arch Culvert 8-1
8.2.3.2 Pipe Laying 8-5
8.1.2.5 Reinforced Elliptical Culvert 8-1
8.2.3.3 Jointing of Pipes 8-5
8.1.2.6 Corrugated Steel Circular Pipe
8.2.3.4 Line and Gradient 8-6
and Pipe Arches 8-1
8.2.3.5 Floatation 8-6
8.1.2.7 Bituminous Coated Corrugated Steel
8.2.3.6 Pipe Built Into Structures 8-6
Circular Pipe and Pipe Arches 8-2
8.2.3.7 Cleaning and Inspecting of Storm
8.1.2.8 Polymer Coated Steel Circular Pipe
Sewer Pipes 8-6
and Pipe Arches 8-2
8.2.3.8 Field Testing: Generally 8-6
8.1.2.9 Concrete and Steel 8-2
8.2.3.9 Air Testing of Pipelines 8-6
8.1.3 Construction Requirements 8-2
8.2.3.10 Hydrostatic Testing of Pressure
8.1.3.1 Excavation, Bedding and Backfilling 8-2
Pipelines 8-7
8.1.3.2 Pipe Laying 8-2
8.2.3.11 Infiltration Test for Gravity Pipes 8-7
8.1.3.3 Precast Concrete Pipe and Pipe Arches 8-2
8.2.3.12 Deflection Tests for GRP Pipes 8-7
8.1.3.4 Corrugated Metal Pipe and Pipe Arches 8-2
8.2.3.13 Hydraulic Individual Joint Test for Pipes
8.1.3.5 Cast-in-Situ Concrete Pipe
Exceeding 1000 mm 8-7
and Pipe Arches 8-3
8.2.4 Method of Measurement 8-7
8.1.4 Method of Measurement 8-3
8.2.5 Basis of Payment 8-7
8.1.5 Basis of Payment 8-3
8.2.6 Items in the Bill of Quantities 8-8
8.1.6 Items in the Bill of Quantities 8-3
8.3 Manholes, Inlets and
8.2 Storm Sewers 8-3
Chambers 8-8
8.2.1 General 8-3
8.3.1 Description 8-8
8.2.1.1 Description 8-3
8.3.2 Materials 8-8
8.2.1.2 Installation and Checking 8-3
8.3.3 Construction Requirements 8-9
8.2.1.3 Submittals 8-3
8.3.3.1 Manholes 8-9
8.2.2 Materials 8-4
8.3.3.2 Chambers for Grated Inlets, Curb Inlets
8.2.2.1 Delivery and Storage 8-4
and Ditch Inlets and Outlets 8-9
8.2.2.2 Concrete and Steel 8-4
8.3.3.3 Ironwork 8-9
8.2.2.3 Concrete Pipes 8-4

copy 249
Ref. Title Page No.
8.3.3.4 Cleaning 8-9
8.3.4 Method of Measurement 8-9
8.3.5 Basis of Payment 8-10
8.3.6 Items in the Bill of Quantities 8-10

8.4 Drainage of Structures 8-10

8.4.1 Description 8-10

8.4.2 Materials 8-10
8.4.2.1 Gully and Channel Gratings
and Frames 8-10
8.4.2.2 Pipes 8-10
8.4.2.3 Drainage Backfilling 8-10
8.4.3 Construction Requirements 8-10
8.4.4 Method of Measurement 8-12
8.4.5 Basis of Payment 8-12
8.4.6 Items in the Bill of Quantities 8-12

copy 249
8.1 Pipe Culverts
8.1.1 General
8.1.1.1 Description
1 This Sub-section describes requirements for
furnishing all materials, constructing and installing
concrete and steel pipe culverts including excavation,
bedding and backfilling and all work described in this
Section of the Specification and as shown on the
Drawings.
8.1.1.2 Submittals
1 Coordination Drawings: Submit drawings showing
culverts and major system components. Indicate interface
and spatial relationship between culverts, system
components, adjacent utilities, and proximate structures.
2 Shop Drawings: Submit shop drawings of culverts
including plan layout and locations, types, sizes, capacities,
and flow characteristics in accordance with the
requirements of this Specification Sub-section 1.11.
3 As-Built Drawings: At project close-out, submit
record drawings of installed culverts, in accordance with
requirements of this Specification, Sub-section 1.11.
4 Certificate of Compliance: Submit certificates of
compliance required by the Client Authority and as
directed by the Engineer.
8.1.1.3 Installation and Checking
1 The work shall be supervised by qualified
representatives of the Contractor and full facilities and
assistance shall be provided by the Contractor to enable
the Engineer to inspect or check the work at any time.
Such inspection or checking shall in no way relieve the
Contractor from any of his obligations.
2 The Contractor shall be responsible for making minor
adjustments to the location of work as necessary to suit
site constraints and road alignment and profile subject to
the approval of the Engineer.
8.1.2 Materials
8.1.2.1 Delivery, Storage and Handling
1 Deliver piping with factory-applied end caps.
Maintain end caps through shipping, storage, and
handling to prevent pipe-end damage and to prevent
entrance of dirt, debris, and moisture.
2 Protect stored piping from moisture and dirt. Elevate
above grade. Do not exceed structural capacity of floor
when storing inside.
3 Protect flanges, fittings, and specialties from
moisture and dirt.
4 Manufacturer’s recommendations on handling,
repairing, laying, jointing, anchoring, cutting and other
works for pipes and fittings are to be strictly followed.
8.1.2.2 Precast Reinforced Concrete Pipe
1 Reinforced concrete pipe shall meet the requirements
of Volume 2 of the Highway Design Standards and shall
comply with BS 5911-1, BS EN 1916 Class H, ASTM C76-02
Class IV or DIN V 1201 and DIN EN 1916. Cement used in
manufacture shall be ordinary Portland cement to BS EN
197-1.
2 Joints shall be gasket type with flexible spigots and
sockets. The shape of the joint shall be designed to
prevent any movement of the gasket during assembly and
to produce full water-tightness. Rubber gasket shall be to
ISO 4633 or BS EN 681-2.
3 Manufactured pipe shall, if required by the Engineer,
be tested, prior to delivery to site, for structural strength,
crushing strength and absorption. The manufacturer's
specification and certificate shall be submitted for prior
approval before pipes are delivered to the site.
4 Pipes that fail to meet the strength requirements may,
with the approval of the Engineer, be incorporated in the
work provided the following requirements are met.
i. The strength does not fall below 80% of that
specified.
ii. The pipes are clearly marked and stored
separately from pipes which fully comply with
strength requirements.
iii. The pipes are bedded in Class 15 concrete.
5 If under-strength pipes are installed with pipes fully
complying with the strength requirements, the whole run
shall be classified as under-strength for record purposes.
8.1.2.3 Unreinforced Concrete Pipe
1 Unreinforced concrete pipe shall meet the
requirements of the Highway Design Standards and shall
comply with BS 5911-1, AASHTO M 86M / M 86, DIN V
1201 and DIN EN 1916 or ASTM C14M and with Paragraph
8.1.2.2 items 2 to 5. Class shall be as designated on
drawings. Cement used in manufacture shall be ordinary
Portland cement to BS EN 197-1.
8.1.2.4 Reinforced Concrete Arch Culvert
1 Reinforced concrete arch culvert shall comply with
AASHTO M 206M / M 206 or ASTM C506-02. Unless
otherwise specified Class A-IV shall be used for spans of
1300mm or less, and Class A-III for larger spans.
8.1.2.5 Reinforced Elliptical Culvert
1 Reinforced concrete elliptical culverts shall be to
AASHTO M 207M / M 207 or ASTM C507M-02. Their Class
shall be as designated on drawings.
8.1.2.6 Corrugated Steel Circular Pipe and Pipe Arches
1 Corrugated steel culvert pipe shall comply with the
requirements of AASHTO M36 and be zinc coated.
2 A certificate of guarantee from an approved pipe
fabricator shall be submitted by the Contractor for each
shipment of pipe delivered to the Site. The Certificate
♦ 8-1 ♦
copy 249
shall show the quantities of material and state that the
listed materials conform to the specified requirements.
3 The Engineer may test any material for compliance
with the Specification at any time and reject any material
which does not meet the requirements even though it has
received prior approval based on a Certificate of
Guarantee.
8.1.2.7 Bituminous Coated Corrugated Steel Circular
Pipe and Pipe Arches
1 Bituminous coated corrugated steel circular pipe and
pipe arches shall comply with AASHTO M 190, and with
Paragraph 8.1.2.6.
8.1.2.8 Polymer Coated Steel Circular Pipe and Pipe
Arches
1 Polymer coated metal pipe and pipe arches shall
comply with AASHTO M 246 and with Paragraph 8.1.2.6.
8.1.2.9 Concrete and Steel
1 Concrete, reinforcing steel and reinforced concrete
shall conform to the requirements of Sub-sections 5.1, 5.2
and 5.3 respectively. Structural steel and other metalwork
shall conform to Sub-section 6.2.
8.1.3 Construction Requirements
8.1.3.1 Excavation, Bedding and Backfilling
1 All excavation and backfill shall conform to the
requirements of Sub-Sections 2.3 and 2.8.
8.1.3.2 Pipe Laying
1 Pipes shall not be placed until the foundation has
been approved by the Engineer. Pipes shall be laid
accurately to line and level and shall have a uniform
bearing at each joint and along the entire length of pipe.
Pipe laying shall begin at the downstream end and
progress upstream.
2 Manufactured pipe shall be handled and assembled
in accordance, with the manufacturer's instructions. When
pipe laying is not in progress, the Contractor shall close
open ends of pipes with properly fitted temporary wooden
plugs or standard caps as directed
3 The Contractor shall use ropes, wire slings, band
slings, spreader beams etc. for lowering pipes as
recommended by manufacturer for each type of pipe and
as approved.
4 All material shall be carefully examined for damage
and tested in accordance with manufacturer's instructions
before laying, to the satisfaction of Engineer.
5 The Contractor shall remove dirt and other materials
before lowering the pipe into the trench and verify the
pipe inside is clear from construction debris before
making joints.
6 Pipe on solid ground: The Contractor shall cut holes
in the bottom of trench to allow proper jointing and for
♦ 8-2 ♦
barrel of pipe to bear evenly on solid ground for its full
length.
7 Pipe on granular bedding: The Contractor shall scoop
out locally at sockets/couplings to enable the pipe to rest
uniformly on the barrel and adjust to the exact line and
level. After testing, the Contractor shall lay and compact
further granular material in 150 mm layers or as approved
to levels shown on the Drawings.
8.1.3.3 Precast Concrete Pipe and Pipe Arches
1 Pipes shall be laid with hub, bell or groove ends
upstream.
2 Where lift holes have been used, they shall be filled
with an approved cement-sand mortar to provide a
watertight section. Mortar shall be finished flush on the
inside of the pipe.
3 Pipe joints shall be sealed with flexible watertight
elastomeric or rubber gaskets, approved bituminous
sealers or plastic sealants. Bituminous or plastic sealants
shall be applied at the time pipe is being laid. Sealants
shall be installed in accordance with the sealant
manufacturer's instructions so that the joint is completely
filled.
4 Multiple pipe culverts, unless otherwise shown on
the Drawings, shall be laid with one-half diameter of pipe
or a minimum of 300mm, whichever is greater, between
the pipes.
8.1.3.4 Corrugated Metal Pipe and Pipe Arches
1 Metal pipe shall be laid with outside laps of
circumferential joints pointing upstream and with
longitudinal laps along the sides. If pipe sections are
jointed on the Site, the ends shall be butted as closely as
corrugations will permit and shall be joined with a firmly
bolted coupling band of the same material as the pipe.
Camber shall be built into the pipe structure to
compensate for settlement from fill loads,
2 Multiple culverts, unless shown otherwise on the
Drawings, shall be laid with one-half span of pipe or a
minimum of 300mm whichever is the greater, between
pipes.
3 The Contractor shall examine material to ensure
internal coating or lining and outer coating or sheathing
are undamaged. If damaged, the Contractor shall make
good or dispose of as directed. Damage to bituminous or
epoxy resin coatings may be repaired on site by
application of a repair material of a brand and type
approved by the Engineer. Pipes having any localized
bends in excess of 5% of the nominal pipe diameter or
dents in excess of 13mm depth will be rejected. Pipes
rejected because of these defects may be used if
satisfactorily repaired and approved by the Engineer.
copy 249
8.1.3.5 Cast-in-Situ Concrete Pipe and Pipe Arches 8.1.6 Items in the Bill of Quantities
1 Cast-in-situ pipes shall be constructed in accordance i. Unreinforced precast concrete
with the Drawings, or in a manner proposed by the pipe culvert (diameter) (lin.m.)
Contractor and approved by the Engineer. ii. Reinforced precast concrete
pipe culvert (diameter) (lin.m.)
2 When the Contractor elects to construct the pipe in a
iii. Reinforced precast concrete arch
trench with no external vertical forms, 40mm of additional
culvert (size) (lin.m.)
concrete cover to the reinforcement steel shall be
iv. Reinforced precast concrete
provided.
elliptical culvert (size) (lin.m.)
3 Longitudinal construction joints will only be v. Corrugated steel pipe culvert
permitted as shown on the Drawings. Transverse (diameter) (coating) (lin.m.)
construction joints will be permitted provided prior vi. Corrugated steel pipe arch
approval is obtained from the Engineer. culvert (size) (coating) (lin.m.)
4 Forms for cast-in-situ pipe shall be approved prior to vii. Cast in-situ concrete pipe and
their use. Inside pipe forms shall be suitably unyielding pipe arches (size, type) (lin.m)
during placement of concrete. Interior arch forms may be
removed after 72 hours if approved by the Engineer. The 8.2 Storm Sewers
Contractor shall take precautions when removing forms to
protect the culvert from damage. Backfilling shall not
8.2.1 General
commence until tests indicate the concrete has attained
strength of 50% of the requirement for its Class. 8.2.1.1 Description

8.1.4 Method of Measurement 1 This Sub-section describes requirements for

constructing pipes for the removal of surface water from
1 Pipe culverts shall be measured by the linear meter roads, including connections to rainwater inlets and
of culvert laid or constructed as per the contract Drawings. discharge to suitable outfall. The work shall include
Culverts of each type, class and size shall be measured furnishing all materials, installing pipes, excavation,
separately. For pipe culverts without headwalls, bedding and backfilling.
measurement shall be taken from end to end along the
centerline of the pipe. For pipes connected to structures, 8.2.1.2 Installation and Checking
measurement shall be taken between the inside faces of
1 Installation and checking shall comply to the
parapet or wall along the centerline of the pipe.
requirements of Paragraph 8.1.1.3.
2 The measured length of corrugated metal pipe shall
2 Collect site information by performing site survey,
include the length of bends (elbows) installed.
researching public utility records, and verifying existing
3 Headwalls, wing walls, aprons and cut-off walls that utility locations.
are part of a pipe culvert installation are measured
separately in accordance with Sub-Section 5.9. 8.2.1.3 Submittals

4 Trench excavation, bedding and backfilling for
culvert pipe runs is measured separately under Sub-
section 2.8, Clause 2.8.4
5 No separate measurement or payment will be made
for connection to drainage structures or to existing pipes.
Nor for additional reinforcing steel, cover and protection
to in-situ concrete pipe culverts and pipe arches, all of
which are considered subsidiary work.
8.1.5 Basis of Payment
1 The quantity of completed and accepted work.
measured as provided for above, will be paid for at the
unit rate per linear meter in the Bill of Quantities for 'the
various types, classes and sizes of pipe and arch culverts,
which rate shall be full compensation for the cost of
supply, transport, handling, installation of pipe, joints,
materials, labor, equipment, tools and other items
necessary for proper completion of the work.
1 Coordination Drawings: Submit drawings showing
pipes and major system components. Indicate interface
and spatial relationship between pipes, system
components, adjacent utilities, and proximate structures.
2 Shop Drawings: Submit shop drawings of storm
sewers systems including plan layout and locations, types,
sizes, and capacities of pipes, manholes and stormwater
inlets in accordance with the requirements of the
Specification Sub-section 1.12.
3 As-Built Drawings: At project close-out, submit
record drawings showing the installed pipes and related
components with sufficient details to allow for locating the
pipes for future maintenance. The As-Built drawings shall
be in accordance with requirements of the Specification,
Sub-section 1.12.
4 Certificate of Compliance: Submit certificates of
compliance as required by the Client Authority and as
directed by the Engineer.

♦ 8-3 ♦
copy 249
8.2.2 Materials
8.2.2.1 Delivery and Storage
1 Delivery, storage and handling shall comply to the
requirements of Paragraph 8.1.2.1.
2 During storage plastic pipes shall be protected from
sunlight and supported to prevent sagging and bending.
8.2.2.2 Concrete and Steel
1 Concrete, reinforcing steel and reinforced concrete
shall conform to the requirements of Sub-sections 5.1, 5.2,
and 5.3 respectively. Structural steel and other metalwork
shall conform to Sub-section 6.2.
8.2.2.3 Concrete Pipes
1 Reinforced and unreinforced concrete pipes shall
comply with the requirements of Paragraphs 8.1.2.2 and
8.1.2.3, respectively.
8.2.2.4 uPVC Pipe
1 Pipes shall conform to DIN 8061 / 8062 Class 6 kg/cm2
or Class 10 as indicated on the Drawings or the Bill of
Quantities. Use concrete encasement if cover is less than 1
meter or greater than 5 meters.
2 Fittings shall be to DIN 8061 / 8062 fabricated from
pipe.
3 Joints shall be to DIN 8061 / 8062, socket spigot with
rubber sealing rings to BS EN 681-2.
4 Under-drain pipes shall be perforated plastic pipe
conforming to DIN 8061 Class 10 kg/cm2 or equivalent.
Perforations may be circular holes or slots. Different filter
requirements shall apply to each type of perforation.
5 Circular perforations shall be between 5 mm and 10
mm in diameter arranged symmetrically in a minimum of
4 rows parallel to the axis of the pipe. All rows shall be in
the lower half of the pipe but no row shall be closer than
36 degrees to the invert. Perforations in each row shall be
at a maximum distance of 100 mm centre to centre.
6 Slotted perforations shall be between 1.5 mm and 3
mm in width, and between 25 mm and 40 mm in length
measured on the inside of the pipe. Perforations shall be
in 2 rows parallel to the axis of the pipes on each side of
the invert. Each row shall be approximately 45 degrees
from the invert. Perforations shall be spaced between 20
and 30 times the average slot width along each row.
7 Pipes and fittings shall be protected from the direct
rays of the sun at all times by means of reflective cover
sheets.
8.2.2.5 Polyethylene (PE) Gravity Pipe
1 Polyethylene (PE) pipes and fittings shall conform
with ASTM D3035-01, ASTM F894. and installation shall be
in accordance to ASTM D2321-00 and manufacturer’s
recommendations.
2 Jointing system should be in accordance with ASTM
F894.
♦ 8-4 ♦
3 Materials used shall have a standard PE code
designation 2406 and a minimum hydrostatic design basis
of 1250 psi (8.6MPa) for water at 73.4°F (23°C) according to
AWWA C906 Table 1.
8.2.2.6 GRP Pipes
1 Pipes and fittings shall conform to BS EN1796 & BS
EN14364 or American Water Works Association AWWA
C950.
2 Pipe and fittings shall include a corrosion resistant
liner, a structural wall and a resin rich exterior surface.
3 The liner shall have a nominal thickness of 1.0 mm.
The liner surface shall be reinforced with C glass. The
remainder of the liner thickness shall be reinforced with an
acid resistant chopped E glass strand or mat.
4 The pipe structural wall shall consist of glass
reinforcement, and fine silica sand, all impregnated with
resin. The fine silica sand shall be added to the structural
layer to achieve the design thickness for the required
stiffness specified such that the overall hoop flexural
modulus (E) for pipe is not less than 24 GN/m2. Silica sand
and filler content shall not exceed 50%.
5 Pipes shall be provided with a resin rich outer layer
reinforced with one layer of C glass veil. The exterior layer
shall have a minimum thickness of 0.2 mm. The layer shall
be resin rich and reinforced with one layer of C glass.
6 The resin used for the corrosion resistant liner of the
pipe and fittings shall be high grade polyester resin
(isophthalic or better) type. For the structural wall and
exterior layer of the pipe a high grade isophthalic
polyester resin shall be used. No dark pigments shall be
used in the pipe or fittings.
7 Pipes shall be designed for a life of not less than 50
years. Contractor shall submit calculations for initial and
long term deflection with truck loads, buckling, vacuum,
pressure class, and strain in accordance with Appendix A
of AWWA C-950 or equivalent. The maximum calculated
long term deflection should not exceed 3%. Copies of the
design calculations shall be submitted to the Engineer for
approval..
i. Stiffness: Minimum 5,000 N/m2. Suitability of
stiffness shall be verified by Contractor for the
various trench and pipe laying conditions and
as recommended by the manufacturer.
Pressure Class; 6 kg/cm2 minimum or as shown
on Drawings.
ii. Longitudinal Strength: Conform to BS EN1796
& BS EN14364 or ASTM D3262 table 7.
iii. Hoop strength shall be according to ASTM
D3517 Table 8.
iv. Strain corrosion resistance tests shall be
carried out as per ASTM D 3681 or to BS
EN1796 & BS EN14364 strain corrosion value at
50 years to equal or exceed 0.7%.
v. Markings shall be to BS EN1796 & BS EN14364
Clause 11.
vi. Joints shall be GRP double socket couplings
with rubber rings to ISO 4633 or BS EN 681-2
copy 249
 . The allowable angular deflection shall
conform to the requirements of BS EN1796 &
BS EN14364.
8.2.2.7 Vitrified Clay Pipes
1 Vitrified clay pipes and fittings shall be to BS EN 295
and shall be marked accordingly.
2 Unless otherwise indicated, pipes and fittings shall
be Extra Strength and shall comply with absorption tests
made in accordance with BS 65.
3 Pipes shall be supplied with approved flexible and
telescopic rubber ring joints which shall be capable of
withstanding the specified tests pressures applied both
internally and externally.
4 Junctions on clay pipe sewers shall be of similar
material and suitable for use with flexibly jointed pipes.
5 Before any length of pipe is laid, it shall be inspected
and stood or slung vertically at the side of the trench
and ’rung’ with a wooden mallet. Any damaged or cracked
pipe shall be rejected.
6 Where shown on the Drawings, pipes for use in the
construction of drains shall be British Standard Surface
Water pipes glazed or unglazed manufactured in
accordance with the requirements of BS 65, with Type 2
sockets or plain ended supplied with sleeve couplings.
7 Perforated pipes shall be Type 1 socketed and sleeve
coupled pipes.
8 Field drain pipes shall comply with the requirements
of BS EN 295-5 and BS 1196.
8.2.2.8 Joints for Concrete Beds and Pipe Surrounds
1 Flexible joints in concrete beds and surrounds to
pipes shall be formed with compressible fibrous board, or
similar approved material, 20mm thick.
8.2.2.9 Bitumen Emulsion
1 Bitumen emulsion shall be to BS 434 and shall
contain not less than 53% of prime bitumen.
8.2.2.10 Pumping Plant
1 Pumping plant is as specified in Section 17.
8.2.3 Construction Requirements
8.2.3.1 Excavation, Bedding and Backfilling
1 All excavation and backfill shall conform to the
requirements of Sub-Sections 2.3 and 2.8.
8.2.3.2 Pipe Laying
1 Pipe laying shall comply with the requirements of
Paragraph 8.1.3.2.
2 For pipe on a concrete bed or surround, the
Contractor shall provide rectangular blocks of concrete
Class 25, made in approved moulds at least 14 days before
use, and approved hardwood folding wedges. The
Contractor shall provide two concrete blocks for each pipe,
♦ 8-5 ♦
set and boned into the correct level on the trench
formation bottom and will lay the pipe properly centered
and socketed.
3 The Contractor shall insert two hardwood folding
wedges (of a width equal to the width of the concrete
block) between the body of the pipe and block, and drive
them together until the pipe is brought to the exact level
required. The Contractor shall leave blocks and wedges
undisturbed while pipes are being jointed and the
concrete bed and haunch or surround are being placed.
The Contractor shall ensure blocks and wedges are of
sufficient size and strength to prevent settlement of pipes.
The Contractor shall leave sufficient space to enable joints
to be made, tested and inspected.
4 The Contractor shall lay pipes on an even formation
true to grade and line, with sockets facing up the gradient.
5 Tolerances shall be 6 mm in level and 25 mm in line
between manholes or access points unless otherwise
specified. Where pipe is to be constructed in straight lines
between manholes the length will not be accepted if a
light at each manhole cannot be seen from adjacent
manholes.
8.2.3.3 Jointing of Pipes
1 Unless otherwise specified, the manufacturer's
instructions shall be followed regarding placement of
bedding and backfilling, cleanliness of joint surfaces,
lubricant used, correct location of components, provision
of correct gaps between end of spigot and back of socket
for flexible joints etc.
2 Concrete pipes shall have watertight joints sealed
with approved rubber rings or flexible gaskets. Joints
shall have a gap formed between the end of the spigot
and the base of the bell of not less than 6mm and not
greater than 20mm. The gap shall then be filled with a
cement mortar composed of 1 part Portland cement and 3
parts fine aggregate, mixed with sufficient water to form a
workable paste. As each section of pipe is laid, the bell or
hub of the preceding pipe shall be wetted and cleaned and
the bottom portion filled with mortar. After the pipe is
placed, the remaining top part of the gap shall be filled.
3 The inside of the joint shall be finished smooth and
wiped clean. The mortar on the outside shall, after its
initial set, be protected from the sun. Plastic joint
compound may be used in lieu of Portland cement mortar,
in which case it shall be prepared in accordance with the
manufacturer’s recommendations.
4 Synthetic or rubber joint rings shall be stored until
needed in a cool place away from direct sunlight.
5 Properly fitted temporary wooden stoppers shall be
used to close the ends of uncompleted pipe lines. The
stoppers shall only be removed when pipes are being laid
and jointed.
6 The Contractor shall not deflect flexible joints beyond
maximum permissible angles given by manufacturer
and/or relevant Standards.
copy 249
7 The Contractor shall strictly comply with special
instructions issued by manufacturers of proprietary joints
when laying and jointing.
8 The Contractor shall joint differing pipe and fitting
material with adaptors as recommended by the pipe
manufacturer.
8.2.3.4 Line and Gradient
1 In open excavation: The Contractor shall provide and
maintain sight rails and boning rods properly painted to
ensure correct alignment of pipe runs. Sight rails shall be
positioned either vertically above the lines of pipes or
immediately adjacent thereto. At no time shall there be
less than three sight rails in position on each length of
pipeline under construction to any one gradient.
2 Where pipes are laid in headings, the Contractor shall
provide and maintain marks to establish line and level of
pipeline. Marks shall be fixed in each working shaft and
two further marks established in each length of heading.
8.2.3.5 Floatation
1 Prevention: Whenever water is excluded from interior
of pipe, the Contractor shall place sufficient backfill above
pipe to prevent floatation.
2 The Contractor shall remove: any pipe that has
floated, correct the bedding and relay.
8.2.3.6 Pipe Built Into Structures
1 The Contractor shall thoroughly clean outside
surface of pipes to be built-in immediately before
installation. Remove protective coating to metal pipes,
and roughen clay and concrete pipes as directed. Plastic
pipes shall be painted with appropriate solvent cement
and sprinkled with dry coarse sand whilst wet. The
Contractor shall cut away sheathing from sections to be
built-in and after installation restore protection up to
external face of structure with approved bituminous
material.
2 Install two flexible joints or flexible patented joints
adjacent to structures. The Contractor shall place first
joint not more than one pipe diameter from face of
structure and second not more than the following
distances away from first:
i. Pipelines not exceeding 450 mm: 2 pipe
diameters.
ii. Pipelines over 450 mm and not exceeding 1000
mm: 1.2 m.
iii. Pipelines over 1000 mm: 1.8 m.
8.2.3.7 Cleaning and Inspecting of Storm Sewer Pipes
1 After backfilling and completion of connections to
manholes, etc, but before the trench surfaces are
permanently reinstated, the interior of the sewers shall be
cleaned out and ready for inspection by the Engineer.
2 Pipelines of 700 mm or more diameter will, where
practicable, be inspected from the inside and the
♦ 8-6 ♦
Contractor shall provide a suitable personnel trolley for
this purpose.
3 Pipelines less than 700 mm diameter and larger pipes
which cannot be inspected from the inside shall have a
mandrel formed from a cylinder, of diameter 25mm
smaller than the pipe diameter and of length not less than
the internal diameter of the sewer, passed through.
4 On completion the drains and sewer pipes shall be
flushed from end to end with water and left clean and free
from obstructions and debris.
8.2.3.8 Field Testing: Generally
1 All test equipment and related items shall be
provided on site before the test. i.e. pressure gauges,
instruments, water etc...
2 The Contractor shall carry out tests in the presence of
the Engineer's Representative.
3 Fittings and joints shall be permanently anchored
before testing and all joints shall be exposed for checking.
4 Sections of pipeline under test shall not exceed 500m
in length for any one test.
5 Test plugs at the ends of each section shall be
secured by struts.
6 The Contractor shall apply pressure by manually
operated test pump or, in the case of large diameter mains,
by power driven test pump, if approved.
7 The Contractor shall examine exposed joints and
repair visible leaks.
8 Should a test fail, the Contractor shall locate leak and
replace or make good defective pipe or replace and make
good faulty joint and retest main.
9 The Contractor shall keep test records in an approved
form and hand original copy to the Engineer immediately
after completion of test.
10 The Contractor shall carry out hydrostatic test while
pipeline is partially backfilled.
8.2.3.9 Air Testing of Pipelines
1 As soon as practicable after a length of pipe has been
completed it shall be subjected to an air test to BS EN
1610. The length shall be plugged and sealed and air
pumped into the pipe by approved method (ie. hand
pump) until a pressure 100 mm head of water is indicated
on a U-tube connected to the system
2 The Contractor shall allow 5 minutes for stabilization
of air temperature and adjust pressure to 100 mm. The
section will not be considered satisfactory if the air
pressure fails from 100mm to 75mm head of water in 5
minutes or less.
3 Failure to pass the air test is not conclusive and if no
leakage can be traced by external application of soapy
water to all sealing areas then a hydrostatic test shall be
carried out before final rejection.
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8.2.3.10 Hydrostatic Testing of Pressure Pipelines
1 The pipeline shall be filled slowly with water from the
lowest point. After filling with water, absorbent pipes shall
be allowed to stand for at least 24 hours before testing to
allow for complete absorption.
2 Entrapped air shall be bled and pressurizing shall
then proceed until the specified test pressure is reached in
the lowest part of the pipeline section under test. Further
quantities of entrapped air shall be bled while the pressure
is being raised.
3 Unless otherwise specified, the test pressure shall be
equal to 1.0 m head of water above pipe soffit at highest
point and not greater than 6 m head of water at lowest
point of section under test but shall in no case exceed 75%
of the factory hydrostatic test pressure. If maximum head
is exceeded, the Contractor shall test section in stages.
4 The test pressure shall be maintained for one hour by
pumping using a separate test pump. Pumping shall then
be stopped for 2 hours, at the end of which time the line
shall be re-pressurized to the original test pressure and the
volume of water pumped into the line recorded.
5 The pipeline shall be deemed to have failed the test if
visible leaks are detected (regardless of leakage being
within the allowable specified limit) or if the volume of
water pumped to restore original test pressure after the
period when pumping was stopped exceeds 0.05
liter/linear meter/meter diameter/30 minutes.
8.2.3.11 Infiltration Test for Gravity Pipes
1 The Contractor shall carry out infiltration test after
total backfilling of length under test.
2 All inlets to the section under test shall be plugged
and the residual flow measured by an approved method.
3 The following limits are not to be exceeded:
i. Pipelines not exceeding 700 mm: 0.02
liters/hour/100 linear meters/mm diameter,
ii. Pipelines over 700 mm: 0.03 liters/hour/100
linear meters/mm diameter.
5 The section shall be deemed to have failed if
allowable infiltration of water is exceeded. The Contractor
shall locate source of excessive infiltration by approved
means i.e. traversing light and mirrors or inflated rubber
plug etc, make good, and repeat tests until successful.
8.2.3.12 Deflection Tests for GRP Pipes
1 The Contractor shall conduct deflection tests for GRP
pipes (as % of overall pipe diameter) as required by the
Engineer at three stages. Deflection shall be measured at
the spigot end at mid point and at socket end.
i. Stage 1: at completion of primary backfill
(deflection at this stage should be below 0.5%).
ii. Stage 2: at final backfill (maximum allowable
deflection 2.5%).
iii. Stage 3: six months after final backfill
(maximum allowable deflection 4.0%).
2 Pipes not passing the deflection tests at Stage 2 or
Stage 3 will be removed and replaced.
8.2.3.13 Hydraulic Individual Joint Test for Pipes
Exceeding 1000 mm
1 The Contractor shall carry out procedures to BS 5886,
Type 2 testing after backfilling, or equivalent. The
Contractor shall pressurize the joint to 2 bars and wait for
10 minutes then re-pressurize to 2 bars and again wait for
5 minutes. No pressure drop should be observed at the
end of the latter period. If a pressure drop is observed, the
Contractor shall remedy the failed joint to the Engineer’s
approval.
8.2.4 Method of Measurement
1 Trench excavation, bedding and backfilling are
measured under Sub-section 2.8, Clause 2.8.4.
2 Pipes shall be measured in linear meters; each type,
class and size is measured separately. Measurement shall
be as a straight line between the inside wall faces of
manhole, inlet, sump or gully connection. No allowance
will be made for cut ends and waste.
3 No separate measurement will be made for jointing
materials, junctions and pipe fittings, nor for ancillary
work such as breaking into existing pipelines or chambers,
cleaning, protection and testing of pipelines, or any other
item necessary for the proper completion of the work, but
shall be considered subsidiary work the costs of which
shall be deemed to be included in the rates and prices for
pipes stated in the Bill of Quantities.
8.2.5 Basis of Payment
1 The amount of completed and accepted work.
measured as provided for above, will be paid for at the
unit rates listed in the Bill of Quantities, which unit rates
shall be full compensation for installation, fitting,
supplying materials, transport, labor, equipment, forms,
tools and other items necessary for the proper completion
of the work as specified in Section 1.
2 Excavation, bedding and backfilling shall be paid for
as indicated in Sub-section 2.8, Clause 2.8.5.
3 Rates for pipes shall include for the following:
i. Staking out, field surveying and preparation of
shop and coordination drawings.
ii. Pipe fittings, specials and couplings.
iii. Transportation to and hauling about the Site,
loading, unloading and lowering materials in
the trench.
iv. Lubricating agent used for assembling the pipe
sections.
v. Cutting, machining, chamfering, etc. of
standard length pipes.
vi. Assembling the pipes and couplings and
connecting to inlets, manholes and/or
structures as applicable.
vii. Testing as per the specification.
viii. Ancillary works and materials.
♦ 8-7 ♦
copy 249
 ix. Flushing, cleaning, painting, lining and coating.
8.2.6 Items in the Bill of Quantities
i. Storm sewer (type) (diameter) (lin.m.)
8.3 Manholes, Inlets and Chambers
8.3.1 Description
1 This Sub-section specifies works related to manholes,
grate inlets, chambers, grated channels, curb inlets, ditch
inlets and ditch outlets.
8.3.2 Materials
1 Concrete, reinforcing steel and reinforced concrete
shall conform to the requirements of Sub-sections 5.1, 5.2
and 5.3 respectively. Structural steel and other metalwork
shall conform to Sub-section 6.2.
2 Plain (blinding) and reinforced concrete shall be
Class 15 and 25, respectively. Cement shall be ordinary
Portland cement to BS EN 197.
3 Concrete manholes shall comply with BS EN 1917
and BS 5911 Part 3. Thickness shall be as indicated on the
Drawings.
4 Manholes and chambers covers, gratings and frames
shall comply with BS EN 124 or equivalent. Two sets of
lifting keys shall be supplied with each removable cover.
Covers and frames shall be non-rock, locking, solid top.
Grades shall be as follows:
i. For roadways: heavy duty test load 40 tons.
ii. For sidewalks, carriage drive and cycle tracks:
medium duty test load 25 tons.
iii. For footpaths and fields: light duty, test load 7
tons.
5 Manhole covers shall be of circular pattern unless
otherwise indicated on Drawings with a clear opening of
not less than 560 mm diameter. Frames shall be provided
with openings for fixing bolts which ensure solid frame
embedment into the concrete manhole neck. Covers and
frames shall be coated to BS 3416, Minimum thickness 250
microns. Manholes covers shall have the words
“Stormwater Drainage" inserted, unless instructed
otherwise by the Concerned Authority.
6 Grated inlets and channel gratings and frames shall
comply with BS EN 124 or equivalent. Grated inlet grating
shall have a clear open area of not less than 600x600 mm
and shall be coated to BS 3416. Minimum thickness 250
microns. The Contractor shall submit manufacturer's
details of the proposed grated inlet grating and frame for
prior approval by the Engineer.
7 Bricks shall be to BS EN771-1. Net volume of clay
masonry units shall be determined according to BS EN
772:3. Water absorption of clay masonry shall be
determined according to BS EN 772:7.
8 Steel ladders shall be mild steel to BS 4211,
galvanized to BS EN ISO 1461 with 200 grams of zinc per
square meter.
♦ 8-8 ♦
9 GRP ladders shall be obtained from an approved
experienced manufacturer, fabricated to an approved
pattern and purpose made to suit the depth of each
installation as shown on the Drawings. The ladders shall
be drilled for wall fixing at both ends and additional
intermediate fixing connections shall be provided at
centers not greater than 1.5 meters. Rungs shall be at 300
mm centers and at a distance of not less than 150 mm
from the wall.
i. The resins, glasses and synthetic fabrics used
in the manufacture of the ladders shall be
chosen to produce a chemically resistant
product with a resin-rich surface layer suitable
for use in aggressive atmospheres likely to the
encountered in sewers and sewage pumping
stations.
ii. Rungs of tubular construction shall be no less
than 30 mm outer diameter and stringers shall
be of a rectangular or channel section, no less
than 70 mm x 25 mm in size. The upper face of
non-tubular rungs shall be finished with a non-
slip surface such as silica sand. All remaining
surfaces shall be free of sharp edges,
protrusions etc.
iii. Each rung shall be able to withstand a point
load of 5000 N.
iv. When supported horizontally over a span of 1
m with the climbing face uppermost and with a
load of 1000 N applied at the centre of the span
the ladder shall not deflect more than 15 mm at
the point of application of the load and shall
show no permanent deflection after removal of
the load. Each ladder fixing shall be capable of
withstanding shear and pull-out loads of 5000
N.
v. All ladders shall comply with BS 5395: Part 3.
All fixings shall be stainless steel.
10 Fixing bolts shall be steel, type suitable for particular
purpose and use and to approval. When used to fix
galvanized material, washers are to be galvanized and
fixing bolts and nuts cut to pre-plating limits and
electroplated with zinc to BS ENISO 2081.
11 Steel castings shall be mild to medium strength
castings and shall conform to AASHTO M103M/M103.
Unless otherwise shown on the Drawings or instructed by
the Engineer, castings shall be grade 65-35 fully annealed.
Steel castings shall conform to the dimensions shown on
the Drawings. Test bars shall be prepared and tested as
specified in AASHTO M103M/M103.
12 Mortar for masonry shall be mixed in the proportions
1:3 (cement::sand) by volume, or 1:4:4 (cement:lime: sand).
The sand shall be well graded.
13 The Contractor shall submit to the Engineer
manufacturers' Certificates of Guarantee for steel, cast
iron cast steel and wrought iron parts, stating that the
materials supplied meet the applicable AASHTO or ASTM
specification and Standards. The submission of such test
certificates shall not relieve the Contractor of his
copy 249
obligations to carry out independent tests at an approved
laboratory, as directed by the Engineer, at his own
expense.
8.3.3 Construction Requirements
1 All excavation and backfill shall conform to the
requirements of Sub-Sections 2.3 and 2.7. -
2 Formwork for cast in place concrete chambers, and
the placing, curing, and protection of the concrete shall
conform to the requirements of Sub-section 5.3, Clause
5.3.3.
8.3.3.1 Manholes
1 Precast units shall be cast in steel watertight forms at
least 3 weeks before sections are used. Lowest unit shall
be bedded on in situ concrete base and bed and haunch in
cement mortar. Joints of units shall be liberally coated
with approved bituminous material of trowelling grade
prior to fixing. Joints shall be filled solid and neatly
stroked off surplus compound. Work shall remain
undisturbed for 7 days thereafter. Alternatively joints may
be sealed with approved preformed jointing strip in
accordance with manufacturer's instructions. The precast
concrete cover slab shall be bedded in cement mortar on
the top unit.
2 Channels in bottom of manhole shall be smooth,
semi-circular and sized equal to diameter of adjacent
sewers. For straight through manholes, channels of half
pipe sections shall be installed. Changes in direction of
flow shall be made with smooth curves as large as
manholes permit. Changes in size and grade of channels
shall be gradual and even.
3 Benching shall be formed with sulfate resisting
concrete Class 250/20 to rise vertically from top of
channels to a height not less than soffit of outlet pipe, then
it shall be sloped upwards 1 in 10 to walls. Floating shall
then be carried out within 3 hours with a coat of sulfate
resisting cement-sand mortar 1:2. Smooth finishing shall
then be accomplished with a steel trowel.
4 Manholes and chambers shall be coated externally
with three layers of asphaltic composition that shall be
applied by brush in accordance with manufacturer's
instructions. Minimum thickness shall be 600 microns.
5 Internal faces of manholes and chambers shall be
coated with four coats of coal tar epoxy paint, 70% epoxy
and 30% coal tar. The coating shall be applied by brush in
accordance with manufacturer's instructions. Minimum
thickness shall be 1000 microns.
6 Adjustment of level shall be accomplished with top
courses of brickwork or concrete rings after completion of
surrounding levels. Final levels shall be even and accurate.
7 The Contractor shall test manholes as follows:
i. Plug manhole inlets and outlets.
ii. Fill manhole with water and allow it to stand
for at least 24 hours or such longer period to
allow for complete absorption.
iii. Re-top with water.
iv. Allowable leakage over 24 hours shall not to
exceed 1% of total volume of manhole,
otherwise necessary repair and re-testing shall
be carried to achieve the required results.
8.3.3.2 Chambers for Grated Inlets, Curb Inlets and
Ditch Inlets and Outlets
1 Construction shall be in situ concrete, precast
concrete or blockwork as indicated on the Drawings.
2 Brick and blockwork shall be laid on a full bed of
mortar. Whole bricks and blocks shall be used except
where closers must be cut.
3 Courses shall be stepped back and not raised above
the general wall level more than 900 mm. Courses shall
be horizontal. Reinforcement in the masonry shall be fully
embedded in the mortar joint.
4 If pointing is required, the joint shall be raked out to a
depth of 12mm after completion of the entire face.
5 Brick and blockwork shall be protected by
impermeable sheeting or damp cloth for 3 days after
completion of laying.
6 The nearest pipe line joint to any chamber or grated
inlet shall be not more than 500mm from the inner wall
face and shall not be restricted by concrete or masonry
from the structure.
8.3.3.3 Ironwork
1 Frames for covers and gratings shall be solidly
bedded in mortar and fixed firmly using fixing bolts. They
shall be positioned centrally over the opening and level
and square with surrounding finishes. Covers shall be set
in position to prevent twisting.
2 The upper surface of grated inlet gratings shall be flat.
Slots shall not be parallel to traffic flow unless the slots
are less than 150mm long or less than 20mm wide.
8.3.3.4 Cleaning
1 Manholes, grated inlets, grated channels, curb inlets,
ditch inlets and ditch outlets shall be thoroughly cleaned
on completion, and shall be free from dirt and debris at
the time of final inspection.
8.3.4 Method of Measurement
1 Manholes and inlets shall be measured by the
number of each structure constructed and installed
including the supply and installation of chambers, frames,
grates, covers and ladders as applicable. Grated channels
shall be measured per linear meter.
2 No separate measurement or payment shall be made
for any other concrete works, excavation, shoring,
sheeting or backfilling, or for breaking into existing pipes
or culverts in order to install new manholes, chambers,
inlets and the like. All such work prescribed in this Sub-
section shall not be measured for direct payment, but shall
be considered as subsidiary work, the costs of which shall
♦ 8-9 ♦
copy 249
be deemed to be included in the unit rates for manholes
etc stated in the Bill of Quantities.
3 No separate payment shall be made for blinding,
painting, equipment, forms, tools, furnishing and placing
materials, labor, transport, or any other item necessary for
the proper completion of the work. All such items Pipe Material Pipe Standard
prescribed in this Sub-section shall not be measured for Ductile Iron BS EN 545 [1]
direct payment, but shall be considered as subsidiary work,
BS EN 1452 [9] or to DIN 8061/8062,
the costs of which shall be deemed to be included in the uPVC
Series 4 and 5
unit rates for manholes etc stated in the Bill of Quantities.
Polyethylene ISO 4427, DIN 8074/8075 or AWWA
(PE) C906 Class 10
8.3.5 Basis of Payment
Table 8.4.2-1: Drainage Pipe Standards for Bridge Deck
1 The amount of completed and accepted work
measured as provided for above, will be paid for at the 2 Pipes for filter drains shall be to the standards listed
unit rates of 'Manholes', ‘Grated Inlets’, 'Curb Inlets’, in Table 8.4.2.2 or equivalent and as specified in Clause
‘Grated Channels’, 'Ditch Inlets' and 'Ditch Outlets' in the 8.2.2.
Bill of Quantities, which rates shall be full compensation
for excavation, installation, fitting, testing, backfilling, Pipe Material Pipe Standard
supplying materials, labor, transport, equipment, forms, DIN 8061 Class 10
uPVC
tools and other items necessary for the proper completion kg/cm2
of the work. ASTM D3035and ASTM
Polyethylene (PE)
F894
8.3.6 Items in the Bill of Quantities
Vitrified clay BS 65
i. Manholes (size and type) nr.
AASHTO M175M/M175
Concrete
ii. Grated Inlet (type) nr. or ASTM C444M
Table 8.4.2.2: Drainage Pipe Standards for Filter Drains
iii. Curb inlet (type) nr.

iv. Ditch inlet (type) nr. 8.4.2.3 Drainage Backfilling

v. Ditch outlet (type) nr. 1 Permeable backfilling to structures shall be crushed

rock or precast porous concrete blocks to BS 6073-2 laid in
vi. Grated Channel (width and depth) lin.m. stretcher bond with dry joints. The minimum thickness of
backfilling shall be 225mm.
8.4 Drainage of Structures 2 Granular backfill to structures shall be natural sand
and gravel or with a particle size distribution as given in
8.4.1 Description Table 8.4.2.3.
1 This Sub-section describes requirements for gully
AASHTO sieve size % passing (by mass)
and channel gratings and frames on bridge decks,
subways and underpasses with the associated pipework. It 75.0 mm 100
includes the supply and placing of permeable drainage 37.5 mm 85-100
backfilling to structures.
9.5 mm 45-100
8.4.2 Materials 4.75 mm 25-85

8.4.2.1 Gully and Channel Gratings and Frames Table 8.4.2.3: Granular Backfill to Structure

1 Gully and channel gratings and frames shall be 8.4.3 Construction Requirements
heavy duty and shall conform to the requirements of BS
1 Drainage pipes cast into the concrete structure shall
EN 124 or equivalent. Integral hoppers shall be of the
be firmly supported to prevent their displacement during
same grade and quality as the gully or channel grate and
the concreting operation. Pipes located within the cellular
frame. Molded uPVC or GRP shall be to the approval of the
sections of a bridge deck where access after completion of
Engineer who may require material and load testing.
the deck is limited, shall be installed, tested and approved
8.4.2.2 Pipes by the Engineer before the deck construction is allowed .to
proceed to the stage where access to the pipes will not be
1 Pipes used in bridge decks shall be to the possible
standards listed in Table 8.4.2.1 or equivalent
with a minimum internal diameter of 100mm.

♦ 8-10 ♦
copy 249
2 Pipe joints in bridge decks shall be flexible and
watertight Seals and gaskets shall be appropriate for the
pipe material- used.
3 Joints between bridge deck waterproofing and
drainage components shall be watertight and the sealants
shall be compatible with the waterproofing system.

♦ 8-11 ♦
copy 249
4 Granular drainage backfill shall be placed and
compacted in accordance with Sub-section 2.5, Paragraph
2.5.4.2.
5 Drainage pipes and connections in bridge decks shall
be tested for water tightness on completion in accordance
with Clause 8.2.3.
6 All excavation and backfill shall conform to the
requirements of Sub-Sections 2.3 – ‘Roadway Excavation’
and 2.7 – ‘Excavation and Backfilling for Structures.
7 PE pipes installation shall be in accordance to ASTM
D2321 and manufacturer’s recommendations.

8.4.4 Method of Measurement

1 Gully gratings and frames shall be measured by
number; each type shall be measured separately
2 Pipework shall be measured in linear meters,
measured as the actual length installed, including nominal
length of bends and fittings; each type and size shall be
measured separately.
3 Permeable backfilling shall be measured in cubic
meters of the volume placed in position.
4 Granular backfill shall be measured in cubic meters
of the volume placed in position.
5 No separate measurement shall be made for blinding,
painting, equipment, forms, tools, furnishing and placing
materials, labor, or any other item .necessary for the
proper completion of the work. All such items prescribed
in this Sub-section shall be considered as subsidiary work,
the costs of which shall be deemed to be included in the
rates and prices stated in the Bill of Quantities.

8.4.5 Basis of Payment

1 The amount of completed and accepted work
measured as provided for above, will be paid for at the
unit rate for the various items of 'Drainage for Structures'
in the Bill of Quantities, which rate shall be full
compensation for supplying, fabricating, connecting and
testing, and for labor, transport, materials, equipment,
tools, and other items necessary for the completion of the
work.

8.4.6 Items in the Bill of Quantities

i. Gully grate and frame (type) nr.

ii. Drainage pipe in structure

(type) (diameter) (location) lin.m.

iii. Permeable backfilling cu.m.

iv. Granular backfill cu.m.

♦ 8-12 ♦
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Ref. Title Page No. Ref. Title Page No.
9.1 Riprap 9-1 9.4.3.3 Pull Out Tests for Anchored Bolts 9-6
9.4.3.4 Pull Out Tests for Untensioned Bolts 9-7
9.1.1 Description 9-1
9.4.3.5 Rock Anchoring Procedures 9-7
9.1.2 Materials 9-1
9.1.3 Construction Requirements 9-1 9.4.3.6 Tensioning Tendons 9-7
9.4.3.7 Grouting for Rock Anchors 9-8
9.1.4 Method of Measurement 9-2
9.4.3.8 Testing of Rock Anchors 9-8
9.1.5 Basis of Payment 9-2
9.1.6 Items in the Bill of Quantities 9-2 9.4.3.9 Application of Sprayed Concrete
and Mortar 9-8
9.2 Gabions 9-2 9.4.3.10 Reinforcement Mesh 9-9
9.2.1 Description 9-2 9.4.3.11 Paint 9-9
9.2.2 Materials 9-2 9.4.3.12 Wire Netting 9-9
9.2.3 Construction Requirements 9-2 9.4.4 Method of Measurement 9-10
9.2.4 Method of Measurement 9-3 9.4.5 Basis of Payment 9-10
9.2.5 Basis of Payment 9-3 9.4.6 Items in the Bill of Quantities 9-10
9.2.6 Items in the Bill of Quantities 9-3 9.5 Rock Grouting 9-10
9.3 Slope Netting 9-5 9.5.1 Description 9-10
9.3.1 Description 9-3 9.5.2 Materials 9-10
9.3.2 Materials 9-3 9.5.3 Construction Requirements 9-10
9.3.3 Construction Requirements 9-3 9.5.4 Method of Measurement 9-11
9.3.4 Method of Measurement 9-3 9.5.5 Basis of Payment 9-12
9.3.5 Basis of Payment 9-3 9.5.6 Items in the Bill of Quantities 9-12
9.3.6 Items in the Bill of Quantities 9-4 9.6 Reinforced Concrete Slope
9.4 Rock Bolts, Anchors Protection 9-12
and Sprayed Concrete 9-4 9.6.1 Description 9-12
9.4.1 Description 9-4 9.6.2 Materials 9-12
9.4.2 Materials 9-4 9.6.2.1 Concrete 9-12
9.4.2.1 Cement Grout 9-4 9.6.2.2 Reinforcement 9-12
9.4.2.2 Rock Bolts Generally 9-4 9.6.3 Construction Requirements 9-12
9.4.2.3 Resin-Anchored Rock Bolts 9-4 9.6.4 Method of Measurement 9-12
9.4.2.4 Mechanically Anchored Rock Bolts 9-4 9.6.5 Basis of Payment 9-12
9.4.2.5 Drain Holes 9-4 9.6.6 Items in the Bill of Quantities 9-12
9.4.2.6 Rock Anchors 9-4 9.7 Sacked Concrete Revetment 9-12
9.4.2.7 Sprayed Concrete and Mortar 9-5
9.4.2.8 Wire Netting 9-5 9.7.1 Description 9-12
9.7.2 Materials 9-12
9.4.3 Construction Requirements 9-5
9.7.2.1 Sacks 9-12
9.4.3.1 General 9-5
9.4.3.2 Rock Bolting Procedures 9-5 9.7.2.2 Concrete 9-12

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Ref. Title Page No. Ref. Title Page No.
9.7.3 Construction Requirements 9-12 9.11.3.2 Stabilization with Bituminous
9.7.4 Method of Measurement 9-13 Materials 9-16
9.7.5 Basis of Payment 9-13 9.11.3.3 Stabilization with Vegetative
9.7.6 Items in the Bill of Quantities 9-13 Treatment 9-16
9.11.3.4 Blankets 9-16
9.8 Paving Tile Slope Protection 9-13
9.11.4 Method of Measurement 9-16
9.8.1 Description 9-13 9.11.5 Basis of Payment 9-16
9.8.2 Materials 9-13 9.11.6 Items in the Bill of Quantities 9-16
9.8.3 Construction Requirements 9-13
9.8.4 Method of Measurement 9-13
9.12 Mechanically Stabilized Earth
9.8.5 Basis of Payment 9-13
Retaining Walls 9-16
9.8.6 Items in the Bill of Quantities 9-13
9.12.1 Description 9-16
9.9 Ditch Lining 9-13
9.12.1.1 General 9-16
9.9.1 Description 9-13 9.12.1.2 Standards and Codes 9-17
9.9.2 Materials 9-13 9.12.2 Materials 9-17
9.9.3 Construction Requirements 9-13 9.12.2.1 General 9-17
9.9.3.1 General 9-13 9.12.2.2 Concrete Face Panels 9-17
9.9.3.2 Precast Slabs 9-14 9.12.2.3 Concrete Footings 9-18
9.9.3.3 Stone Ditch Lining and Wash Checks 9-14 9.12.2.4 Steel Reinforcing and Tie Strips 9-18
9.9.4 Method of Measurement 9-14 9.12.2.5 Reinforced (Polymer) Grids 9-18
9.9.5 Basis of Payment 9-14 9.12.2.6 Fasteners 9-19
9.9.6 Items in the Bill of Quantities 9-14 9.12.2.7 Non Metallic Friction Ties and Fixings 9-19

9.10 Filter Layers 9-14 9.12.2.8 Joint Filler (For Use with Concrete Face
Panels) 9-19
9.10.1 Description 9-14
9.12.2.9 Joint Filler (For Use with Concrete Face
9.10.2 Materials 9-14 Panels 9-19
9.10.3 Construction Requirements 9-14
9.12.3 Construction Requirements 9-20
9.10.3.1 Granular Filter 9-14
9.12.3.1 Wall Excavation 9-20
9.10.3.2 Fabric Membrane 9-15 9.12.3.2 Foundation Preparation 9-20
9.10.4 Method of Measurement 9-15
9.12.3.3 Erection of Concrete Face Panels 9-20
9.10.5 Basis of Payment 9-15
9.12.3.4 Backfill Placement 9-20
9.10.6 Items in the Bill of Quantities 9-15 9.12.3.5 Trial Embankment 9-20
9.11 Barriers for Sand Dunes 9-15 9.12.4 Monitoring 9-21
9.12.4.1 General 9-21
9.11.1 Description 9-15
9.12.4.2 Selected Backfill 9-21
9.11.2 Materials 9-15
9.12.4.3 Settlements 9-21
9.11.2.1 Fences 9-15
9.12.4.4 Horizontal Displacements 9-21
9.11.2.2 Bituminous Materials 9-15
9.12.4.5 Durability 9-21
9.11.2.3 Vegetative Materials 9-15
9.12.4.6 Testing Frequency 9-21
9.11.2.4 Water 9-15
9.12.5 Method of Measurement 9-22
9.11.2.5 Blanket Covers 9-15
9.12.6 Basis of Payment 9-22
9.11.3 Construction Requirements 9-15
9.12.7 Items in the Bill of Quantities 9-22
9.11.3.1 Fencing 9-15

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Ref. Title Page No.
9.13 Coastal Protection 9-22
9.13.1 Description 9-22
9.13.2 Materials 9-23
9.13.2.1 Quarried Stone for Armour Layers and
Underlayers 9-23
9.13.2.2 Core Material 9-23
9.13.2.3 Filter Fabric – Geotextiles 9-24
9.13.3 Construction Requirements 9-24
9.13.3.1 General 9-24
9.13.3.2 Placement of Core Material 9-24
9.13.3.3 Placement of Armour and Underlayer
Stones 9-25
9.13.3.4 Surveying Technique 9-25
9.13.3.5 Storage, Handling, and Laying of
Geotextiles 9-25
9.13.4 Method of Measurement 9-26
9.13.4.1 Marine Works Generally 9-26
9.13.4.2 Underlayer, rock armour, quarry run and
bedding layer 9-26
9.13.4.3 Dredging for embedded toe protection 9-26
9.14.4.4 Fabrics and membranes ( Geotextile) 9-26
9.13.5 Basis of Payment 9-26
9.13.5.1 Marine Works Generally 9-26
9.13.5.2 Underlayer, rock armour, quarry run and
bedding layer 9-26
9.13.5.3 Dredging for embedded toe protection 9-26
9.13.5.4 Fabrics and membranes ( Geotextile) 9-26
9.13.6 Items in the Bill of Quantities 9-26

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copy 249
9.1 Riprap
9.1.1 Description
1 The Sub-section describes requirements for
construction of loose or mortared riprap slope protection
and riprap Cut-off walls or watercourse channel protection.
9.1.2 Materials
1 Stone for loose and mortared riprap shall consist of
natural stones of broad flat shapes as far as practicable.
All stone shall be hard, sound, durable, and highly
resistant to weathering and shall be suitable as protection
material for the intended purpose.
2 Samples of the stone material proposed for use shall
be submitted to the Engineer for approval prior to its use
in the work.
3 The minimum apparent specific gravity of the stone
material shall be 2.5 and the maximum absorption shall be
6% when tested in accordance with AASHTO T 85. The
stone shall have an abrasion loss not greater than 45%
when tested in accordance with AASHTO T 96.
4 The weight of individual stones for the various
classes of riprap shall be as follows:
% of Total
Weight
Weight of Stone (kilograms) Smaller than
Weight
Shown
Class
Class B Class C Class D
A recommended procedures, as approved by the Engineer.
50 200 1,000 5,000 95-100
20 100 400 2,000 50-100
5 20 100 500 0-50
1 5 20 100 0-10
Table 9.1.2.1: Classes of riprap stones and rocks
5 Unless otherwise indicated on the Drawings or
directed by the Engineer, stones for loose and mortared
riprap shall conform to Class B gradation. Stones shall
generally weigh between 20 and 70 kg. with at least 60%
weighing more than 45 kg.. Nevertheless, any of the
classes shown in Table 9.1.2.1 above can be used for loose
riprap, as indicated on the drawings. For mortared riprap,
stones of classes A or B only can be used, as indicated on
the Drawings.
6 Mortar for mortared riprap shall consist of 1 part
Portland cement to 3 parts sand by volume. Water added
shall be the least amount which will yield a workable mix.
Sand and cement shall conform to the relevant
requirements of Sub-section 5.1. The 28 day compressive
strength of the mortar shall be not less than 15 MPa
measured in accordance with BS 1881, Part 108.
7 Filter material for use under loose or mortared riprap,
as shown on the Drawings shall comply with the
requirements of Sub-section 9.10 “Filter Layers”.
8 Expansion joint filler shall be rot-proof and of the
preformed, non-extruding, resilient type made with a
bituminous fiber and shall conform to the requirements of
ASTM Standard D1751, Specification for Preformed
Expansion Joint Fillers for Concrete Paving and Structural
Construction.
9.1.3 Construction Requirements
1 The stones shall be wetted and hand-laid with the
flattest face uppermost and parallel to the prepared slope,
starting from the toe and progressing upwards. Stones
shall be arranged in close contact so as to minimize voids,
the largest being placed in the lower courses. Spaces
between large stones shall be filled with smaller stones of
suitable size. The surface of the riprap protection shall be
trimmed and prepared as shown on the Drawings.
2 The mortar bed shall be progressively spread ahead
of stone placing. Stones faces in contact with the mortar
shall be clean and free from any defects that will impair
the bond with the mortar. Stones shall be washed to
remove any dirt or dust immediately before applying
mortar. Mortar shall be spaded and rodded between the
stones until the voids are completely filled.
3 Expansion joints shall be constructed where the
riprap is placed against any structure, or where directed
by the Engineer. A 13 mm thick fiber joint filler (as
specified in Item 8 of Clause 9.1.2) shall be installed in
expansion joints. The fiber joint shall extend from the base
of the grout layer up to 13 mm below the grout surface. A
bond breaker, as approved by the Engineer, shall be
placed along the bottom of the 13 mm deep by 13 mm
wide notch, and the top shall be filled with flexible joint
sealant in accordance with the manufacturer's
4 The completed work shall be cured for at least 7 days
by a curing method approved by the Engineer. After the
expiry of this period, the exposed surfaces shall be cleared
of loose mortar and broken stone fragments.
5 Loose riprap stone shall be placed in the same
manner as for mortared riprap. The stones shall be
properly selected and placed so as to minimize voids
which shall be filled with pieces of the largest possible size.
6 After completion and approval of the loose riprap
placement, the surface voids of the riprap in the footing
trench and on the lower portions of the slope shall be
filled with excavated material, compacted to 95% max. dry
density and dressed to the satisfaction of the Engineer.
7 Unless otherwise shown on the Drawings, the
thickness of the loose or mortared riprap layer shall not be
less than 1.5 times the nominal stone size and is
commonly 1.8 - 2.0 times the nominal stone size.
8 Where shown on the Drawings, a filter layer (as
specified in Sub-section 9.10) or an approved construction
fabric shall be laid on the prepared surface to receive
loose riprap. Thickness of filter layer shall be as shown on
the Drawings or directed by the Engineer. The slope shall
be prepared, trimmed and excavated to the surface
approved by the Engineer and as the cross sections and
levels shown on the Drawings. The filter material shall
♦ 9-1 ♦
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then be laid and compacted to 95% max. dry density, to Engineer’s approval. Samples and manufacturer’s
the satisfaction of the Engineer. certificates shall accompany the proposal.
4 Gabion dimensions shall be as shown on the
9.1.4 Method of Measurement Drawings. A tolerance of ±5% on width and height, and
1 Riprap work shall be measured by the cubic meter of ±3% on length shall be allowed. Gabion shall have
material placed in position. Measurement shall be based diaphragms at 1m centers.
on the dimensions shown on the Drawings. 5 The edges of gabion panels shall be selvedged to
2 Filter material shall be measured by square meter of prevent unraveling of the mesh. Steel wire core used for
the thickness placed in position. Measurement shall be selvedges shall have a nominal diameter of not less than
based on the dimensions shown on the Drawings. 3.5mm. Lacing wire shall have a nominal diameter of not
less than 2.2mm for the wire core. Wire for selvedges and
3 Filter membrane shall be measured in square meter
lacing shall otherwise comply with the same specification
of the material placed in position. Measurement shall be
for the wire used in the mesh.
the area shown on the Drawings.
6 Where shown on the Drawings wire shall be coated
9.1.5 Basis of Payment with a minimum thickness of 0.55mm of dark green or
black PVC, or any other color to the approval of the
1 The amount of completed and accepted work Engineer, which shall be capable of resisting the effects of
measured as provided for above will be paid for at the unit immersion in sea water and exposure to ultra violet light
rates indicated in the Bill of Quantities, which rate shall be and abrasion, when tested for a period not less than 3000
full compensation for selection of materials and removal hours in accordance with ASTM Test G23.
of discarded material, slope preparation, excavation, 7 Stones for gabion filling shall be hard, sound,
backfilling, placing, trimming, finishing and protection of durable and highly resistant to erosion, to the approval of
finished work and expansion joints and for materials, the Engineer. The specific gravity of the stones shall be
transportation, hauling, labor, equipment, tools, supplies not less than 2.5. The stone size distribution in each
and other items necessary for the proper completion of individual box shall be as given in Table 9.2.2.1.
the works.
Size of stones (mm) % of total (by no.)
9.1.6 Items in the Bill of Quantities
80-125 7% maximum
i. Loose stone riprap (class). (cu.m)
ii. Mortared stone riprap (class) (cu.m) 125-200 88% minimum
iii. Filter material (thickness) (sq.m) 200-250 5% maximum
iv. Filter membrane (sq.m)
Table 9.2.2.1: Stones for Gabions

9.2 Gabions 8 Mastic asphalt constituents shall be sand,

penetration grade bitumen and filler. The mastic shall
have the characteristics given in Table 9.2.2.2.
9.2.1 Description
% of total (by
1 This Sub-section describes requirements for gabions Constituents Material Type
mass)
consisting of supplying, building and placing of stone- Sand (5mm Natural sand or
filled galvanized steel wire mesh baskets (or other 55-72
nominal size) crushed rock
approved types of heavy duty plastic mesh) as slope or
Bitumen 80-100 Pen 15-18
watercourse channel protection.
Portland
Filler cement or 13-16
9.2.2 Materials
hydrated lime
1 Gabion boxes shall be made of a hexagonal woven Table 9.2.2.2: Characteristics of Mastic Asphalt
mesh of double twisted hot-dip galvanized steel wire. The Constituents
nominal mesh size shall be 80mm x 100 mm. details of the
type of mesh proposed for use shall be submitted to the 9 Sand-cement grout shall be composed of one part of
Engineer for approval. Portland cement and four parts of sand measured by
volume, mixed with sufficient water to a consistency so
2 Wire used in the fabrication of the gabion shall be
that the grout can flow into and completely fill the voids.
mild steel to ASTM A390 Class 3 or to BS 1052 having an
average tensile strength, before coating of 380 to
500N/mm2. The core wire diameter shall be 3.00 mm 9.2.3 Construction Requirements
before galvanizing. Galvanizing shall comply with BS 443. 1 Gabions shall be placed and built to the lines, levels
3 Non-metallic material for gabion boxes, such as and patterns shown on the Drawings, on a prepared
extruded polypropylene, may be proposed for the

♦ 9-2 ♦
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horizontal foundation surface for gabion boxes and
mattresses and/or sloping foundation surface for gabion
mattresses, excavated as required, and compacted as
instructed by the Engineer.
2 Gabion cages shall be securely wired together at
corners and edges, and where there is more than one
course of gabions, the upper course cages shall be laced
to the lower course. Before filling, the cage shall be in its
permanent position and laced to adjoining previously
filled cages.
3 Non-metallic gabion cages of proprietary type shall
be constructed according to the manufacturer’s
instructions.
4 Stones shall be packed by hand inside the cages as
tight as practicable with the minimum of voids. The wires
shall be fixed inside the compartments and the units
tensioned in accordance with the manufacturer’s
instructions.
5 The cages shall be overfilled with stones to allow for
subsequent settlement and the lid laced down with
binding wire to the top of each of the four sides and to the
top of the diaphragm panels.
6 Where shown on the Drawings, the Contractor shall
grout gabions with hot poured mastic asphalt. The mastic
shall be mixed at a temperature of 160-200˚C and poured
to fill the voids between the stones for the depth shown.
The actual rate of application shall be as approved by the
Engineer during construction.
7 Where shown on the Drawings, the Contractor shall
grout gabions with sand-cement grout. Immediately
before pouring the grout, the stones should be wetted by
sprinkling. The grout shall be poured to fill the voids
between the stones for the depth shown. The actual rate
of application shall be as approved by the Engineer during
construction. The grout shall be allowed to set and harden
before any stormwater is received. The grout shall be kept
moist with water for a period of not less than 72 hours.
9.2.4 Method of Measurement
1 Gabions shall be measured by the cubic meter of
installed gabion, based on the dimensions shown on the
Drawings. Rates shall be deemed to include for provision
and installing all materials, protection of finished work and
all preparatory work including excavation and preparation
of ground.
2 Where grouting is required, it shall be measured by
the cubic meter of sand-cement or of mastic asphalt
applied.
9.2.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid at the unit
rate for “Gabion” in the Bill of Quantities, which rate shall
be full compensation for slope preparation, protection,
drainage, excavation, backfilling, and for materials, labor,
equipment, tools, supplies and other items necessary for
the proper completion of the work.
9.2.6 Items in the Bill of Quantities
i. Gabions (size). (cu.m)
ii. Mastic asphalt grout. (cu.m)
iii. Sand-cement grout. (cu.m)
9.3 Slope Netting
9.3.1 Description
1 This Sub-section describes requirements for
supplying and installing steel wire mesh netting as rock
slope protection.
9.3.2 Materials
1 Wire slope netting shall consist of a hexagonal
woven mesh of double twisted hot-dip galvanized steel
wire. The nominal mesh size shall be 80mm x 100mm.
2 All wires shall be mild steel conforming to BS 1052,
having a minimum nominal diameter of 2.7mm. The wire
shall be hot-dip galvanized in accordance with ASTM A
767, Class II (610g Zinc/sq.m., 2.0 oz. Zinc psf), after
fabrication and bending.
3 Spikes for wire slope netting attachment shall be as
shown on the Drawings and the steel shall comply with
the relevant requirements of Section 6.
9.3.3 Construction Requirements
1 The wire netting shall be securely anchored to the
rock face with the driven steel spikes spaced at an average
of not more than 5m vertically and horizontally around the
perimeter of each section.
2 For rock slope faces in excess of 5m high, the netting
shall be hung from hooked rock bolts installed
untensioned as specified in Sub-section 9.4 at spacing
between 5m and 10m horizontally and vertically.
3 The rock slope face shall be trimmed to the profile
shown on the Drawings and in accordance with the
relevant requirements of these specifications. The
proposed new section dimensions and fixing points shall
be submitted for prior approval by the Engineer. Intact
sound rock masses shall be selected for the bolts and
spikes positioning.
9.3.4 Method of Measurement
1 The approved wire netting slope protection work
shall be measured by the square meter of the area
installed. Preparation of the rock face and spikes and
fixation accessories shall not be separately measured, but
shall be deemed included in the rate for wire netting slope
protection.
9.3.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate for “Wire Slope Netting” in the Bill of Quantities
which rates shall be full compensation for slope and
♦ 9-3 ♦
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foundation preparation, drilling, fixing and for materials,
labor, equipment, tools, supplies and other items
necessary for the proper completion of the work.
9.3.6 Items in the Bill of Quantities
i. Wire netting slope protection (sq.m)
9.4 Rock Bolts, Anchors and Sprayed
Concrete
9.4.1 Description
1 This Sub-section describes stabilization of cut or
natural slopes in soil or rock by one or combination of the
following methods: rock bolting, rock anchoring and
grouting, shotcreting or guniting, and wire netting.
9.4.2 Materials
9.4.2.1 Cement Grout
1 Grout for use in rock bolting and rock anchors, shall
normally consist of a mixture of cement and water only.
Fine sand aggregate passing No. 16 sieve may be added, if
approved, for grouting of large holes, etc.
2 Admixtures and filler may be used only if approved
by the Engineer and shall be free from chlorides..
3 Cement, sand and water shall conform to the
requirements of Section 5. Sulfate resisting and rapid
hardening cements shall be used only if specified and
approved.
4 The compressive strength of 150 x 150 mm cubes
made of grout and measured in accordance with BS1881
shall not be less than 17 MPa. at 7 days. Cubes shall be
cured in a moist atmosphere for the first 24 hours and
subsequently under water.
5 Grout mixes shall have good fluidity and low
sedimentation or bleeding in the plastic state, good
durability and density with low shrinkage in the hardened
state, in order to bond with the side of boreholes and to
provide protection for bolts and anchors, etc. Mix
proportions shall be as specified for the various
applications of grout, and grouting trials shall be
undertaken as directed by the Engineer.
6 All materials shall be proportioned by weight.
9.4.2.2 Rock Bolts Generally
1 All bolts, required to provide support for excavated
or natural rock faces, shall be deformed high tensile steel
bars conforming to the relevant requirements of Sub-
section 5.2 "Reinforcing Steel" or other type in accordance
with Drawings.
2 Rock bolts can be continuously threaded or threaded
to allow extension to be fitted as required. One end of the
bolt shall be threaded for a tensioning locking nut,
sufficient to ensure that a 10 to 50mm thread length
extends beyond the locking nut. The thread on the bolt
shall be ISO metric coarse series to BS 4190. The washer
♦ 9-4 ♦
shall be flat mild steel plate 150 by 150 by 8mm thick with
free fit holes. Nuts shall conform to BS 490 and washers
shall conform to BS 4320.
3 Rock bolts may consist of tensioned or untensioned
dowel bars anchored by resin or grout or mechanically
anchored.
4 Protection of rock bolts against corrosion shall be as
shown on Drawings.
9.4.2.3 Resin-Anchored Rock Bolts
1 The point resin anchor shall be formed using a
cartridge system. The remaining length of the bolt shall be
grouted with cement if required by the Engineer. The
grout may be injected after the installation of the bolt and
anchor, or the resin and cement grout may be placed in
the hole and the bar pushed through the cement grout
into the resin.
2 If the Engineer so directs, rock bolts shall be de-
bonded along the length of bar which is not required for
anchorage purposes by means of a suitable plastic sheath
preventing the formation of a bond between the grout and
the bar.
3 If untensioned dowel bars are used, all voids shall be
completely filled with grout.
4 If resin-anchored rock bolts are used, the tests
specified in ASTM D4435 shall be carried out. The
Contractor shall ensure that the resin is not adversely
affected by the cement grout.
9.4.2.4 Mechanically Anchored Rock Bolts
1 These shall be of the expansion shell type and full
details of the type of bolt and anchorage to be used shall
be submitted for approval prior to installation. If approved,
mechanical anchorage bolts shall be used in accordance
with the manufacturer's instructions as approved or
modified by the Engineer who may require mechanically
anchored rock bolts to be cement grouted.
9.4.2.5 Drain Holes
1 Drain holes shall be drilled into the rock slope to
relieve water pressure buildup in the rock slope. The drain
holes shall be lined with slotted PVC drain pipe and
plumbing systems shall be installed to direct water flows
away from the rock slope, as shown on the Drawings or as
directed by the Engineer.
9.4.2.6 Rock Anchors
1 Rock anchors required to provide support for
excavated or natural rock faces, and at tunnel portals, shall
consist of steel tendons in excess of 10 m in length and
shall conform to AASHTO M204: "Uncoated Stress
Relieved Wire for Pre-stressed Concrete".
2 Corrosion protection shall be as shown on the
Drawings.
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9.4.2.7 Sprayed Concrete and Mortar 8 Prior to proceeding with the shotcreting works, the
Contractor shall prepare three test panels for approval,
1 Sprayed concrete (Shotcrete) shall be a mixture of
using the proposed materials, mix design and equipment.
water, cement, sand and aggregate, projected onto the
Each test panel shall be approximately 750mm square,
area of placement, without interruption, by means of a
using plywood or other similar material for the back form
purpose made machine. Sprayed concrete (Shotcrete)
against which the shotcrete is to be sprayed. The
with 28 day cube compressive strength of 25 MPa with an
thickness of sprayed material shall be a minimum of
aggregate smaller than 12.5 mm particle size shall be used.
75mm or the thickness that is to be used in the structure,
2 Sprayed mortar (Gunite) shall be a mixture of water, whichever is greater.
cement and sand projected onto the area of placement
9 After curing the test panels, cores shall be taken for
without interruption, by means of a purpose - made
compression testing at 7 and 28 days. The cores shall be
machine Sprayed mortar (Gunite) with 28 day cube
at least 75mm in diameter and shall be measured and
compressive strength of 25 MPa with sand of maximum
tested in accordance with AASHTO T 22. In addition to
particle size 7mm shall be used.
compression testing, the cores shall be carefully examined
3 Materials, equipment and application procedures visually for soundness or evidence of non-uniformity in
shall generally conform to the latest revision of ACI 506.2 - the consistency of the concrete or mortar.
"Specifications for Shotcreting" unless otherwise specified
hereunder. 9.4.2.8 Wire Netting
4 Portland cement, fine aggregate, coarse aggregate 1 All wires shall be mild steel conforming to BS 1052,
and mixing water shall conform to the requirements of having a minimum nominal diameter of 2.7mm. The
Sub-section 5.1 - "Concrete Materials and Mixes”. The maximum mesh shall be 100mm x 80mm, the wire shall
mixture of coarse and fine aggregate for applications up to be hot-dip galvanized in accordance with ASTM A 767,
250 mm in thickness and applications exceeding 250 mm Class II (610g zinc/sq.m., 2.0 oz. zinc psf), after fabrication
in thickness shall conform to the following grading and bending.
requirements:
2 The hexagonal wire mesh netting shall be triple
Percent Passing By Weight twisted and suitably woven to produce a flexible uniform
net pattern, free of any damage. Both longitudinal sides
Standard Sieve Size Thickness of the netting sheets shall be edged with a wire of
Thickness up
exceeds 250 equivalent standard to that of the netting but greater in
to 250 mm diameter. The lacing-wire used for fixing adjacent netting
mm
sheets shall also be of equivalent standard.
12.5 mm (1/2 in.) 100
9.4.3 Construction Requirements
9.5 mm (3/8 in.) 100 90-100
9.4.3.1 General
4.75 mm (No. 4) 95-100 65-82
1 Before any of the works is commenced, the
2.36 mm (No. 8) 80-95 45-68 Contractor shall submit a detailed method statement to
the Engineer for his approval. The method statement shall
1.18 mm (No. 16) 45-80 30-53 include adequate details concerning the materials, work
procedures, means and methods and frequency of testing
0.600 mm (No. 30) 30-60 20-38 for grouts and anchors; intended by the Contractor, to
carry out the work and achieve the specified requirements.
0.300 mm (No. 50) 10-30 7-22
9.4.3.2 Rock Bolting Procedures
0.150 mm (No. 100) 2-10 2-10
1 After drilling holes of the required diameter and
0.075 mm (No. 200) 0-3 0-3 depth, and after inspection and approval of the holes and
their locations, rock bolts shall be installed and anchored
Table 9.4.2.1: Gradation of Sprayed Concrete Combined
by one of the approved means as described below,
Aggregates depending upon the type of rock bolts being installed.
5 The Cement content per cu.m. of aggregate shall be 2 Grouting equipment shall be of a type capable of
not less than 375 kg.. producing a grout of colloidal consistency by means of
6 If approved by the Engineer, water-reducing, non- high local turbulence while imparting only a slow motion
chloride accelerator admixture, complying with ASTM to the body of the grout. The injection equipment shall be
C494, Type E, and containing not more than 0.1 percent capable of continuous operation with little variation of
chloride ions, may be used. pressure and shall include a system for re-circulating the
grout while actual grouting is not in progress.
7 Reinforcement shall conform to the requirements of
Sub-section 5.2 – “Reinforcing Steel”.

♦ 9-5 ♦
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Compressed air shall only be used if approved.
Equipment shall have a delivery pressure not exceeding 1
MN/sq.m. All baffles to the pump shall be fitted with 1.2
mm sieve strainers. All equipment and piping shall be
thoroughly washed with clean water after every series of
operations and more frequently if directed. Intervals
between washings shall not exceed 3 hours.
3 Mixing of grout shall proceed by water being added
to the mixer first, followed by the cement. When these are
thoroughly mixed any admixture or sand shall be added.
Mixing shall continue for at least 2 minutes until a uniform
consistency is obtained. The water: cement ratio of the
mix shall not exceed 0.45 by weight. Mixing by hand will
not be permitted.
4 Grout shall be injected continuously and in such
manner as to avoid causing segregation of the grout. The
method of injection shall ensure complete filling of the
boreholes and complete immersion of the bolt in the grout.
The volume of the spaces to be filled by the injected grout
shall be compared with the quantity of grout injected.
Grout shall be allowed to flow from the free end of the
borehole until its consistency is equivalent to that of the
grout injected. The opening shall then be firmly closed.
Injection tubes shall be sealed off under pressure until the
grout has set.
5 Polyester resin gel and cure times shall be suited to
the working temperature and method of installation of the
bolt. The main resin and filler content shall be enclosed in
an outer sheath or skin and the catalyst shall be enclosed
in a separate container within the main sheath. The resin
and catalyst shall be mixed by rotating the bolt by means
of a power tool for such time and at such speed as will
ensure the thorough intermixing of the two constituents.
The viscosity of the resin shall be such that complete
disintegration of the resin sheath is achieved and the
pieces of sheath material do not have a detrimental effect
on the final strength of the anchorage.
6 Expansion shells for mechanical anchorage shall be
of an approved type and shall be installed in accordance
with the manufacturer's instructions as approved or
modified by the Engineer. Where such bolts are used in
close proximity to a rock face where blasting is taking
place, the security of the anchorages shall be checked
after blasting and the bolts re-tightened or replaced, if
necessary in a new hole.
7 Each hole shall be drilled straight and each bar shall
lie centrally in the hole and not be in contact with the rock.
The diameter shall be 10 mm greater than the bolt
diameter if grouted with cement. For resin anchored bolts,
the hole size shall be determined according to the
anchorage or cartridge size and in accordance with the
manufacturer's recommendations. Allowance shall be
made for the hole size to be slightly greater than the bit
size. Tolerance on the diameter of hole shall be plus or
minus 2 mm. The hole shall be thoroughly flushed and
cleaned after drilling.
8 The rock surface around each hole shall be trimmed
flat in a plane normal to the axis of the rock bolt to ensure
♦ 9-6 ♦
an even bearing surface for the cover plate. Where this
procedure is not possible, a conical aligning seating shall
be used. Epoxy mortar packing between the bearing plate
and rock shall be used where directed.
9 Anchored rock bolts shall be tensioned by either
applying a specified torque to the nut or by using a
hydraulic jack. The Engineer shall instruct the Contractor
as to which method is to be used in particular cases.
10 Where the torque method of tensioning is used, the
required tension shall be agreed by the Engineer and tests
shall be carried out to establish the applied torque
required to achieve this load. Care shall be taken to
ensure that the threads on the bar and nut are clean and
free from obstructions.
11 Where tension is to be applied by hydraulic jack, the
Engineer may require tests to establish the jack gauge
calibration. In calculating the initial load to be applied,
loss of tension due to the transfer of load to the locking
nut and washer shall be allowed for.
12 Permanent load measuring instruments shall be
incorporated in selected rock bolts as directed and the
tension in these bolts shall be monitored. Monitoring
shall be carried out at hourly intervals for the first 4 hours,
then at 4-hour intervals up to the first 24 hours, then at
daily intervals up to 20 days after tensioning or at such
other times as may be directed.
13 Where the Engineer directs that the lengths or part of
the length of a rock bolt shall be de-bonded from the
surrounding grout, this de-bonding shall be achieved by
means of a plastic sheath closely fitting around the steel
bolt.
14 All relevant data shall be recorded and presented in
an approved form. If the Engineer is not satisfied that the
anchorage of the bolt is adequate, the Contractor shall
take approved remedial measures to ensure adequate
anchorage.
9.4.3.3 Pull Out Tests for Anchored Bolts
1 Before commencement of any work requiring rock
bolts, pull out trials shall be carried out to measure the
ultimate load carrying capacity of all types of bolts to be
used. Pull out tests shall be carried out according to ASTM
Standard method D4435 or BS equivalent.
2 Trials shall be carried out in rock of a similar nature
to that in which the rock bolts will be used. The
deformation of rock bolts and the load shall be continually
monitored until failure. A minimum of 4 tests on each
type of bolt to be used shall be performed. Details of
proposed procedures shall be submitted for approval
before commencement of the trials. The anchorage must
be capable of carrying twice the specified working load.
3 These tests will be used to assess the suitability of
proposed anchorage systems in the particular location
where the bolts are to be used. Where rock conditions
change, such that anchorage characteristics are affected,
further trials shall be carried out as directed.
copy 249
4 During construction approximately 5% of all bolt
types shall be tested to twice the specified working load. If
significant failures are obtained in the tests results, the
Contractor shall carry out further tests and shall take
approved remedial measures as directed by the Engineer.
5 A protective barrier (wire netting) shall be erected
around the testing equipment to protect and safeguard
against any injury to any personnel involved in the testing
works and any other measures as deemed necessary by
the Engineer.
9.4.3.4 Pull Out Tests for Untensioned Bolts
1 The efficiency of grouting shall be checked by pulling
out the bolts (according to ASTM D4435) after such time
as will ensure that the cement grout or mortar remains
bonded to the bolt when the bolt is withdrawn from its
hole. A total of 10% of all untensioned bolts shall be
tested in this way. The grouted boreholes shall then be
cleaned out and bolts free from hardened grout reinstalled
to the Engineer's satisfaction.
2 If, in the Engineer's opinion, an unacceptably high
percentage of the initial 10% selection of bolts is not fully
grouted along their length, the Engineer will require
further tests to be carried out.
9.4.3.5 Rock Anchoring Procedures
1 Care shall be taken to avoid mechanically damaging,
work hardening or heating tendons while handling. All
tendons shall be stored clear of the ground and protected
from the weather, from any other materials and from
splashes from the cutting operation of an oxy-acetylene
torch, or arc-welding processes in the vicinity. In no
circumstances shall tendons be subjected to any welding
operation, or on-site heat treatment or metallic coating
such as galvanizing.
2 When tendons have been stored on site for a
prolonged period, the Engineer may require tests to show
that the quality of the tendons has not been significantly
impaired by corrosion, stress-corrosion, loss of cross-
sectional area or changes in any other mechanical
characteristics.
3 All tendons shall be free from loose mill scale, loose
rust, oil, paint, grease, soap or other lubricants, or other
harmful matter at the time of incorporation in the rock
anchor. Cleaning of tendons shall be carried out either by
wire brushing or by passing through a pressure box
containing carborundum powder. Solvent solutions shall
not be used for cleaning without approval.
4 Low relaxation and normal relaxation wire shall be in
sufficiently large diameter coils to ensure that the wire
pays off straight. In cases where, in the opinion of the
Engineer, straight as-drawn wire is not essential, wire in
small diameter coils corresponding to the diameter of the
blocks in the drawing machine may be used.
5 Pre-stressing strand, however manufactured, shall be
in sufficiently large diameter coils to ensure that the
strand pays off straight.
6 Pre-stressing bars as delivered shall be straight. Any
small adjustments for straightness necessary on Site shall
be made by hand under the supervision of the Engineer.
Bars bent in the threaded portion will be rejected. Any
straightening of bars shall be carried out cold.
7 All cutting to length and trimming of ends shall be by
high speed abrasive cutting wheel, friction saw or any
other mechanical method approved by the Engineer. In
rock anchor systems, the cutting action shall be not less
than one diameter from the anchor, and the heating effect
on the tendon shall be kept to a minimum.
8 The tendon or tendons shall be accurately located
and maintained in position. Spacers are to be used to
keep the tendons in their correct position in the borehole.
9 The tendon or tendons shall terminate at the back of
the hole in the rock secured in a ribbed steel cylindrical
anchorage block or be grouted into place over the
'anchorage length' defined for the working load required.
The end of the borehole shall be filled with a polyester
resin or cement mortar. The length of anchorage shall be
sufficient to take the load on the tendons with a safety
factor of 2. The remaining length of tendon, (the free
length) shall be encased in a corrosion-protected grease-
packed, plastic de-bonding sheet.
9.4.3.6 Tensioning Tendons
1 All wires or strands stressed in one operation shall
be taken, where possible, from the same parcel. Each
cable shall be tagged with its number and the coil number
or numbers of the steel used. Cables shall not be kinked
or twisted, and individual wires and strands shall be
readily identifiable at the end of the member. No strand
that becomes unraveled shall be used.
2 A tendon when tensioned contains a considerable
amount of stored energy, which, in the event of any failure
of the tendon, anchorage or jack, may be released
violently. The Contractor shall ensure that adequate
precautions are taken during and after tensioning to
safeguard persons from injury and equipment from
damage which may be caused by the sudden release of
this energy.
3 Hydraulic jacks shall be used for tensioning tendons.
The tensioning apparatus shall meet the following general
requirements:
i. The means of attachment of the tendon to the
jack shall be safe and secure.
ii. Where two or more wires or strands are
stressed simultaneously, care shall be taken
that they are of approximately equal lengths
between anchorage points at the datum of load
and extension measurement. The degree of
variation shall be small compared with the
expected extension.
iii. Tensioning shall be such that a controlled total
force is imposed gradually and no dangerous
secondary stresses are induced in the tendons,
anchorage or concrete.
♦ 9-7 ♦
copy 249
 iv. The force in the tendons during tensioning
shall be measured by direct reading load cells
or obtained indirectly from gauges fitted in the
hydraulic system to determine the pressure in
the jacks. Facilities shall be provided for the
measurement of the extension of the tendon
and of any movement of the tendon in the
gripping devices. The load-measuring device
shall be calibrated to an accuracy within plus
or minus 2% and checked at frequent intervals
agreed with the Engineer. Elongation of the
tendon shall be measured to an accuracy
within 22% or 2 mm, whichever is more
accurate.
v. Complete records shall be kept of all tensioning
operations, including the measured extensions,
pressure-gauge, or load-cell readings and the
amount of pull-in at each anchorage.
vi. Anchorage of the tendons at the rock face end
of the borehole shall conform to BS 4447.
vii. The form of anchorage system shall facilitate
the even distribution of stress in the concrete
bearing pad.
viii. Split wedge and barrel-type anchors shall be of
such material and construction that, under the
loads imposed during the tensioning operation,
the strain in the barrel will not allow such
movement of the wedges to reach the limit of
their travel before causing sufficient lateral
force to grip the tendon, or before the limit of
travel of the wedges causes an excessive force
in the tendon.
ix. If proprietary forms of anchorage are used, the
anchoring procedure shall be in accordance
with the manufacturer's instructions and
recommendations and as approved by the
Engineer.
x. All bearing surfaces of the anchorages of
whatever form shall be clean prior to the
tensioning operation.
xi. Any allowance for draw-in of the tendon during
anchoring shall be in accordance with the
Engineer's instructions and the actual slip
occurring shall be recorded for each individual
anchorage.
xii. After tendons have been anchored, the force
exerted by the tensioning apparatus shall be
decreased gradually and steadily so as to avoid
shock to the tendon or the anchorage.
xiii. Provision shall be made for the protection of
anchorages against corrosion.
9.4.3.7 Grouting for Rock Anchors
1 The space in the borehole around the tendons shall
be grouted with a cement grout such that the void shall be
completely filled.
2 Grouting shall be carried out as soon as practicable
after the tendons have been stressed.
♦ 9-8 ♦
3 Grouting procedures, injection of grout and strength
of grout shall be as specified for rock bolting.
9.4.3.8 Testing of Rock Anchors
1 Before commencement of any part of the permanent
anchorage works, two trial anchors shall be installed and
tested to ensure that they can carry the specified load with
a safety factor of 2. Anchor pull tests shall be performed
according to ASTM D4435 Standard method or BS
equivalent
2 Load/elongation curves shall be plotted and
interpreted by the Contractor and presented with all
relevant data in a form approved by the Engineer.
3 If either of the trial tests shows that the anchor has a
safety factor of less than 2, then the anchorage length and
formation shall be modified and two further tests shall be
carried out.
9.4.3.9 Application of Sprayed Concrete and Mortar
1 Carry out shotcreting in a sequence and according to
a program to be approved by the Engineer
2 Provide good lighting, rigid and sufficiently wide
working platforms in area where shotcreting is taking
place
3 Protect properly surfaces which are not to be coated
and keep them free from sprayed concrete.
4 Clean and wet all surfaces thoroughly with a strong
blast of air and water, immediately prior to the application
of sprayed concrete.
5 Safety: if the exposed rock profile is considered by
the Engineer to be unsafe, then ensure that the personnel
manning the sprayed concrete operation are protected
from falling rock. In this respect the Contractor is advised
to consider the use of a remote controlled-sprayed
concrete machine.
6 Control the thickness and the alignment of the
sprayed material by either guide wires, mortar spotting or
plastic studs, to indicate depth. Drill through the concrete
lining to establish the thickness of the lining at points
selected by the Engineer. Build up each layer of sprayed
concrete or mortar by making several passes of the nozzle
over the working area. Project the sprayed concrete or
mortar from the nozzle in a steady uninterrupted flow.
Should the flow become intermittent for any reason, the
nozzle man shall direct it away from the work until it again
becomes constant.
7 Layer thickness is governed mainly by the
requirement that the concrete or mortar should not sag.
Where thick layers are applied it is important that the top
surface be maintained at approximately a 45 degree slope.
The minimum allowable thickness of layer according to
the American Shotcrete Association ASA
recommendations is 25mm. There is no stated maximum
thickness for shotcrete layer.
copy 249
8 Where necessary a layer of sprayed concrete or
mortar may be covered by succeeding layers, but it shall
first be allowed to take its initial set. All laitance, loose
material and rebound must first be removed. Remove any
laitance, which has taken final set by grit blasting. Finally
clean and wet the surface using adequate blast of air and
water. The time between applications of successive layer
shall not exceed 24 hours. A longer break may be
accepted if it can be shown by tests that sufficient bond
can be achieved
9 Under no circumstances shall rebound material be
worked back into the construction. Keep the work
continually free of rebounded material, by use of a high
pressure air jet or any other necessary means.
10 The distance of the nozzle from the work shall be
between 600mm and 1000mm. It shall be, as a general
rule, aimed perpendicular to the application surface.
Commence application for vertical or near vertical
surfaces, at the bottom. Embed completely the
reinforcement, at least, in the first layer.
11 Provide suitable screening of the nozzle and the
application surface during windy and draughty conditions.
12 Keep the spraying equipment in good condition by
cleaning frequently. This shall be done at least once per
shift. The spraying nozzle shall be in such condition that
an even and continuous flow of material is obtained.
Change nozzle cover as soon as excessive wear is found in
the cover. The arrangement for the addition of water at
the nozzle must give a uniform wetting of the material. If
the dry mix process is used, add liquid admixtures, if
approved, with the mixing water at the nozzle. If dry
admixture is used, add it into the dry mix at the latest
possible time. In either case, employ accurately calibrated
and adjustable mechanical means to dispense the
admixture in the correct approved proportions.
13 The capacity of the compressor plant and water
supply shall be large enough to ensure a constant and
sufficiently high pressure. The water pressure should be
somewhat higher than the air pressure. Manometers
should be provided to measure the air and water pressure.
14 Damp cure sprayed concrete or mortar for at least 7
days.
15 Make the profile of the finished surface even. Fill any
area of excessive overbreak with sprayed concrete, or
other approved cavity filler, to bring the finished surface
level with the general profile of the surrounding finished
sprayed concrete or mortar.
16 Sprayed concrete or mortar surfaces shall not be
trowelled, screeded or disturbed in any way unless
specified otherwise.
17 Construction joints shall be tapered to a thin edge
over a width of approximately 300mm, unless specifically
instructed by the Engineer. No square joints are allowed.
Clean and wet the entire joint thoroughly prior to the
placement of adjacent sprayed material.
18 Testing of sprayed concrete: During the work, three
test panels as described for preliminary testing (under
Paragraph 9.4.2.7) shall be made on a daily basis and shall
represent each application crew, change in mix design, or
change in procedure. After curing along with and in the
same manner as the structure, the panels shall be cored in
the same manner as described for preliminary testing and
shall be tested in accordance with AASHTO T 22. Should
cores from any of the test panels fail to meet strength
requirements, the materials in the structure itself shall be
cored, taking at least 4 cores for each 100 sq.m.
represented by the failed test panel. If the average
strength of these cores meets strength requirements and
no single core is less than 75% of design strength, the
materials shall be accepted; otherwise the materials in the
structure shall be cut out and replaced.
19 Cut and replace any work which is not accepted by
the Engineer
9.4.3.10 Reinforcement Mesh
1 The reinforcing mesh shall be made up from 5mm
diameter steel bars. Weld the bars to form a 150mm
square grid and fix it firmly to the rock by an approved
means such that it is rigidly held during the subsequent
application of sprayed concrete. Ties, anchors and
supports shall be of a material approved by the Engineer.
2 Avoid spraying through the reinforcement as the
reinforcement can make hollows and arching effect, which
hinder the production of a homogeneous concrete layer.
Fix reinforcement as late as possible. If a number of
reinforcement layers are used then they shall be fixed and
concreted one at a time. When shooting through bars is
unavoidable, hold the nozzle closer than usual and at a
slight angle in order to permit better encasement, and
facilitate the removal of rebound. Clean reinforcement of
any previously deposited rebound material which may
prevent a proper bond.
3 The method of fixing shall be such that sprayed
concrete can be compacted soundly behind the
reinforcement at all points.
4 The minimum cover of mesh reinforcement to the
rock surface is to be 25mm. The minimum cover to mesh
reinforcement from the required finished surface of the
sprayed concrete is to be 20mm.
9.4.3.11 Paint
1 Wherever shown on the Drawings, sprayed concrete
shall be painted with the indicated material type and color,
to the Engineer’s approval.
9.4.3.12 Wire Netting
1 Wire netting is to be used to secure loose rock on the
cut slopes it may be used in conjunction with rock bolts
and sprayed concrete. The netting is to be secured to the
rock face in a manner approved by the Engineer.
♦ 9-9 ♦
copy 249
9.4.4 Method of Measurement
1 Rock bolts shall be measured by lin.m. of each
category installed, including borehole drilling, grouting
and de-bonding if required..
2 Rock anchors shall be measured by lin.m. of each
specified capacity installed including borehole drilling,
tensioning, securing and grouting.
3 Drilling boreholes, de-bonding of rock bolts, trial
bolts and trial rock anchors, testing and monitoring of rock
bolts and rock anchors, grouting of rock bolts and rock
anchors, and other ancillary items and work shall not be
measured separately for direct payment, but shall be
considered as subsidiary work the costs of which will be
deemed to be included in the rates for rock bolts and
anchors.
4 Shotcrete (concrete) or gunite (mortar) shall be
measured by the cubic meter, applied, The area and
thickness shall be computed from the Drawings unless
otherwise directed by the Engineer. The rates shall be
deemed to include for all ancillary work, including
preparation of rock surfaces, provision and maintenance
of spraying equipment, finishing and protection of
surfaces and all tests.
5 Reinforcing mesh shall be measured by the sq.m of
net area, installed, based on the Drawings unless
otherwise directed by the Engineer. Rates are deemed to
include for all fixings and laps at joints in the mesh
6 Painting of the shotcrete (if required) shall be
measured by the sq.m. of area painted, based on the
Drawings unless otherwise directed by the Engineer. Rates
shall include for all primers and preparatory work.
7 Wire netting shall be measured by the sq.m. of net
area , installed, based on the Drawings unless otherwise
directed by the Engineer. Rates are deemed to include for
all fixings and laps at joints..
9.4.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rates for the various items stated in the Bill of Quantities
which rates shall be full compensation for slope and
foundation preparation, drilling, fixing and for materials,
labor, equipment, tools, supplies and other items
necessary for the proper completion of the work.
9.4.6 Items in the Bill of Quantities
i. Rock Bolts (lin.m)
ii. Rock Anchors (lin.m)
iii. Shotcrete (cu.m)
iv. Gunite (cu.m)
v. Wire Netting for Shotcrete (sq.m)
vi. Reinforcing Mesh (sq.m)
vii. Painting (sq.m)
♦ 9-10 ♦
9.5 Rock Grouting
9.5.1 Description
1 This Sub-section describes installation, drilling and
grouting rock as slope stabilization.
9.5.2 Materials
1 Grout shall consist of a mixture of cement and water.
For grouting of large holes fine sand aggregate passing
1.18mm AASHTO standard sieve may be added if
approved by the Engineer. Chemical admixture and filler
may only be used with prior approval of the Engineer.
2 The compressive strength of the grout measured in
accordance with BS 1881 shall exceed 15 MPa at 7 days.
3 Grout mixes shall have the minimum cement content
consistent with the required workability. The grout shall
not be subject to bleeding in excess of 2% after 3 hours,
nor 4% maximum, when measured at 18˚C in a covered
cylinder approximately 100 mm diameter with a height of
grout of approximately 100 mm, and the water shall be
reabsorbed by the grout during the 24 hours after mixing.
9.5.3 Construction Requirements
1 Rock grouting is the injection under pressure of grout
to consolidate areas of fractured rock. Grouting shall
normally proceed from the bottom of the rock slope
upwards.
2 Details of methods to be adopted and materials to be
used, sequence, spacing, diameter and depth of holes to
be adopted shall be submitted to the Engineer for prior
approval before proceeding with any pressure grouting.
Grouting work shall be under the direct control of skilled
and experienced operatives.
3 The rock slope shall be trimmed and prepared as
specified in Section 2, Paragraph 2.3.3.6 before grouting is
begun.
4 Clean water shall be used as the flushing medium for
drilling, with flows not less than 15 l/minute.
5 The Contractor shall ensure that, at all times,
grouting work is under the direct control of skilled and
experienced operatives. The Engineer may vary the
methods, materials and grouting pressures if, in his
opinion, the conditions dictate a change of technique. All
holes to be grouted shall be numbered, as directed and
grouting operations shall take place in the following order:
i. Drilling of holes
ii. Washing of holes
iii. Water testing
iv. Pressure grouting
6 The hole spacing shall normally be 1.6m to 5.0m with
additional holes as required to intersect individual weaker
areas. Hole depth shall be limited to the range 3-10m and
hole diameter shall be within the range 38-78mm, drilled
with either rotary or rotary-percussive drilling equipment.
copy 249
Water or air flush may be used unless otherwise directed
by the Engineer.
7 Holes shall be jetted using a water flow, under such
pressure as may be directed. The injection of water shall
be followed by injection of air under pressure, these
operations alternating until air bubbles appear at an
adjacent hole. All other holes shall be capped and water
forced under pressure into the first hole, until unwanted
material from fissures washes out from the uncapped hole.
This process shall continue until no more fine material is
removed, or until directed. The outlet hole shall then be
capped and the other holes opened. The sequence shall
be repeated until connections between all holes have been
established and all fine material removed. After washing,
all holes shall be capped.
8 Holes shall be water tested in stages or as the
Engineer may require. For stage testing, a twin packer
and nozzle pipe system shall be used. Water testing
equipment shall be capable of ensuring steady pressures
and a delivery of water of 100 l/min at the required
pressure. The equipment shall include all necessary tanks,
gauges and water meters. Water shall be pumped at the
proposed grouting pressure into the hole to be tested and
the flow measured for 5 or 10 minutes as directed. The
Contractor shall keep a record of the water flow expressed
in l/min for each stage tested. Additional testing may be
required as the grouting operation proceeds.
9 All grout mixes shall be prepared using high speed,
high shearing action mixers to ensure uniform consistency.
When storing mixed grout for short periods, prior to
pumping, only purpose made agitator tanks shall be used.
Where clay or bentonite are incorporated in the grout,
separate mixing tanks shall be provided in which the
bentonite-water mix can be prepared and kept agitated
until required.
10 Ram type pressure pumps shall be used for grouting.
Precise control of pump pressure and delivery over the
whole range of pressures and volumes are required.
Valves shall be readily accessible for ease of maintenance.
All hoses and piping should be of small diameter to
ensure high velocity flow without segregation. Injection
may be carried out by either the single line or circulating
system. Each borehole shall be provided with a short
standpipe threaded at its outer end to accept a manifold
with a pressure gauge, relief valve and valve enabling
delivery from the pump to be cut off from the hole.
Pressure gauges shall also be provided at pumps.
11 Once grouting has commenced, it shall be continued
without interruption until completion. Grouting shall
commence with a mix of 8:1 water: solids ratio. The mix
shall be thickened progressively until pressure begins to
build up. If pressure build up occurs too quickly, the mix
may be thinned again. The final injection shall use a 1.5:1
water: solids mix. If no pressure build up occurs with a
1.5:1 mix, sand may be mixed with the grout, provided
that the sand: cement ratio does not exceed 2:1 by weight.
When the desired pumping pressure is achieved, with
extremely low grout flows, final injection shall take place
with a neat 1:1 water: solids mix
12 Grouting can be considered complete when the
absorption of grout at the required pressure is less than 2 l
per min over a period of 10 minutes.
13 Grouting shall proceed with caution until experience
of the ground conditions has been gained. Thereafter, if
conditions allow, injection shall proceed at high pressure
to achieve maximum flow from the start of injection.
Grout pressure, as measured at the mouth of the hole,
shall correspond to 0.4 bar/ per meter depth of hole for
those areas where the strata to be treated have no
structures in the vicinity. In the vicinity of structures the
pressure shall be 0.25 bar per meter depth. Uplift gages
shall be installed and continuously monitored as grouting
proceeds.
14 If the required grouting pressure is not attained using
a sand-cement mix, grouting shall be suspended and the
hole washed. After several hours, grouting may proceed
again using the sand-cement mix until the desired
pressure is achieved. Should there be any grout leakage
between two holes occurs, both holes shall be grouted
concurrently or the initial hole grouted whilst the second
hole is capped. When injection is interrupted before it is
complete, the hole shall be washed using not less than
500 liters of clean water.
15 After grout consumption has reached the limits
previously specified, the Engineer will require additional
holes to be core drilled. The diameter of the retrieved
grouted rock cores shall not be less than 50 mm. Three
representative samples for each 3 m of core shall be taken
and unconfined compression tests shall be carried out on
each core sample. The mean strength of each group of
cores shall not be less than 3 MN/sq.m. If this value is not
reached then additional grouting of the rock shall be
performed until further tests indicate that the strength of
grouted rock cores achieves 3 MN/sq.m. For every 8
treatment holes or at the Engineer's discretion, at least
one hole shall be cored and the cores tested as outlined
above. In the core drilled hole the Engineer may require a
water test to be carried out.
16 Complete details of drilling, water testing and
grouting operations including pressures, mixes and grout
takes, shall be recorded on daily progress sheets. A
graphical record of such results shall be compiled and
copies of all progress sheets and records shall be
submitted promptly for approval.
9.5.4 Method of Measurement
1 Rock grouting shall be measured by the volume of
grout used and the linear meter of rock drilling carried out
at the diameter required. Measurement shall be based on
the actual quantities of grout material used and boreholes
drilled, as approved by the Engineer. The rates shall be
deemed to include for water jetting of rock faces and
boreholes, and any other ancillary work.
♦ 9-11 ♦
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9.5.5 Basis of Payment 7 Concrete shall be cured using water curing with wet
burlap for 7 days. Curing compound can be used in
1 The amount of completed and accepted work
urgent conditions only, to the approval of the Engineer.
measured as provided for above will be paid for at the unit
rate in the Bill of Quantities for ‘Rock Grouting’, which rate
9.6.4 Method of Measurement
shall be full compensation for drilling, pumping, testing,
and materials, labor, equipment, tools supplies and other 1 Reinforced concrete slope protection shall be measured
items necessary for the proper completion of the work. by cu.m. Measurement shall be based on the area and
thickness shown on the Drawings.
9.5.6 Items in the Bill of Quantities
9.6.5 Basis of Payment
i. Drillholes for grouting rock (dia) (lin.m)
ii. Rock grout (cu.m) 1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
9.6 Reinforced Concrete Slope rates indicated in the Bill of Quantities, which rate shall be
full compensation for slope preparation, excavation,
Protection backfilling, supply, mixing, testing, laying, finishing,
curing, protection of concrete, provision and fixing of
9.6.1 Description reinforcement, and for materials, transportation, hauling,
1 This Sub-section describes requirements for labor, equipment, tools, supplies and other items
construction of reinforced concrete slope protection. necessary for the proper completion of the works.

9.6.2 Materials 9.6.6 Items in the Bill of Quantities

9.6.2.1 Concrete i. Reinforced concrete slope protection (cu.m)

1 Concrete for reinforced concrete slope protection 9.7 Sacked Concrete Revetment
shall be Class 25 as specified in Sub-section 5.1 and
Clause 5.1.3. The slump limits shall comply with the
9.7.1 Description
requirements stipulated in Sub-section 5.7, Paragraph
5.7.2.7. 1 This Sub-section describes requirements for
construction of sacked concrete revetments at
9.6.2.2 Reinforcement embankment slopes, bridge abutments and similar
1 Reinforcement for reinforced concrete slope locations.
protection and elsewhere if required, shall conform to the
relevant requirements of Sub-section 5.2 - “Reinforcing 9.7.2 Materials
Steel ".
9.7.2.1 Sacks

9.6.3 Construction Requirements 1 Sacks for sacked concrete revetments shall be made
from burlap of minimum 200 gm per sq.m. . Sack
1 Reinforced concrete slope protection shall be
dimensions shall be approximately 0.6 m by 0.9 m
constructed at the locations shown on the Drawings.
measured when empty. Relatively clean reclaimed sacks
Placing, finishing and curing of concrete shall conform to
may be used if approved.
all relevant requirements of Section 5, except that only
hand finishing methods will be required.
9.7.2.2 Concrete
2 After the slopes have been properly trimmed and
prepared according to the Drawings, and before laying 1 Concrete for sacked concrete revetments shall be
concrete , the Contractor shall furnish screed rails or other Class 15 as specified in Sub-section 5.1.
grade-indicating devices to control the minimum depth of
concrete and uniformity of the top surface. 9.7.3 Construction Requirements
4 Reinforcing steel shall be cut and fixed in accordance 1 The sacks shall be filled with concrete loosely
with the requirements of Sub-section 5.2. (uncompacted) placed so as to leave room for tying and
5 Joints shall be laid out or referenced accurately. sewing. Approximately 0.035 cu.m. of concrete shall be
Construction joints shall be placed at designated placed in each sack. The sacks shall be closed by sewing,
contraction joints where possible. or at expansion joints if tied with strong twine. Immediately after closing, the
the construction joint falls within 5 m from a free edge or sacks shall be placed and trampled lightly to cause them
expansion joint. Joints for poured joint filler may be
formed in place or sawn in the fresh concrete.
6 Surface finish shall be either a uniform floated or
broomed finish, as directed by the Engineer..

♦ 9-12 ♦
copy 249
to conform to the earth surface and the adjacent sacks
already in place.
2 After the slopes have been properly prepared and
approved, the sacked concrete elements shall be placed.
The sacks shall be laid in accordance with the details
shown on the Drawings. All dirt and debris shall be
removed from the top of the sacks before the next course
is laid. Sacks shall be placed so that the tied ends will not
be adjacent to one another. Not more than 6 courses of
sacks shall be placed in any tier until initial set in the first
course of any such tier has taken place.
3 Care shall be taken in placing and shaping the sacks
so that the minimum dimensions shown on the Drawings
are obtained, and the finished sacked concrete revetment
has minimum voids.
9.7.4 Method of Measurement
1 Sacked concrete revetment shall be measured by
cu.m. of concrete filled sacks , installed. Measurement
shall be based on the dimensions shown on the Drawings.
9.7.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rates indicated in the Bill of Quantities, which rate shall be
full compensation for slope preparation, excavation,
backfilling, and for materials, transportation, labor,
equipment, tools, supplies and other items necessary for
the proper completion of the works.
9.7.6 Items in the Bill of Quantities
i. Sacked concrete revetment (cu.m)
9.8 Paving Tile Slope Protection
9.8.1 Description
1 This Sub-section describes requirements for paving
tiles, laid as protection to embankments, bridge
abutments and similar locations.
9.8.2 Materials
1 Precast paving tiles (slabs) used for slope protection
shall be manufactured as specified in Section 12.
2 Preformed joint filler shall conform to AASHTO M 33:
"Preformed Expansion Joint Filler for Concrete". Hot-
poured joint filler shall conform to AASHTO M 282: "Joint
Sealants, Hot Poured, Elastomeric Type, for Portland
Cement Concrete Pavements".
9.8.3 Construction Requirements
1 Embankment slopes where precast tiles are to be laid
shall first be rolled. Close to any structures, to prevent
possible damage, a hand rammer shall be used; otherwise
use of a mechanical roller shall be permitted.
2 Embankment slopes at bridge abutments and
elsewhere as shown on the Drawings shall be trimmed to
proper line and grade. A blinding layer of Class 15
concrete, as specified in Sub-section 5.1, shall be placed
over the full area of surface to be paved, to a minimum
depth of 50 mm. Precast tiles shall then be laid to the
lines and levels shown on the Drawings, on a bedding of
20 mm thick, 1:3 cement: sand mortar and joints shall be
properly aligned and finished, all as specified in Section 12.
9.8.4 Method of Measurement
1 Paving tile slope protection shall be measured by
sq.m. of tiles, laid, including all necessary base course,
bedding, blinding and joint filling. Measurement shall be
based on the dimensions shown on the Drawings.
9.8.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rates indicated in the Bill of Quantities, which rate shall be
full compensation for slope preparation, excavation,
backfilling, and for materials, transportation, labor,
equipment, tools, supplies and other items necessary for
the proper completion of the works.
9.8.6 Items in the Bill of Quantities
i. Paving Tile Slope Protection (sq.m)
9.9 Ditch Lining
9.9.1 Description
1 This Sub-section describes requirements for stone,
concrete and concrete paving slabs laid as linings to
ditches and water courses.
9.9.2 Materials
1 Paving slabs for channel and ditch lining shall be
Class 25 concrete fabricated in accordance with the
relevant requirements of Sub-section 5.1 and to the
dimensions shown on the Drawings.
2 Stone for ditch lining and wash checks shall be as
specified for riprap in Sub-section 9.1.
3 Grout for ditch lining and wash checks shall consist
of 1:3 cement:sand mortar, by volume.
4 In situ concrete for ditch lining and wash checks shall
be Class 25, as specified in Section 5.
9.9.3 Construction Requirements
9.9.3.1 General
1 Ditch and watercourse channel sides shall be
trimmed to profiles as shown on the Drawings.
♦ 9-13 ♦
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9.9.3.2 Precast Slabs shall have a loss on abrasion value of no more than 40%
measured by AASHTO T 96.
1 Precast concrete slabs shall be laid to the lines and
levels shown on the Drawings, on a bedding of 20mm 2 Filter material particle size distribution shall be as
thick 1:3 cement:sand mortar. Joints shall be 10mm wide given in Table 9.10.2.1.
and filled with 1:3 cement:sand mortar. Joints shall be
AASHTO Sieve % passing (by mass)
cured by an approved method for at least 4 days.
50 mm 100
9.9.3.3 Stone Ditch Lining and Wash Checks
37.5 mm 95 - 100
1 Ditch lining and wash check stones shall be placed
with ends and sides abutting and the joints between each 19 mm 50 - 100
row breaking with the joints in the preceding row. The 9.5 mm 15 - 55
larger spaces between stones shall be filled with
4.75 mm 0 - 25
fragments. The stones shall be rammed and compacted.
2.36 mm 0 - 10
2 After the stone surface has been approved the spaces
between stones shall be completely filled with grout, 75 μm 0-5
brushed or broomed into the spaces. The grout shall be Table 9.10.2.1: Filter Material Gradation
cured as specified in Sub-section 9.1.
3 Filter membrane shall be a thermally bonded non-
9.9.4 Method of Measurement woven fabric produced from continuous filament synthetic
fibers. The hydraulic properties shall allow water passage
1 The approved ditch lining works shall be measured of 50-100 l per sq.m.per sec under a 100mm head. The
by the square meter of lining of paving slabs or wash pore size distribution shall be 50% not greater than 70 μm.
checks installed. Measurement of slabs or wash checks
4 The mechanical properties of the membrane fabric
shall be made perpendicular to the ditch centerline along
(that will have a minimum thickness of 1.0mm) shall be as
the top surface at the upstream edge of each wash check.
given in Table 9.10.2.2.
Blinding and bedding will not be separately measured, but
shall be deemed included with the rate for ditch lining. Allowable
Property Test Method
Value
9.9.5 Basis of Payment
Grab Strength 82Kg. ASTM D 4632
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit Seam Strength 73Kg. ASTM D 4632
rate for ‘Ditch Lining’ in the Bill of Quantities, which rate Puncture Strength 36Kg. ASTM D 751
shall be full compensation for slope preparation, laying, 2
Burst Strength 2N/mm ASTM D 3766
grouting, blinding, bedding, and for materials, labor,
equipment, tools, supplies and other items necessary for Trapezoid Tear 23 Kg. ASTM D 4533
the proper completion of the work.
Apparent Opening Size ASTM D 4571

9.9.6 Items in the Bill of Quantities 1. Soil with 50% or less

particles by mass <0.6mm
i. Paving slab protection and ditch
lining (type, thickness) (sq.m) passing 75 μm sieve
ii. Grouted stone ditch lining 2. Soil with more than
(type, thickness) (sq.m) <0.927mm
50% particles by
iii. Grouted stone wash checks
weight
(type, thickness) (sq.m)
passing 75 μm sieve KFabric>KSoil ASTM D 4491

9.10 Filter Layers Permeability, K 70% ASTM D 4355

Strength
Ultraviolet Degradation
9.10.1 Description at 150 hours
Retained

1 This Sub-section describes requirements for granular

filter material or filter membrane as an underlayer to loose
riprap or gabions.
9.10.2 Materials
1 Granular filter material shall be a mixture of sand and
hard, clean gravel or crushed rock. The coarser material
Table 9.10.2.2: Fabric Filter Membrane Properties
9.10.3 Construction Requirements
9.10.3.1 Granular Filter
1 Sand and gravel filter material shall be spread evenly
on a prepared bedding avoiding segregation of particle
sizes. The layer shall be lightly compacted and finished to

♦ 9-14 ♦
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an even surface. Bedding and filter layer shall be of the
thickness shown on the Drawings.
9.10.3.2 Fabric Membrane
1 The surface to receive the fabric membrane shall be
smooth and free from sharp projections. The membrane
shall be loosely laid with its long dimension parallel to the
length of the protection work. Adjoining sheets of fabric
membrane shall be overlapped a minimum of 0.5m or
15% of the sheet width, whichever is less. To prevent
slippage of the fabric the areas of overlap shall be secured
as recommended by the manufacturer and approved by
the Engineer.
9.10.4 Method of Measurement
1 Granular filter layers shall be measured by the
square meter, of the thickness installed on the basis of the
area shown on the Drawings.. Rates are deemed to
include for preparation of the ground.
2 Fabric membrane filter that shall be measured by the
square meter of net area laid, based on the dimensions
shown on the Drawings. Rates are deemed to include for
preparation of the ground and overlaps at joints.
9.10.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate for ‘Filter Layers’ in the Bill of Quantities, which rate
shall be full compensation for ground preparation, placing
and fixing and for materials, labor, equipment, tools
supplies and other items necessary for the proper
completion of the work.
9.10.6 Items in the Bill of Quantities
i. Granular filter layer (thickness) (sq.m)
ii. Fabric membrane. (sq.m)
9.11 Barriers for Sand Dunes
9.11.1 Description
1 This Sub-section describes requirements for
construction of barriers for sand dunes, to protect against
wind erosion and adverse weather conditions, formed of
fences, bituminous blankets and vegetation generally as
shown on the Drawings or as directed by the Engineer.
2 The Engineer will determine the types and locations
of the protective barriers to be constructed in particular
areas, based on trials and studies of the prevailing
conditions.
9.11.2 Materials
9.11.2.1 Fences
1 Fences shall be made of rolled prefabricated bundles
made of wood slats, slender poles, stalks or perforated
plastic sheets bound together and attached to vertical or
horizontal supports, and presenting up to 50 percent
openings. Samples of the fencing material shall be
submitted to the Engineer for approval.
9.11.2.2 Bituminous Materials
1 Petroleum resin emulsion shall be 1 part petroleum
resin emulsion diluted with 4 parts of water.
2 Asphalt emulsion: The proportion of water to dilute
an asphalt emulsion shall be according to the
manufacturer’s recommendation for the type of asphalt
emulsion to be used.
3 The technical data sheet of the proposed emulsion
shall be submitted to the Engineer for approval.
9.11.2.3 Vegetative Materials
1 Slow growing perennial shrubs shall be drought
resistant and adapted to the climate and soil and shall be
as described in Section 16”
2 Long-lived trees shall be of species recommended in
“Planting list for proposed highway landscape”.
9.11.2.4 Water
1 Water shall be clean and free of deleterious
substances.
9.11.2.5 Blanket Covers
1 Blanket covers shall be made of bituminous or
concrete pavements, prefabricated landing mats,
membranes, aggregate, and seashells, as shown on
Drawings.
9.11.3 Construction Requirements
9.11.3.1 Fencing
1 The fence bottom shall be installed about 30cm
above ground level
2 The entire windward surface of the dune shall be
stabilized with dust-control materials, such as bituminous
material (refer to Paragraph 9.11.2.2), prior to erecting the
first fence.
3 To maintain the effectiveness of the fencing system,
a second fence shall be installed on the crest of the sand
accumulation.
4 Existing old fences shall not be removed during or
after the addition of new fences.
5 The proper spacing and number of fences required to
protect a specific area shall be determined by trial and
observation.
6 Mock-ups of the proposed fencing system shall be
constructed to the Engineer’s satisfaction prior to final
approval of the fencing system.
♦ 9-15 ♦
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9.11.3.2 Stabilization with Bituminous Materials
1 Trial section shall be laid over an area of 25 square
meters, using approved bituminous material, at the
specified rate below and to the satisfaction of the Engineer,
prior to commence the actual works.
2 Destroy the dune symmetry by spraying the
bituminous materials at either the center or the ends of
the dune.
3 Spray the bituminous emulsion at the rate of 2.25
liters per meter square to obtain the desired stickiness of
the sand.
9.11.3.3 Stabilization with Vegetative Treatment
1 The upwind boundaries of the vegetated area shall
be protected by fences or dikes, to prevent the engulfment
of the vegetation.
2 Selected seed shall be spread as directed and
protected by mulch sprayed with a bituminous material.
3 Seed on slopes shall be anchored by mulch or
matting.
9.11.3.4 Blankets
1. After placement of blanket covers, a spray
application of bituminous material shall be required to
prevent blanket decomposition and subsequent dust.
9.11.4 Method of Measurement
1 Fencing shall be measured by the linear meter
installed.
2 Stabilization with bituminous materials shall be
measured by the square meter of area sprayed.
3 Stabilization with vegetative treatment shall be
measured by the square meter of area, installed (to the
approved frequency by the Engineer), watered, completed,
and accepted. All trials ordered by the Engineer prior to
the final vegetative treatment works shall not be paid
separately, but shall be deemed to be included in the rate
for the approved final treatment works.
4 Stabilization with blankets shall be measured by the
square meter of area, installed, using the specified
materials and to the dimensions shown on the Drawings,
or ordered by the Engineer. All trials ordered by the
Engineer prior to the installation of the final blanket works
shall not be paid separately, but shall be deemed to be
included in the rate for the approved final blanket works.
9.11.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate for ‘Barriers for Sand Dunes’’ in the Bill of Quantities,
which rate shall be full compensation for ground
preparation, placing and fixing and for materials, labor,
♦ 9-16 ♦
equipment, tools supplies and other items necessary for
the proper completion of the work.
9.11.6 Items in the Bill of Quantities
i. Fences for dune stabilization
(height, type). (lin.m)
ii. Bituminous stabilization of dunes. (sq.m)
iii. Vegetative stabilization of dunes. (sq.m)
iv. Dune stabilization with blankets. (sq.m)
9.12 Mechanically Stabilized Earth
Retaining Walls
9.12.1 Description
9.12.1.1 General
1 This work shall consist of constructing retaining walls
using a proprietary system of precast concrete panels
restrained by tie-backs into a compacted earth fill, as
approved by the Engineer. They shall be constructed in
accordance with the manufacturer’s drawings and
specifications and be within the tolerances for lines,
grades and dimensions shown in the Contract Documents
or as established by the Engineer. The wall shall consist of
a type of mechanically stabilized earth wall system
acceptable to the Engineer, and which must be
constructed by a specialized firm having a minimum of
five years of documented successful experience in the
design and construction of such wall systems. The
Contractor shall provide a complete set of typical detailed
shop drawings and complete specifications of the
proposed wall system for the approval of the Engineer 90
days prior to ordering materials to construct these walls.
2 The design shall address the climate and soil
conditions existing in Oman and provide a minimum
design life of seventy-five years. The specification as
presented to the Engineer shall also state any
requirements for the thickness of reinforcing strips and/or
limitations on the backfill used in the structure to ensure
the design life. The final thickness shall be subject to the
approval of the Engineer.
3 The term “reinforced soil wall” shall be deemed to
have the same meaning as “mechanically stabilized earth
retaining walls”.
4 The works shall include the following:
i. Reinforced Earth components (panels, high
adherence galvanized steel strips, connection
and joint materials)
ii. Selected backfill
iii. Pre-casting panels
iv. Leveling pads
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 v. Wall erection
vi. Monitoring
5 Only materials supplied by accredited sub-contractor
or supplier shall be used as Reinforced Earth Components.
6 The Contractor shall submit for prior approval a
detailed Method Statement that describes all means,
method and techniques to be adopted for construction
and installation of the “mechanically stabilized earth
retaining walls”. The Method Statement shall include
details of equipment to be used, method of installation of
each reinforced earth component taking into consideration
the manufacturer’s recommendations, backfill materials to
be used backside of wall, testing and reporting, work
program and any other information required by the
Engineer.
9.12.1.2 Standards and Codes
1 The following standards and codes in their latest
edition shall be particularly applied to works covered
by this Specification.
i. A 36M (AASHTO M183) - Structural Steel
ii. A 123M - Zinc (Hot Galvanized) Coating on
Products Fabricated from Rolled, Pressed
and Forged Steel Shapes, Plates Bars and
Strips
iii. A 153M - Zinc Coating (Hot Dip) on Iron and
Steel Hardware
iv. A 325 - High Strength Bolts for Structural
Steel Joints Including Suitable Nuts and
Plain Hardened Washers
v. A 1011M - Standard Specification for Steel,
Sheet and Strip, Hot-Rolled, Carbon,
Structural, High-Strength Low-Alloy and
High-Strength Low-Alloy with Improved
Formability
vi. A 615 - Deformed and Plain Billet-Steel Bars
for Concrete Reinforcement
vii. D 1752 - Preformed Sponge Rubber and
Cork Expansion Joint Fillers for Concrete
Paving and Structural Construction
viii. AASHTO T90 - Determining the Plastic Limit
and Plasticity Index of Soils
9.12.2 Materials
9.12.2.1 General
1 The Contractor shall make his own arrangements to
provide the face panels, reinforcing and tie strips,
fasteners, joint filler, and all necessary attachments as
recommended by the Manufacturer and approved by the
Engineer.
2 Materials and construction of reinforced earth
components shall comply with Section 5 of these
Specifications.
9.12.2.2 Concrete Face Panels
1 Concrete shall be Class 30 in accordance with Section
5 of these Specifications, except as specified herein.
2 All appurtenances and lifting and handling devices
shall be set in place to the dimensions and tolerances
shown on the approved shop drawings prior to casting.
i. Reinforcing steel shall comply with Sub-
Section 5.2 of the Specifications.
ii. Concrete Finish – The concrete surface
pattern and finish for the exposed faces
shall conform to Section 5 of the
Specifications. The rear face of the panel
shall be roughly screeded to eliminate
surface distortions in excess of 6.5 mm. The
color and texture of the finish shall be
approved by the Engineer based on three
trial panels provided by the Contractor prior
to producing the final panels.
iii. Tolerances – All units shall be
manufactured within the following
tolerances:
a- All dimensions within +5 mm.
b- Angular distortion with regard to the
height of the panel shall not exceed 7
mm in 2 m.
iv. Compressive Strength – Acceptance of the
concrete face panels with respect to
compressive strength will be determined in
accordance with Section 5 of the
Specifications, except that a minimum of
one set of test cubes shall be taken from
each lot of 50 panels or part thereof.
v. Additional Compressive Tests: An
additional 4 specimens shall be field-cured
in the same manner as the concrete facing
panels. Compression tests on these
specimens shall be used to determine the
length of curing time required and
acceptability. Panels will be accepted after
7 days, provided the compressive strength
of field-cured cylinders exceeds 65% of the
required 28-day strength. Panels with
defects that indicate imperfect molding,
honeycombing, or open texture concrete, or
that do not correspond with the quality of
the approved test panel will be rejected.
vi. Rejection – Units shall be subject to
rejection by the Engineer if not in
conformance with these Specifications or if
any of the following defects are evident by
visual inspection:
a- Defects that indicate imperfect
moulding.
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 b- Defects indicating honeycombed or
open texture concrete.
vii. Marking – The date of manufacture shall be
clearly scribed on the rear face of each
panel.
viii. Handling, Storage and Shipping – All units
shall be handled, stored and shipped in
such manner as to eliminate the danger of
chipping, cracks, fractures and excessive
bending stresses. Panels in storage shall be
supported on firm blocking located
immediately adjacent to tie strips or toggles
to avoid damage to these tie strips and
toggles. Any panels, including fastening
hardware, damaged during handling,
storage, or shipping shall be rejected by the
Engineer.
ix. Joint spacing and details for expansion,
contraction, construction and control joints
in the coping and the concrete barrier
parapet shall be as recommended by the
manufacturer and as approved by the
Engineer.
x. Test Panels: The Contractor shall construct
and submit at least 3 test panels. The
materials, including formwork, used in
construction of all test panels shall be as for
those proposed for use in the Works. The
test panel finish shall be approved by the
Engineer prior to production of any panels
for incorporation in the Works. The rear
face of each panel shall have a dense,
rough texture without honeycombed areas.
The approved panels shall remain available
on Site throughout the duration of the
Contract, as a standard for judging the
completed works.
9.12.2.3 Concrete Footings
1 The class of concrete shall be as shown on the
approved shop drawings and shall conform to Section 5 of
these Specifications.
9.12.2.4 Steel Reinforcing and Tie Strips
1 Tie strips shall be shop fabricated of hot rolled steel
conforming to the minimum requirements of ASTM A-
1101M, Grade 36 or equivalent. Reinforcing strips shall be
hot rolled steel and shall conform to the requirements of
ASTM A-36M or equivalent. The tie strips and reinforcing
strips shall be hot dip galvanized conforming to the
requirements of ASTM A-123M.
2 The properties of the backfill material to be used
shall be one of the main factors in determining the strip
thickness required to meet the specified design life.
3 Prior to galvanizing, the tie strips and reinforcing
strips shall be cut to length and tolerances shown on the
plans and the holes for bolts shall be punched in the
locations shown. All reinforcing and tie strips shall be
♦ 9-18 ♦
carefully inspected to ensure they are true to size and free
from defects that may impair their strength and durability.
4 The Contractor shall furnish the Engineer with a
Certificate of Compliance certifying that these materials
comply with the applicable Specifications.
5 Physical and Mechanical Properties: Reinforcing
strips and tie strips shall have a minimum yield point of
2,400 kg/sq.cm (235 MN/sq.m); minimum tensile strength
of 3,700 - 4,500 kg/sq.cm (363-441 MN/sq.m); 0.06%
maximum phosphorus; and 0.05% maximum sulfur. The
weight of zinc coating shall be not less than 500 gm/sq.m.
9.12.2.5 Reinforced (Polymer) Grids
1 General: Shapes and dimensions of these elements
shall conform to the dimensions and tolerances shown on
the Drawings.
2 Grid reinforcing elements shall be manufactured by
stretching a punched polyethylene sheet in one direction
under controlled conditions to produce a high tensile
strength orientated structure.
3 Mechanical Properties: The grid shall have a short
term strength of not less than 79 kN/m width, determined
from tensile testing at 20 degrees Celsius under a constant
rate of extension of 50 mm/minute. For each batch of
reinforcing material delivered to Site, or at such other
times as may be required by the Engineer, the Contractor
shall submit a test certificate from an approved
independent testing laboratory confirming that the
required strength characteristics have been met. The
120 year characteristic strength shall be not less than
29 kN/m width.
4 Physical Properties: The weight of grid shall not be
less than 0.85 kg/sq.m. It shall be immune to attack from
ultra-violet light for a minimum period of 3 years and shall
be immune to attack from all chemicals naturally found in
soils and to biological attack from micro-organisms. The
Contractor shall furnish the Engineer with the
manufacturer's warranty to this effect. The minimum roll
width shall be 1 m. Methods of joining reinforcing
material shall be approved and in accordance with the
manufacturer's instructions.
5 Upon manufacture, the reinforcing elements shall be
placed in approved wrapping material which shall prevent
ultra-violet light from reaching the reinforcing elements.
The reinforcing elements shall be identified with their date
of manufacture. Upon delivery to Site the Contractor shall
provide the Engineer with copies of the manufacturer's
certificates clearly stating the dates of manufacture of the
reinforcing elements. No reinforcing elements shall be
incorporated into the Works if at the time of proposed
incorporation the elements are more than three years old.
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9.12.2.6 Fasteners Sieve Size % Passing
250 mm 100
1 Fasteners: Bolts and nuts shall have hexagonal heads
100 mm 75-100
and conform to AASHTO M 164, Type 2, except as
0.075 mm 0-15
modified hereunder. Bolts shall be 12 mm in diameter,
30 mm in length with 20 mm of thread length. Fasteners
ii. The Contractor may request that the
shall be hot dip galvanized to AASHTO M 232, Class C. acceptance limits be increased for material
Bolts shall have a minimum yield point of 6,400 kg/sq.cm not meeting the requirement for % passing
(627 MN/sq.m); minimum tensile strength of a 0.075 mm sieve provided an analysis is
8,000 kg/sq.cm (784 MN/sq.m); and minimum elongation submitted, showing that the material
of 12%. passing the 0.075 mm sieve is less than
10% smaller than 0.015 mm, or
9.12.2.7 Non Metallic Friction Ties and Fixings
alternatively that the material is less than
20% smaller than 0.015 mm and the angle
1 The stabilized earth wall structure shall be reinforced
of internal friction as determined by ASTM
with friction strips of polyethylene coated polyester fiber
D 2850 is 25 degrees minimum.
strips or similar material approved by the Engineer. The
iii. Materials shall have a minimum resistivity
reinforcing strips shall have the ultimate strength
when measured in accordance with
indicated on the Drawings, and manufacturer’s test ASTM G 57 of 5,000 ohm-cm.
certificates shall be provided to verify this. iv. Materials having a resistivity less than the
above but greater than 1,000 ohm-cm may
2 Reinforcing strips shall be fixed to the facing panels be acceptable provided that the pH value of
using plastic coated steel anchor loops and toggles, unless the material measured in water extracted
otherwise noted on the approved shop drawings and in from a water-soil mixture is between 5 and
accordance with approved samples. The Contractor shall 10 when tested in accordance with
furnish the Engineer with a Certificate of Compliance ASTM G 51, and that the water extracted
certifying that these materials comply with the applicable from the water-soil mixture has a chloride
Specifications. content of less than 200 ppm and a
sulphates content of less than 1,000 ppm
9.12.2.8 Joint Filler (For Use with Concrete Face Panels)
when tested in accordance with AASHTO T
1 Filler for vertical joints between panels shall be 26.
flexible open cell polyethylene foam strips, unless v. The total sulphide content of the fill shall be
otherwise noted on the approved shop drawings. less than 0.3 gm/kg.
vi. Organic matter content, (difference
2 Filler for horizontal joints between panels shall be between total carbon content and mineral
resin bonded cork filler conforming to ASTM D 1752 (Type carbon content) shall not be greater than
II) unless otherwise noted on the approved drawings. 100 ppm.
vii. If required by the Engineer, the Contractor
9.12.2.9 Joint Filler (For Use with Concrete Face Panels)
shall carry out a test for Biochemical
1 Reinforced Earth selected backfill material can be Oxygen Demand (BOD). The BOD value
either natural soil or material of industrial origin. Backfill shall not exceed 0.004 gm/liter.
shall not contain chalk, unburnt colliery shale, pulverized
full ash, material from swamps, marshes or bogs, organic 4 Backfill for Reinforcing Polymer Grid System
or other materials which, in the opinion of the Engineer,
would result in the structure becoming unfit for its i. Frictional Fill: This material shall contain a
intended use. Prior to placing the granular fill, the maximum of 10% passing the 0.075 mm
Contractor shall certify to the Engineer that the material (No.200) sieve.
conform to the requirements as per specifications and ii. Gradation Requirements: Backfill material
drawings. shall conform to the following gradations:
Sieve Size %(byweight Passing
2 Selected Filter Material for Drainage Layers: Filter
backfill material shall conform to the relevant 125 mm 100
requirements of Section 2. 90 mm 85-100

3 Backfill for Steel Reinforcing Strip System 9.5 mm 25-100

0.600 mm 10-65
i. The selected fill shall conform to the
0.075 mm 0-10
following gradation and shall have a
coefficient of uniformity not less than 2
(Cu=D60/D10 2) :

♦ 9-19 ♦
copy 249
9.12.3 Construction Requirements
9.12.3.1 Wall Excavation
1 Structure excavation shall be in accordance with the
requirements of Section 2. Limits and construction stages
shall be as shown on the Drawings.
9.12.3.2 Foundation Preparation
1 The foundation for the structure shall be graded level
for a width equal to or exceeding the length of reinforcing
material or as shown on the plans. Prior to wall
construction, except where constructed on rock, the
foundation shall be compacted with a smooth wheel
vibratory roller.
2 Any foundation soils found to be unsuitable shall be
removed and replaced in accordance with the procedures
in Section 2.
3 When concrete face panels are specified, at each
panel foundation level a concrete leveling footing shall be
provided as shown on the plans. The footing shall be
cured a minimum of 24 hours before placement of wall
panels.
9.12.3.3 Erection of Concrete Face Panels
1 Precast concrete panels shall be aligned vertically
using inserts cast into the top edge of panels. Panels shall
be placed in successive horizontal lifts in the sequence
shown on the approved plans as backfill placement
proceeds. As fill material is placed behind a panel, the
panels shall be maintained in vertical position by means of
clamps placed at the junction of adjacent panels and
temporary wooden wedges placed in the horizontal or
vertical joint at the junction of the two adjacent panels on
the external side of the wall. External bracing may also be
required for the initial lift. Vertical tolerances (plumbness)
and horizontal alignment tolerances shall not exceed 25
mm when measured along a three meter straight edge.
The maximum allowable offset in any panel joint shall be
25 mm. The overall vertical tolerance of the wall
(plumbness from top to bottom) shall not exceed 25 mm
per three meter of wall height.
9.12.3.4 Backfill Placement
1 Backfill placement shall closely follow the erection of
each lift of panels. The filling material will be graded and
compacted before the placement of a new layer. The
gradation of the selected granular backfill should be tested
periodically during construction to assure compliance with
specifications. This gradation testing should be performed,
at least once for every 500 cubic meter of material placed
and/or whenever the appearance or behavior of the
material changes noticeably. Material shall be laid with
layers of uniform thickness, taking care to avoid
segregation and water content variations.
2 As shown on the shop drawings, reinforcements
shall be placed normal to the face of the wall.
♦ 9-20 ♦
3 Backfill shall be placed in accordance with Section 2
of these Specifications and compacted in accordance with
the requirements shown below and on the Drawings. The
maximum lift thickness shall not exceed 250 mm (before
compaction) and shall closely follow panel erection. The
Contractor shall decrease this lift thickness if necessary to
obtain the specified density.
4 At the end of each day’s operations, the Contractor
shall shape the last level of backfill so as to permit run-off
of rainwater away from the wall face.
5 Backfill outside roadway embankment areas shall be
compacted to at least 90% AASHTO T 180 maximum
density. Backfill within roadway embankment areas shall
be compacted to 95% AASHTO T 180 maximum density
except for backfill in sub-grade zones which shall be
compacted to 100% AASHTO T 180 maximum density.
6 The acceptance criteria for control of compaction
shall be given by first the equivalent Relative Density as
determined by ASTM D-2049. Then by large-scale plate
bearing test, which defines the type of the equipment,
energy, lift thickness, etc ... before beginning compaction,
it is necessary to check that the moisture of the backfill
material is the optimum (± 1.5%) value of modified
AASHTO standard.
7 The compaction shall be carried out in such a way as
to obtain a uniform density, rollers shall move to and from,
always parallel to the wall and assuring that the
overlapping between one run and the next shall not be
less than 10% of the roller width. Backfill compaction shall
be accomplished without disturbance or distortion of
reinforcements and panels. Compaction in a strip one
meter wide adjacent to the backside of the wall shall be
achieved using an approved manually operated vibrating
compactor.
8 If a reinforcing polymer grid and connections are
used, they shall be handled and installed in accordance
with the manufacturer's instructions and
recommendations, copies of which shall be submitted to
the Engineer before commencement of these Works. The
reinforcing grid shall not contain any cuts, kinks, twists,
blisters or other defects which, in the opinion of the
Engineer, would render it unsuitable for its intended use.
9.12.3.5 Trial Embankment
1 If shown on the Drawings, or if required by the
Engineer, a trial embankment shall be constructed prior to
start filling. The Contractor shall perform a full scale trial
compaction test.
2 The allocation of the testing area, the system for the
execution of the embankment and the testing program
shall be fixed by the Engineer considering the following:
i. The equipment shall be the same to be
used during all the construction.
copy 249
 ii. The trial area shall be leveled and
compacted, at approved locations or at
locations adjacent to the Site.
3 The Engineer shall approve the materials and
procedures on the basis of the trial results.
9.12.4 Monitoring
9.12.4.1 General
1 The scope of the required monitoring is related to
verifying and certifying the compliance of the work with
the design assumptions and construction procedures. In
the meantime, some monitoring is devoted to guide the
construction phases of the embankment in order to
minimize the effect of settlements. Those aspects will
control the following:
i. Selected backfill
ii. Settlements
iii. Horizontal displacements and overall
stability
iv. Material durability
9.12.4.2 Selected Backfill
1 Each layer must be subjected to control tests and
meet the requirements before placement of the following
layer.
2 The testing frequency, as specified, must be
considered as a minimum and must be increased
whenever the appearance and/or behavior of the material
noticeably changes,
3 The location of testing and/or sampling will be
determined by the Engineer, Test certificates in proper
forms shall be promptly sent to the Engineer during the
construction,
4 As indicated in the following table, the frequency of
3 in the backfill of the Reinforced Earth mass during the
the testing can be reduced after 5000 m . However, this
can be done only when the gradation and physical
properties of the material becomes practically constant.
9.12.4.3 Settlements
1 Survey of settlements will be done during the
construction, particularly where the embankments lay on
compressive soils intending to settle. Settlements shall be
monitored by means of two different procedures:
i. Topographic measurements on the wall
face
ii. Vertical settlements on the foundation
2 Topographic measurements will be performed with
leveling instruments and reference points installed on the
wall face and with benchmarks located in stable areas.
3 An appropriate quantity of fixed reference points
(steel plates) shall be installed on the panels every 7.5
meters elevation within each selected cross-section, For
those measurements, a tolerance of ± 2 mm is required.
4 Foundation settlements shall be monitored using
steel bars fixed on concrete at a distance of 1-2 meters
from the wall facing. The vertical steel bar is to be
protected by means of pipes. Measurements shall be
taken from the top of the steel bars.
9.12.4.4 Horizontal Displacements
1 Possible horizontal displacements will be measured
within the foundation soil and on the wall surface.
Inclinometers shall be placed in similar locations to the
settlements devices. They shall be installed within the
solid bedrock. The measurements shall be frequent and
related to the construction program. Possible horizontal
displacements can easily be checked by a pendulum
(plumb bob).
9.12.4.5 Durability
1 These investigations are only related to reinforcing
strips and are generally carried out at the time of the
regular detailed inspections of the structure, with a
frequency of approximately 10 to 15 years. It may also be
opportune to make such investigations if the structure has
serious anomalies, the origin of which is likely to be
sought in the mechanical failure of the strips.
2 The investigation method may vary according to
whether the structure is or is not equipped with durability
test samples. This monitoring and investigation is
performed with special techniques and investigation
method. In order to collect reliable and complete
information in long term, it is vital that these operations
be entrusted to a qualified specialist laboratory.
3 At every investigation, a certain number of test
samples are extracted and the backfill sample is taken in
the vicinity of these test samples. Durability test samples
are samples of reinforcing strips of 60 cm long, of the
same type as those used in the structure. They are placed
construction and can be extracted for the monitoring of
corrosion phenomena.
4 As a general rule, durability test samples are located
either at the lower part of the structure or, if the latter is at
considerable height, at each change in the section of the
strips.
5 At every investigation, one indicator is extracted
from each zone in which test samples are located. In case
of abnormal corrosion development, complementary
investigations must be made; excavations must be opened
for examining the first beds of reinforcements.
9.12.4.6 Testing Frequency
Testing shall be as follows in Table 9.12.4.1:
♦ 9-21 ♦
copy 249
 ii. Standard Coping on MSERW (lin.m)
TEST Within first After first iii. Conc. Barrier Parapet on MSERW (lin.m)
3 3
5000 m 5000 m
Grain Size 500 5000 9.13 Coastal Protection
Resistivity 500 5000
9.13.1 Description
pH 500 5000
1 Quarried stone shall consist of natural rock imported
Soluble Salt Content 500 5000
to site from approved quarry sites complying with the
In-situ Density 500 5000 requirements of this section.
Plate Bearing 250 1000 2 Quarry run shall consist of natural rock fragments
Water Content 1000 5000 and complying with the requirements of this section.

Table 9.12.4.1 – Testing Requirements 3 Armour rock shall be the quarried stone placed in the
top or outer layer(s) of the structure exposed to sea
9.12.5 Method of Measurement conditions.

4 Underlayer shall be the quarried stone placed under

1 Mechanically Stabilized Earth Retaining Walls,
including concrete face panels and footings shall be
measured by the sq.m of net area of as shown on the
Drawings.
2 Vertical limits of each wall for measurement
purposes shall be between the top of the foundation on
the outer face (low side) of the stabilized earth wall and
the top of the proposed grade at the backside (high side)
of such walls. Horizontal limits for measurement purposes
shall be from end of wall to abutment or from end to end
of walls.
3 Standard coping, including concrete, reinforcement,
joint filler, incidentals and erection shall be measured by
linear meter, complete and in place.
4 Concrete barrier parapet (on stabilized earth walls),
including concrete, reinforcement, fasteners, joint filler
and incidentals and erection shall be measured by linear
meter of concrete barrier, complete and in place.
9.12.6 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate for ‘Mechanically Stabilized earth Retaining Walls’ in
the Bill of Quantities, which rate shall be full
compensation for ground preparation, placing and fixing
of reinforcement, fasteners, joint filler, material testing
and certificates, trial embankment, excavation, backfill,
compaction, waterproofing, integral incidentals (such as
light pole foundations, sign structure foundations,
drainage structures and appurtenances), erection, and for
materials, transportation, hauling, labor, equipment, tools,
supplies and other items necessary for the proper
completion of the work.
9.12.7 Items in the Bill of Quantities
the armour rock layer(s)
5 Core means the quarry run material forming the bulk
portion of the slope and erosion protection fill sections
protected by underlayers and/or armour rock.
6 Filter fabric (geotextile) shall be a membrane placed
between the underlayer and the seabed soil or the core
stone that shall allow passage of water while retaining of
seabed soil or core stone in place without clogging.
7 The Contractor shall submit for the Engineer’s
approval a Quality Control Manual for the proposed slope
and erosion protection construction.
8 The Contractor shall submit the following method
statements for the Engineer’s approval at least 45 days
prior to the commencement of work on site:
i. Method for preparation of seabed as the base.
ii. Method for placement of core material,
underlayers and rock armour protection.
iii. Method for surveying procedures to establish
lines and levels of the various slope and erosion
protection components.
iv. Method of quarry selection and armour stone
production.
9 The Contractor shall submit the following test reports
directly to Engineer from approved testing services:
i. grading size of material
ii. aspect ratio of material
iii. apparent oven dry density of quarried stone
iv. Los Angeles abrasion
v. water absorption
vi. sodium sulphate soundness
vii. unconfined compressive strength
viii. methylene blue absorption

i. Mechanically Stabilised Earth

Retaining Walls (MSERW) (sq.m)

♦ 9-22 ♦
copy 249
10 The Contractor shall submit detailed design drawings,
plans, longitudinal profiles and cross-sections across the
slope and erosion protection at 50m intervals and at
transition zones between the different design sections.
The drawings shall be based on the up-dated survey
carried out at the slope and erosion protection area.
11 The Contractor shall submit bathymetric charts at the
slope and erosion protection at suitable scales of 1:1000
and 1:500 including ACAD computer file diskettes in the
form of point No., x, y, z.
12 The work shall be performed in accordance with:
i. The requirements of the Authorities
ii. BS 6349, BS 812 and ASTM D 1557.
iii. Recommendations of Construction Industry
Research and Information Association (CIRIA)
Special Publication No.83 (SP 83).
13 The Contractor shall employ and pay for a competent
independent geotechnical testing laboratory with proven
track records to perform testing on rock material to be
placed in the core, underlayers and armour layers of the
structure.
9.13.2 Materials
9.13.2.1 Quarried Stone for Armour Layers and
Underlayers
1 The Contractor shall use armour and underlayer
stones consisting of quarried rock, dense, sound, fresh,
strong, free from weathering, mechanical weaknesses or
chemical decomposition. The stones shall not be liable to
decomposition under the action of sea water. They shall
also be free from any visible defects such as joints,
discontinuities, fractures, clay seams or bands and water
soluble material.
2 The contractor shall use rock materials in armour
layers and underlayers conforming to the classes defined
by the engineer
3 The contractor shall use quarry stone containing no
more than 5% of stones with a length to thickness (l/d)
ratio greater than 3, where the length (1), is defined as the
greatest distance between two points on the stone and the
thickness,(d), as the minimum distance between two
parallel straight lines through which the stone can just
pass. Carry out the test in accordance with CIRIA SP 83,
Appendix 2.
4 The contractor shall use quarry stone for armour and
underlayers for testing having a minimum apparent oven
3 complying with the following requirements:
dry density of 2560 kg/m with 90% of the stones having a
density of at least 2600 kg/m3 in accordance with CIRIA SP
83.
5 The loss of material using the Los Angeles Abrasion
test in accordance with ASTM C-131 shall not exceed 35%.
6 The water absorption of quarry stone, carried out in
accordance with BS 812: Part 2 shall be less than 3%.
7 Sodium sulphate soundness carried out in
accordance with BS 812: Part 121 using the 63-125mm
crushed rock and a 50mm sieve to determine losses shall
be less than 12%.
8 The average point load index Is (50) in the planar
direction of the most pronounced layering, should any
visible anisotropy exist, and for sampling testing and
reporting in accordance with ISRM 1986 recommended
method, shall be not less than 4.0 MPa with the average
minus the standard deviation of the point load index at
least 3.0 MPa; where at least ten valid test results obtained
from pieces originating from ten randomly selected stones
have been used to calculate the average and standard
deviation.
9 Methylene blue absorption tests shall be carried out
in accordance with CIRIA SP 83, Appendix 2, in order to
indicate the presence of deleterious clay minerals, the
results of this test shall not exceed 1.0g/100g.
10 The contractor shall carry out for each quarry the
three sets of tests as listed in the relevant Clauses above.
The contractor shall submit the results for the Engineer's
approval of the source of quarried stone for underlayers
and armour layers.
11 The contractor shall carry out at least three sets of
the tests listed in the above Clauses on each consignment
of quarried stone for under-layers and armour layers
imported to site. A higher frequency of testing may be
required as instructed by the Engineer, if this, in the
opinion of the Engineer, is deemed necessary.
12 Materials failing to comply with any of the
requirements listed above shall not be used in the Works
and shall be considered not in compliance with this
specifications.
9.13.2.2 Core Material
1 The contractor shall use core material consisting of
well graded quarry run complying with the gradation
defined by the engineer.
2 The used fill material shall be quarry run material
with percentage of fines (passing sieve 0.075mm) shall not
be more than 20%.
3 The contractor shall use selected quarry run with
material percentage lighter than 1.0 kg (80mm of
equivalent diameter) not exceeding 10% and complying
with the size gradation defined by the engineer.
4 The contractor shall use quarry run material
i. Apparent oven dry density > 2.3 t/m3
ii. Water Absorption < 3.0 %
iii. Sodium Sulphate Soundness < 12.0 %
iv. Los Angeles Abrasion < 35.0 %
♦ 9-23 ♦
copy 249
 v. Methylene blue absorption < 1.0g/100g
5 The contractor shall carry out for each quarry three
sets of the tests as listed in the above Clauses. The
selection of the quarry source will be based on the results
submitted and subject to Engineer's approval.
6 During construction, the contractor shall take
sufficient sample for every 5000 t of material produced or
production for a working day whichever is greater. Three
sets of the tests as listed in the above Clauses shall be
carried out and submitted to the Engineer. A higher
frequency of testing may be required as instructed by the
Engineer, if this, in the opinion of the Engineer, is deemed
necessary.
7 Materials failing to comply with any of the
requirements listed above shall not be used in the Works
and shall be considered not in compliance with this
specification.
9.13.2.3 Filter Fabric - Geotextiles
1 The work shall consist of furnishing and placing a
geotextile. The geotextile is designed to allow passage of
water while retaining seabed soil without clogging. The
suitability of used geotextile should be checked against
these functional requirements before laying taking into
consideration the seabed soil conditions.
2 Non-woven TERRAM 4000 or equivalent material can
be used with the following properties:
2 5
i. Weight : 350 g/m
2 slope and erosion protection is natural seabed material
ii. Tensile strength : 23 kN/ m
iii. O85 (diameter of holes in a fabric): a suitable
hole diameter to prevent the wash out of seabed
and core material ant to retain them in place
without clogging.
3 The contractor shall provide evidence of the
resistance to deterioration of the geotextiles from
exposure to ultraviolet light and seawater.
4 The contractor shall carry out sampling of geotextiles
for testing in accordance with sampling procedures
indicated in ASTM - D4354-99.
5 The contractor shall carry out for geotextiles three
sets of tests to certify the required properties and submit
the results for the approval of the Engineer.
6 The contractor shall carry out at least three sets of
tests to verify the required properties on each
consignment of geotextile imported in the site. A higher
frequency of testing may be required as instructed by the
Engineer, if this, in the opinion of the Engineer is deemed
necessary.
7 Materials failing to comply with any of the
requirements listed above shall not be used in the works
and shall be considered not in compliance with these
specifications.
♦ 9-24 ♦
9.13.3 Construction Requirements
9.13.3.1 General
1 The contractor shall carry out sounding of the seabed
at the slope and erosion protection site in order to
produce a detailed seabed profile using echo sounder or
side-scan sonar together with a surface-towed sub-bottom
or similar seismic profiler and a tide gauge and collecting
seabed samples. Obtain approval of the Engineer on the
results of soundings and bathymetry as well as seabed
samples before the works commence, and finally
incorporate the same in the drawings.
2 Seabed clearances: Remove prior to commencing
filling works, all unsuitable material, wrecks, floating
debris, silt, clay, loose sand and loose material over the
whole area of the slope and erosion protection. Dispose of
unsuitable material as directed by the Engineer.
3 The contractor shall remove, in accordance with the
instructions of the Engineer any silt, loose sand or clay
that exists in the top layers of the seabed. Remove any silt,
loose sand and clay layers to the levels and areas as
instructed by Engineer.
4 The contractor shall relocate or redirect, at his own
expense, all underwater services, installations etc. that
may lie in the area to receive rockfilling. He shall carry out
all such redirection or relocation in accordance with
requirements of the relevant local authorities.
The contractor shall ensure that the founding bed for
when working in the sea, consisting of sand, a mixture of
sand and gravel or rock. No filling on silt, loose sand or
clay layers shall be allowed.
6 The contractor shall make his own arrangements for
the supply and transport of slope and erosion protection
material either by land or sea or both and use appropriate
marine and/or land operated plants for filling.
7 The contractor shall protect all placed material from
erosion by the action of sea during construction. The
Contractor shall be held responsible for all loss of material
and displacements that may arise, and shall make good
such losses and displacements at his own expense.
Furthermore, the Contractor shall be responsible for any
obstruction that may be caused by the deposition of any
material washed out from the filling and remove the same
in accordance to the instructions of the Engineer.
8 The contractor shall take all the necessary
precautions to protect the environment and any damage
to the environment arise from the Works shall be the
Contractor's responsibility.
9.13.3.2 Placement of Core Material
1 The contractor shall place materials used to form the
core to the profiles and levels shown on the Drawings with
a tolerance of zero above the theoretical level.
copy 249
2 The contractor shall take measurement of each
material profile as placed before any subsequent layer of All Armour
Design
material is placed to ensure compliance with the specified Depth of Placing Layers and
Profile to
tolerances. Below Low Water Individual
Actual Mean
3 The contractor shall carry out placement of core Level Measurements
Profile(m)
material underwater in such a manner to minimize (m)
segregation of material and to ensure its proper mixing.
The placement methods are subject to Engineer's Dry: above water + 0.35 Dn 50
approval. ± 0.3 Dn 50
level - 0.25 Dn 50
4 The contractor shall place core material 0.75m above
mean sea level and higher in layers not more than 1.0m in + 0.6 Dn 50
loose depth and compact as specified. Less than 5m ± 0.5 Dn 50
5 Before compaction, the contractor shall moisten each - 0.4 Dn 50
layer as necessary. He shall compact each layer with the
More than 5m ± 0.5 Dn 50 ± 1.0m
minimum number of roller passes as agreed with the
Engineer. Where, Dn50 is the diameter of a placement with
6 The contractor shall carry out compaction by heavy equivalent volume to the block with median weight.
vibratory compactor not less than 12 t capacity.
Table 9.13.3.1: Vertical Placing Tolerances
9.13.3.3 Placement of Armour and Underlayer Stones
5 The tolerance on two consecutive mean actual
1 For placing above high low water level, the
profiles shall not be negative. Notwithstanding any
contractor shall place the stone to grade and in such a
accumulation of positive tolerances on underlying layers,
manner to ensure that the larger rock fragments are
the thickness of the layer shall not be less than 80% of the
uniformly distributed and the smaller rock fragments fill
nominal thickness when calculated using mean actual
the spaces between the larger fragments to achieve a well
profiles
keyed, densely packed structure of the specified
dimensions. Hand placing or barring will be required only 9.13.3.4 Surveying Technique
to the extent necessary to secure the results specified.
1 The contractor shall carry out survey measurements
2 The contractor shall not drop or tip into position
using a probe with a spherical end of diameter 0.5 (Dn 50).
quarried stone, but shall place them individually into the
For land-based survey this shall be connected to a staff;
structure in order to achieve an adequate stability and
for underwater survey it will be a weighted ball on the end
deformation to maintain lines and levels shown on
of a sounding chain.
Drawings. He shall tightly pack the stones together so as
to achieve as near as possible a target unit weight of stone 2 The contractor shall carry out measurement profiles
placed of 1.6 t/m3 and do not place them so that they can at intervals of 25m along the length of the structure and at
rock or obtain their stability on a plane by frictional intervals of 3m across the measurement profile.
resistance alone prior to placing further stones.
3 The contractor shall make provisions for diving
3 The contractor shall fill any void below finished
inspections for any part of the structure where
profile level in excess of mean rock size with an
achievement of tolerances may otherwise appear in doubt.
appropriate stone or stones.
4 The contractor shall place rock materials to the levels, 9.13.3.5 Storage, Handling, and Laying of Geotextiles:
dimensions and slopes shown on drawings, and the
1 The contractor shall store and handle geotextile in
surface profile measured in accordance with the surveying
accordance with ASTM D4873-02
procedure outlined in Paragraph 9.13.3.4, to be within the
vertical placing tolerances given in Table 9.13.1.1. 2 For Geotextiles placement, the contractor shall use
overlaps in accordance with manufacture requirements,
and in no case less than 50 cms.

3 The contractor shall place bedding layer as soon as

possible after placement of the geotextile, according to the
approved method statement of the construction procedure.

4 Where seams are required, the contractor shall make

them in accordance with the manufacture requirements.
All seams shall be subjected to the approval of the
Engineer.

5 The contractor shall remove and replace any

damaged or punctured section before or after laying.

♦ 9-25 ♦
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9.13.4 Method of Measurement supply of materials, fabrics and membranes, sampling and
testing, ground preparation for laying on horizontal,
1 Underlayer, Rock Armour, Quarry Run and Bedding
sloping, vertical and curved planes, transportation, placing,
Layer shall be measured by the Cu.m of BUND material
protection, labor, equipment, tools, supplies and other
and rubble base (Quarry run), rock armour, and bedding
items necessary for the proper completion of the works.
layer, placed to the lines and levels as shown on the
Drawings.
9.13.6 Items in the Bill of Quantities
2 Dredging for embedded toe protection shall be
measured by the cu.m of material dredged in sand, clay or i. Underlayer (cu.m)
any other material except rock to the lines and levels as ii. Quarry Run (cu.m)
shown on Drawings. Rates inserted by the Contractor shall iii. Rock Armour (cu.m)
be deemed to include for all over cutting in width and iv. Dredging (cu.m)
depth and for sweeping the dredged areas. v. Fabrics and Membranes(type) (sq.m)

3 Fabrics and membranes (geotextile) shall be

measured by the sq.m of the area covered to any width or
girth including extra material for lapping and jointing. No
deduction is made for voids not exceeding 1.00 m2.

9.13.5 Basis of Payment

1 General: In addition to basis of payment of each
particular item, all marine works are also deemed to
include:
i. all surveying works and seabed sounding
ii. clearance of the seabed; removal of unsuitable
material, objects or obstructions,
iii. inspection for and relocation of any existing
underwater services,
iv. protection from sea action,
v. losses due to erosion or damage,
vi. losses/damage due to wave conditions which
may occur during the Contract period including
the Period of Maintenance.
2 The amount of completed and accepted work
measured as underlayer, quarry run, rock armour, and
bedding layer will be paid for at the unit rates indicated in
the Bill of Quantities which rate shall be full compensation
for selection and supply of materials, stone/rockfill,
crushing, screening, testing, transportation, hauling,
stockpiling, relocation, placing, compacting, trimming the
underlying material and slope preparation, removal of
discarded material, excavation and backfilling, finishing
and protection, labor, equipment, tools, supplies and other
items necessary for the proper completion of the works.
3 The amount of completed and accepted work
measured as Dredging for Embedded Toe Protection will
be paid for at the unit rates indicated in the Bill of
Quantities which rate shall be full compensation for
supply and installation of all plant and equipment required
to carry out dredging, pumping and transportation of
dredged material to whatever distance required, hauling,
stockpiling, disposal of discarded material to approved
locations, protection, labor, equipment, tools, supplies and
other items necessary for the proper completion of the
works..
4 The amount of completed and accepted work
measured as Fabric and Membranes (Geotextile) will be
paid for at the unit rates indicated in the Bill of Quantities
which rate shall be full compensation for selection and

♦ 9-26 ♦
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Ref. Title Page No.
10.1 Piling: General 10-1
10.1.1 Description 10-1
10.1.2 Materials 10-1
10.1.3 Construction Requirements 10-1
10.1.3.1 General 10-1
10.1.3.2 Cast in Place Piles 10-3
10.1.3.3 Placing Concrete 10-4
10.1.3.4 Preliminary Drilled Piles 10-4
10.1.3.5 Precast Concrete Piles 10-4
10.1.3.6 Steel piles 10-5
10.1.3.7 Tolerances 10-5
10.1.4 Method of Measurement 10-5
10.1.5 Basis of Payment 10-5
10.1.6 Items in the Bill of Quantities 10-5

10.2 Pile Testing 10-5

10.2.1 Description 10-5
10.2.2 Submittals 10-5
10.2.3 Execution 10-6
10.2.3.1 Preparation 10-6
10.2.3.2 Static-Load Testing 10-6
10.2.3.3 Non-Destructive, Low-Strain Integrity
Testing 10-6
10.2.3.4 Test Records 10-7
10.2.4 Method of Measurement 10-7
10.2.5 Basis of Payment 10-7
10.2.6 Items in the Bill of Quantities 10-7

♦ 10-0 ♦
copy 249
♦ 10-0 ♦
copy 249
10.1 Piling: General
10.1.1 Description
1 This Section describes requirements for supplying
and installing precast concrete, cast in-situ concrete and
steel piles by boring and/or driving.
10.1.2 Materials
1 Concrete and steel reinforcement shall be as
specified in the relevant Clauses of Section 5.
2 Concrete mixes, mixing and curing procedures shall
be as specified in the relevant Clauses of Section 5.
Concrete mixes for use in piles shall be capable of
maintaining a slump of 200 mm for 2 hours after
placement. Concrete mixes shall be designed to resist
aggressive soils and ground water if encountered in
compliance with the requirements of the Construction
Industry Research and Information Association – CIRIA
‘Guide to the Construction of Reinforced Concrete in the
Arabian Peninsula’.
3 Steel pipe casings shall comply with the
requirements of ASTM A 283M, Grade C; or ASTM A 36M
carbon-steel plate, with vertical joints full-penetration
welded according to AWS D1.1.
adequate notice of any intention to work outside normal
site hours.
3 The Contractor shall engage an experienced installer
who has specialized in installing drilled or driven piles
similar to those required for the Project.
4 The Contractor shall protect structures, utilities,
sidewalks, pavements and other facilities, on or adjacent
to the Site, from damage caused by settlement, lateral
movement, vibration, and other hazards created by drilled
or driven pile operations.
5 The Contractor shall carry out the piling work in such
a manner and at such times to minimize noise and
disturbance to the general public. If, during execution of
the work, damage is likely to be caused to utilities or
adjacent structures, the Contractor shall submit to the
Engineer proposals for the repair or avoidance of such
damage.
6 Piles shall be installed to the tolerances given in
Table 10.1.3.1.
Characteristic Allowable Limit
75mm in any direction at the
Position
pile head
Verticality 1 in 75 deviation

4 Welds for fabricating steel piles and connecting steel Rake

pile lengths shall be as specified in the relevant Clauses of
Section 6.
5 Sand-cement grout shall consist of Portland cement
manufactured according to ASTM C 150, Type I; and clean
natural sand complying with ASTM C 404. Unless
otherwise indicated, mix at ratio of 1 part cement to 2-1/2
parts sand, by volume, with sufficient water to permit flow
during placement.
6 Slurry shall consist of pulverized sodium bentonite,
pulverized attapulgite, or polymers, mixed with potable
water to form a stable colloidal suspension; complying
with ACI 336.1, and the values indicated for density,
apparent viscosity (in centipoise), gel strength (in N/sq.m.),
sand content, and pH.
1 in 25 deviation
(for raked piles only)
Table 10.1.3-1: Pile Installation Tolerances.
7 The Contractor shall submit daily records to the
Engineer within 24 hours giving the information listed in
Table 10.1.3.2.
8 On completion of piling, the Contractor shall deliver a
final schedule of installed piles giving the information
required by Table 10.1.3.2.

10.1.3 Construction Requirements

10.1.3.1 General

1 The Contractor shall submit for prior approval a

detailed method statement that describes all means,
methods and techniques to be adopted for construction
and installation of the drilled or driven piles. The method
statement shall include details of equipment to be used,
method of excavation, slurries to be used method of
concrete placement to ensure removal of slurry from sides
of boring, quality control, testing and report procedures,
work program, and any other information required by the
Engineer.
2 The Contractor shall inform the Engineer each day of
the work program for the following day and shall give

♦ 10-1 ♦
copy 249
 Driven Hollow Cast-
Driven Precast Concrete & Steel Bored Cast-in-Place Concrete
All piles in-Place Concrete
Piles Piles
Piles

1. Date 1. Cross-sectional dimensions. 1. Cross section 1. Diameter of completed

2. Contract 2. Total length of preformed dimensions of pile.
identification, pile. driving tube 2. Diameter of any enlarged
3. Pile identification. 3. Driven length of preformed (temporary base.
4. Pile type. pile. casing). 3. Length of temporary
5. Working load. 4. Sequence of driving in 2. Cross-sectional casing.
6. Ground level at groups. dimensions of 4. Length of permanent
commencement of 5. Final set. completed pile. casing.
operations. 6. Sections and joints used. 3. Length of 5. Length of finished pile
7. Working platform permanent including any enlarged
level. casing. base.
8. Pile toe level. 4. Length of 6. Type of boring.
9. Details of any finished pile 7. Time of commencement
obstructions. excluding any of boring.
10. Delays or other enlarged base. 8. Details of soil strata
interruptions to penetrated.
the sequence of 9. Details of soils samples
work including 1. Time of commencement and completion of driving
taken and in-situ tests
times. or re-driving.
carried out.
11. Cut-off level. 2. Type, weight, drop and mechanical condition of
10. Details of any
12. Head level of hammer used.
interruption in boring.
completed pile. 3. Number, type and condition of the packing on the
11. Standing ground water
13. Ground heave. pile head.
level and water strikes
4. Type and condition of the dolly in the helmet.
during boring.
5. For a single acting hammer, the final drop.
6. For a double acting hammer, the final frequency of
blows.
7. The sets taken at intervals during the last 3 m of
driving, if required.
8. Details of any interruption in driving.
9. Details of re-driving.

1. Method of placing concrete.

2. Concrete mix details:
3. Grade of concrete
4. Nominal maximum aggregate size
5. Cement content
6. Type and quantity of admixtures
7. Water/Cement ratio.
8. Measured slumps.
9. Batch times.
10. Time of commencement of concrete pour.
11. Time of completion of concrete pour.
12. Volume of concrete placed in enlarged base.
13. Volume of concrete placed in pile shaft.
14. Reinforcement details:
15. Number, type and size of main reinforcing bars.
16. Type, size and pitch or spacing of helical binding
or link bars.
17. Length of individual reinforcement cages.
18. Total reinforced length of pile

Table 10.1.3-2: Piling Records.

Notes:

1. The 24 hour clock shall be used.
2. For any pile not completed in the working day
the date shall be entered in the records together
with the times of commencement and
completion.
3. For driving operations not using a piling hammer,
equivalent information to that required on type,
weight, drop etc of hammer, packing and dolly
shall be provided.

♦ 10-2 ♦
copy 249
10.1.3.2 Cast in Place Piles Test Method
and Apparatus
1 Temporary casings or linings shall be used when complying
needed to maintain the stability of the pile borehole with the
during excavation. Casings shall be free from distortion American Samples
Petroleum from
and projections, and shall be uniform section throughout
Institute (API) Sample as excavation
their length. recommended supplied to
Property prior to
2 In case where permanent steel casings is required, practice for excavation placing
steel pipe casings of minimum wall thickness indicated Field Testing concrete
with inside clear diameter not less than diameter of pile of Water-
Based Drilling
shall be installed as follows:
Fluids – API RP
i. Install casings as excavation proceeds, to 13B-1
maintain sidewall stability.
Less than Less than
ii. Fabricate bottom edge of lowest casing section Density Mud balance
1.10 g/ml 1.15 g/ml
with a cutting shoe capable of penetrating rock
Fluid
and achieving a water seal. Low Less than Less than
loss
iii. Connect casing sections by continuous temperature 30 mil 40 mil
(30 min.
test fluid loss (0.762mm) (1.016mm)
penetration welds to form a watertight, test)
continuous casing. 30 to 40 Less than
Viscosity Marsh Cone
iv. Remove and replace, or repair, casings that seconds 60 seconds
have been damaged during installation and Fann
viscometer
that could impair strength or efficiency of Plastic Less than Less than
(material
drilled pile. viscosity 10 cP 20 cP
passing sieve
v. Fill annular void between casing and shaft wall No. 200)
with sand-cement grout. Shear
vi. Corrugated casings formed from zinc-coated strength
Fann 4 to 25 4 to 25
steel sheet may be delivered in sections or (10 min.
viscometer N/m2 N/m2
panels of convenient length, and field gel
strength)
connected according to manufacturer's written
Sand Sand screen Less than Less than
instructions.
content set 1% 3%
3 The drilling fluid shall be maintained at an adequate Electrical pH
viscosity and density. Action shall be taken to prevent the PH meter range 9.5 to 10.8 9.5 to 11.7
spillage of bentonite slurry onto the site. Disposal of used pH 7 to 14
slurry shall be made to a tip approved by the Engineer. Table 10.1.3-3: Tests and Compliance of Slurry.
4 When drilled shafts are to be stabilized with slurry,
the slurry shall be maintained a minimum of 1500 mm iv. Drilled pile shaft shall be excavated and
above ground-water level and above unstable soil strata to completely concreted on same day or the shaft
prevent caving or sloughing of shaft. Excess slurry head is shall be re-drilled, cleaned, re-circulated, de-
to be related to performance of on-going dewatering and sanded, or slurry replaced.
to allow for fluctuations in depressed water levels. v. Bottom of each shaft shall be cleaned before
i. Each batch of freshly prepared or reconstituted concreting.
slurry shall be sampled and tested. Test results 5 Pumping of ground water from boreholes will only
of samples and from excavation shall reflect be permitted where there is no risk of removal of fines
the amount of contamination with saline from the subsoil. Water which cannot be sealed off shall
ground water. be maintained in the borehole at a level above the
ii. At least one sample from the base and one standing ground water.
sample from the top of each shaft shall be
6 On completion of boring, loose soil and debris shall
tested immediately prior to placing steel and
be removed from the base of the pile and the Contractor
concrete. The Engineer may subsequently vary
shall provide facilities required by the Engineer to facilitate
frequency of sampling and testing when a
inspection of the pile base. The method of descent and the
working pattern has been established.
equipment used shall comply with BS 5573.
iii. Tests and Compliance: Values measured at 20
7 If reinforcement cages are used they shall be rigid
deg C shall be as Table 10.1.3.3
and installed and maintained in the correct position during
concreting.

♦ 10-3 ♦
copy 249

10.1.3.3 Placing Concrete
1 The concrete shall be placed without interruption.
Records shall be kept of the workability of the approved
mix. Under water concrete shall be placed only by tremie.
The tremie pipe shall be clean and watertight throughout
and not less than 200 mm internal diameter. Concreting
shall start only after the tremie reaches the bottom of the
pile shaft and concreting shall then proceed with the end
of tremie pipe kept immersed in the concrete for a
minimum depth of 1 m. Spacer blocks shall be installed as
appropriate to maintain the minimum concrete cover to
the reinforcement steel as specified and/or shown on
Drawings.
2 Permanent casing shall be checked for damage. If
necessary the casing shall be withdrawn, repaired, re-
driven, or other action taken to allow the construction of
the pile.
3 Temporary casings shall be extracted while the
concrete remains sufficiently workable. While the casing is
being extracted a sufficient head of concrete shall be
maintained within it to avoid necking in the pile. No
concreting shall be done once the casing has been lifted
above the top of the concrete. Withdrawal of temporary
casing shall be coordinated with concrete placement
operations to maintain a head of concrete no less than
1500 mm above casing bottom.
4 Casings for driven cast-in-place piles shall be
installed to the approved set or specified depth and in the
sequence approved by the Engineer. Each length shall be
driven continuously. Levels shall be taken immediately
when the final depth is approved, before concreting has
begun. The casings shall be watertight.
10.1.3.4 Preliminary Drilled Piles
1 Construct preliminary drilled piles of diameter and
depth and at location indicated or if not indicated, as
directed by the Engineer, of same diameter and depth as
permanent drilled piles, located at least 3 diameters clear
of permanent drilled piles, to demonstrate Installer's
construction methods, equipment, standards of
workmanship, and tolerances.
i. Install casing or use bentonite slurry, excavate
bell if applicable, excavate rock socket, all as
required for permanent drilled piles.
ii. Install reinforcement, fill with concrete, remove
temporary casings, if applicable, and terminate
preliminary drilled pile as instructed by the
Engineer.
iii. If Engineer determines that a preliminary drilled
pile does not meet requirements, excavate for
and cast another until preliminary drilled pile is
accepted.
10.1.3.5 Precast Concrete Piles
1 After a pile has been cast, the date of casting and
reference number shall be permanently inscribed on the
♦ 10-4 ♦
head of the pile. Each pile shall be marked at intervals of
250mm along the top 3m of its length before being driven.
2 Only the designed lifting and support points shall be
used during transport and piles shall be stored on
adequate supports located under these lifting points of the
piles. Piles within a stack shall be in groups of the same
length. Packing of uniform thickness shall be provided
between piles at the lifting points.
3 During driving, piles shall be adequately supported
and restrained by means of leaders, trestles, or other
guide arrangements to maintain position and alignment
and to prevent buckling. The Contractor shall satisfy the
Engineer regarding the suitability, efficiency and energy of
the driving equipment. Piles shall be driven continuously
until the prescribed set or depth has been reached.
4 The final set of the pile shall be recorded either as the
penetration in millimeters per 10 blows or as the number
of blows required to produce a penetration of 25mm.
5 When a final set is being measured, the following
requirements shall be met:
i. The exposed part of the pile shall be in good
condition without damage or distortion.
ii. The dolly and packing, if any, shall be in sound
condition.
iii. The hammer blow shall be in line with the pile
axis and the impact surfaces shall be flat and at
right angles to the pile and hammer axis.
iv. The hammer shall be in good condition and
operating correctly.
v. The temporary compression of the pile shall be
recorded if required.
6 Piles shall be driven in an approved sequence to
minimize the detrimental effects of heave and lateral
displacement of the ground. When a pile has risen as a
result of adjacent piles being driven, the contractor shall
submit to the Engineer proposals for correcting this and
its avoidance in subsequent work.
7 If repairs are needed during driving to the head of a
pile, it shall be cut off square at sound concrete, and loose
material removed by wire brushing, followed by washing
with water. If the pile is to be subjected to further driving,
the head shall be replaced by concrete of an approved
class.
8 Piles shall be lengthened, if required, by stripping off
concrete from the reinforcement and lapping, coupling or
welding additional steel in place. Laps shall be at least 40
x bar diameter. Couplers shall be approved by the
Engineer. Steel to be welded shall be free of concrete for
at least 300 mm below the weld. Welded joints shall be
made in accordance with the relevant Clauses of Section 6.
9 Repaired or lengthened piles shall not be driven until
the added concrete has reached the specified
characteristic strength of the concrete of the pile.
copy 249
10.1.3.6 Steel piles
1 Piles shall be clearly marked in white paint with their
number and overall length. In addition, each pile shall be
marked at intervals of 250mm along the top of 3m of its
length before being driven.
2 If steel piles are to be pre-coated, the preparation of
surfaces and the application of the coating shall be carried
out by experienced specialist labor.
3 Surface preparation, priming and protective coats
shall conform to the requirements of Section 7 “Paint for
Steelwork”.
4 Rolled steel sections shall be within the tolerances
specified in BS 4. For steel piles and proprietary rolled
sections, the deviation from straightness shall not exceed
1/1000 of the length of the section.
5 Cylindrical steel piles shall not deviate from
straightness by more than 1/600 for the length up to 10m
and 1/1000 for lengths greater than 10m. The actual mass
of each section shall be within +5% and -2.5% of the
theoretical mass computed in accordance with Section 6.
6 Sheet piles shall be pitched and supported as a panel
before driving and securely interlocked. Piles shall not
overlap each other and no pile in a panel shall be more
than 1 m in advance of another.
7 Sheet piles previously driven shall not be used in the
Permanent Works unless approved.
8 Steel piles shall be driven to a prescribed set or
depth in a sequence approved by the Engineer. Driving
shall be continuous.
9 If approved, piles shall be lengthened by full
penetration butt welding. Lengthening sections shall be of
the same rolling. Longitudinal and spiral seam welding of
cylindrical piles shall be staggered.
10.1.3.7 Tolerances
Vertical piles shall be constructed to remain within the
following tolerances:
i. Maximum variation from location: Not more
than 75 mm from design center location.
ii. Out-of-plumb: 1 in 75 deviation or not more than
1.5 percent of pile length, whichever is less.
iii. Concrete cutoff level: Plus 25 mm or minus 75
mm from level indicated.
iv. Bottom area of pile: Not less than 96 percent of
pile area required.
v. Shaft diameter for drilled pile: Not less than 98
percent or more than 110 percent of shaft
diameter indicated.
10.1.4 Method of Measurement
1 Setting up at each pile shall be measured by number.
2 Piles shall be measured in linear meters of actual
length placed in the Permanent Works. The measured
length shall be from the tip to the underside of the
foundation, plus the penetration into the foundation
specified on the Drawings. The payment shall be made for
length shown in the approved Drawings or as per the
modifications approved by the Engineer. Any
unauthorized extra length cast by the Contractor shall not
be measured for payment.
3 Expendable piles (non-working piles) that are
constructed for the purpose of carrying out preliminary
load tests shall be measured in linear meters of actual
length, ordered and tested.
10.1.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at
the unit rates for the various types of piles in the Bill
of Quantities, which rate shall be full compensation
for supplying and installing piles and for materials,
labor, equipment, tools, records and other items
necessary for the proper completion of the work.
10.1.6 Items in the Bill of Quantities
i. Setting up at each pile location nr.
ii. Piling (type)(length)(size) lin.m.
iii. Expendable piles (type)(length)(size) lin.m.
10.2 Pile Testing
10.2.1 Description
1 This Sub-section describes requirements for testing
of concrete piles as follows:
i. Static-load testing: ASTM D1143 and ASTM
D3689.
ii. Non-destructive, sonic or low-strain integrity
testing: ASTM D5882.
10.2.2 Submittals
1 The Contractor shall submit a method statement for
each type of testing specified and provide details of
specific techniques and processes proposed to be adopted
for testing. The method statement shall include details of
equipment and instrumentation, quality control and report
procedures, work program, and any other information or
special data required by the Engineer.
i. The method statement shall include details of
loading and arrangement of reaction frame,
reaction piles or anchors. Due consideration
shall be given to the effect of diameters of piles,
socket length, type of bedrock, strain
measurement in steel reinforcement and effect
of dewatering. The structural analysis data shall
be supervised, signed and sealed by the
qualified professional independent engineer
responsible for their preparation.
2 The Contractor shall submit daily work progress
reports, identifying individual piles and type of testing
carried out.
♦ 10-5 ♦
copy 249
3 For non-destructive integrity testing, the Contractor
shall qualify and engage an experienced independent
testing agency, acceptable to the Engineer, who has
specialized in non-destructive testing of drilled piles
similar to that required for the Project.
10.2.3 Execution
10.2.3.1 Preparation
1 The Contractor shall protect structures, utilities,
sidewalks, pavements, and other facilities from damage
caused by settlement, lateral movement, vibration, and
shall verify the feasibility of testing the loads
corresponding to each pile diameter. The pile load tests
shall not be carried out until all shrinkage of the concrete
is complete. The reinforcement in the rock socket shall be
strain-gauged to provide confirmation of the tensile force
reaching the socket.
i. Dynamic formulas will not be permitted in place
of load tests to determine bearing values of the
piles.
ii. Perform and complete testing, and obtain
approval of preliminary pile test before
proceeding with installation of permanent
working piles in the Works.
iii. Select the pile to be tested based on the results
of pile integrity tests and pile construction
records subject to the approval of the Engineer.
iv. The same piles that will be tested in working
compression loading shall be among the
selected piles for the working load test in
tension.
2 Pile Tests: Arrange and perform the following static-
load tests on piles as and when directed in the field:
i. Axial Tension Static-Load Test: ASTM D 3689.
ii. Axial Compression Static-Load Test: ASTM D
1143.
3 Provide pile reaction frame, equipment and
instrumentation with sufficient reaction capacity to
perform tension tests and compression tests. On
completion of testing, remove testing structure,
equipment and instrumentation.
i. Notify Engineer at least 48 hours in advance of
performing tests.
ii. Provide facilities to enable Engineer to observe
and check testing.
4 Apply test loads by jacking against beams or
equivalent reaction system.
i. Center to center spacing of vertical reaction piles
from a test pile shall be not less than 3 times the
diameter of the test pile or the reaction piles or 2
m whichever is the greater.
5 Test Loads: Maximum loads to be applied in
maintained load test shall be as follows:
i. Expendable preliminary piles in tension or
compression load test: Apply test loads up to 2.5
♦ 10-6 ♦
times working load. The Contractor shall perform
at least two preliminary pile tension load tests
and two preliminary pile compression load tests
to cover the different rock configurations or as
specified on the Drawings or in the Special
Specification.
ii. Working piles in tension or compression load
tests: Apply test loads up to 1.5 times working
load, as specified on the Drawings or in the
Special Specifications.
6 In the event of a pile continuing to displace under
constant load before the maximum test load has been
reached, take readings at 15 minute intervals for a period
of one hour while the load is being maintained. Unload
the pile in approximately 4 to 6 equal decrements at 15
minute intervals and allow recovering for 3 hours. Take
one set of displacement readings after each decrement of
load and a further set of readings at the end of the
recovery period.
10.2.3.2 Non-Destructive, Low-Strain Integrity Testing
1 Non-destructive, integrity testing by sonic logging
shall be performed on all piles, or as specified on the
Drawings and \special Specification, recorded, interpreted
and reported by an approved experienced independent
testing agency that has specialized in non-destructive
testing of piles similar to that required for the Project.
Submit proposed test result and report formats to the
Engineer for approval before starting integrity testing.
i. Provide all available details of the ground
conditions, pile dimensions and construction
method to the testing agency before the
commencement of integrity testing, in order to
facilitate interpretation of test results.
ii. Allow a minimum of seven days to elapse after
casting before performing integrity testing on a
pile.
2 Perform low-strain integrity testing according to
ASTM D5882 by the stress wave method, seismic method
or other method approved by the Engineer, based on the
measurement of the axial shaft point mobility at the pile
head.
i. Where the method of testing requires the
positioning of sensing equipment on the pile
head, break down the pile head to expose sound
clean concrete, free from water, laitance, loose,
overspill or blinding concrete, and readily
accessible for the purpose of testing.
10.2.3.3 Test Records
1 General: Maintain accurate test records for each pile,
compiled and attested to by a qualified professional
engineer, and submit to the Engineer at the conclusion of
each pile test. Include the following data:
i. Project name and number.
ii. Pile number and date of testing.
iii. Pile dimensions.
iv. Type and method of pile testing.
copy 249
 v. Test results. 10.2.6 Items in the Bill of Quantities
2 Prepare static load test results in the form of i. Static load testing of expendable piles
tabulated field observations, including the following data: (type) (length) (size). nr.
i. Time vs. displacement curves. ii. Static load testing of working piles (type)
ii. Time vs. load curves. (length) (size). nr.
iii. Load vs. displacement curves. iii. Non-destructive integrity test (type) nr.
iv. Displacement vs. log time for each stage.

The Engineer will review test results and determine if a

pile is acceptable, taking into account the acceptable total
and differential displacements of the superstructure, the
foundation geometry, the pile type and the soil conditions,
etc.

10.2.3.4 Static-Load Testing

1 General: Static-load tests will be used to verify and

confirm design load capacity of piles. Each pile diameter
shall be tested as shown on the Drawings. The Contractor
displacement characteristics compared to preliminary test
piles will not be accepted.
2 Non-Destructive Integrity Testing:
i. All piles shall be subjected to integrity testing.
ii. Submit preliminary test results to the Engineer
within 24 hours of carrying out the tests.
iii. Submit test reports to the Engineer within 10
days of the completion of each phase of testing.
iv. Test reports shall contain test results and
conclusions, together with a summary of the
method of interpretation including all
assumptions, calibrations, corrections,
algorithms and derivations used in the analyses.
Where results are presented in a graphical form,
the same scales are to be used consistently
throughout the report and the units on all scales
clearly marked.
v. If any anomaly in acoustic signal test results
indicates a possible defect in a pile, report such
anomalies to the Engineer immediately.
Demonstrate to the Engineer that the pile is
satisfactory for its intended use or carry out
remedial works to the Engineer’s satisfaction.
vi. Grout sonic logging tubes only after piles have
been demonstrated to the Engineer’s
satisfaction, to be satisfactory.

10.2.4 Method of Measurement

1 Pile loading tests shall be measured per number.
2 Pile integrity tests shall be measured per number.

10.2.5 Basis of Payment

1 The amount of completed work of “Pile testing” will
be paid for at the unit rate in the Bill of Quantities which
rate shall be full compensation for setting up, carrying out,
reporting and for labor, transport, equipment, tools,
materials and other item necessary for the proper
completion of the work.

♦ 10-7 ♦
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copy 249
Ref. Title Page No. Ref. Title Page No.
11.1  Bearings – General 11-1  11.3.2.7  Polytetrafluorethylene (PTFE) Sheet
and Strip 11-6 
11.1.1  Description 11-1 
11.3.3  Construction Requirements 11-6 
11.1.1.1  Definitions 11-1 
11.3.3.1  General 11-6 
11.1.1.2  References 11-1 
11.3.3.2  Sampling and Testing 11-7 
11.1.1.3  Design and Construction Standards 11-1 
11.3.3.3  Installation 11-8 
11.1.1.4  Submittals 11-2 
11.3.4  Method of Measurement 11-8 
11.1.1.5  Quality Assurance 11-2 
11.3.5  Basis of Payment 11-8 
11.1.2  Materials 11-2 
11.3.6  Item in the Bill of Quantities 11-8 
11.1.2.1  Steel 11-2 
11.1.2.2  Material Testing 11-3  11.4 Bridge Expansion Joints 11-8
11.1.2.3  Bedding Material 11-3 
11.4.1  Description 11-8 
11.1.3  Construction Requirements 11-3 
11.4.1.1  Scope 11-8 
11.1.3.1  Manufacture 11-3 
11.4.1.2  Types of Joints 11-8 
11.1.3.2  Manufacture Tolerances 11-3 
11.4.1.3  References 11-9 
11.1.3.3  Testing of Complete Bearings 11-3 
11.4.1.4  Submittals 11-9 
11.1.3.4  Packaging, Handling and Storage 11-4 
11.4.1.5  Quality Assurance 11-9 
11.1.3.5  Construction and Installation 11-4 
11.4.2  Materials 11-9 
11.1.4  Method of Measurement 11-4 
11.4.2.1  General 11-9 
11.1.5  Basis of Payment 11-5 
11.4.2.2  Asphaltic Plug Joints 11-9 
11.1.6  Items in the Bill of Quantities 11-5 
11.4.3  Construction Requirements 11-9 
11.2 Elastomeric Bearings 11-5 11.4.3.1  General 11-9 
11.4.3.2  Nosings 11-9 
11.2.1  Description 11-5 
11.4.3.3  Installation 11-10 
11.2.2  Materials 11-5 
11.4.4  Method of Measurement 11-10 
11.2.3  Construction Requirements 11-5 
11.4.5  Basis of Payment 11-10 
11.2.4  Method of Measurement 11-5 
11.4.6  Items in the Bill of Quantities 11-10 
11.2.5  Basis of Payment 11-5 
11.2.6  Items in the Bill of Quantities 11-5  11.5 Joint Seals and Fillers 11-10
11.3 Pot Bearings 11-6 11.5.1  Description 11-10 
11.5.2  Materials 11-10 
11.3.1  Description 11-6 
11.5.3  Construction Requirements 11-11 
11.3.2  Materials 11-6 
11.5.4  Method of Measurement, Basis
11.3.2.1  General 11-6 
of Payment and Bill of Quantities 11-11 
11.3.2.2  Steel 11-6 
11.3.2.3  Stainless Steel 11-6  11.6 Bridge Parapets and Railings 11-11
11.3.2.4  Elastomeric Rotational Element 11-6 
11.6.1  Description 11-11 
11.3.2.5  Sealant 11-6 
11.6.2  Materials 11-11 
11.3.2.6  Sealing Rings 11-6
11.6.2.1  Materials of Construction 11-11 

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Ref. Title Page No.
11.6.2.2 Aluminum Alloy 11-11
11.6.2.3  Structural Steel 11-11 
11.6.2.4  Reinforced Concrete 11-11 
11.6.2.5  Anchorage System 11-11 
11.6.3  Construction Requirements 11-11 
11.6.4  Method of Measurement 11-11 
11.6.5  Basis of Payment 11-12 
11.6.6  Item in the Bill of Quantities 11-12 

♦ 11-0 ♦
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11.1 Bearings – General
11.1.1 Description
1 This Sub-section describes the requirements for
designing, testing, furnishing and installing replaceable
bridge bearings as shown on the Drawings or in the
Special Specification or as required to complete the work.
11.1.1.1 Definitions
1 Bearing: A structural device that transmits loads
while facilitating translation and/or rotation.
2 Elastomer: A compound containing natural or
chloroprene rubber with properties similar to those of
rubber.
3 Elastomeric bearing: A bearing comprising a block of
elastomer that may be reinforced internally with steel
plates.
4 Plain pad bearing: An unreinforced elastomeric
bearing. It provides limited translation and rotation.
5 Strip bearing: A plain pad bearing for which the
length is at least ten times the width.
6 Laminated elastomeric bearing or steel-reinforced
elastomeric bearing: A bearing made from alternate
laminates of steel and elastomer bonded together during
vulcanization. Vertical loads are carried by compression of
the elastomer. Movements parallel to the reinforcing
layers and rotations are accommodated by deformation of
the elastomer.
7 Pot bearing: A bearing consisting essentially of a
metal piston supported by a disc of unreinforced
elastomer that is confined within a metal cylinder.
Rotations are accommodated by deformation of the
elastomer. It may be movable, guided, unguided or fixed.
Movement is accommodated by sliding of polished
stainless steel on PTFE.
8 Disc bearing: A bearing that accommodates rotation
by deformation of a single elastomeric disc molded from a
urethane compound. It may be movable, guided,
unguided or fixed. Movement is accommodated by sliding
of polished stainless steel on PTFE.
9 PTFE (polytetrafluoroethylene): Also known as Teflon.
10 Fixed bearing: A bearing that prevents differential
translation of abutting structural elements. It may or may
not provide for differential rotation.
11 Movable bearing: A bearing that facilitates
differential horizontal translation of abutting structural
elements in a longitudinal and/or lateral direction. It may
or may not provide for rotation. Translation may be
constrained to a specified direction by guide bars.
12 Sliding bearing: A bearing that accommodates
movement by translation of one surface relative to
another. Translation may be constrained to a specified
direction by guide bars.
13 Roller bearing: A bearing that carries vertical load by
direct contact between two metal surfaces and that
accommodates movement by rolling of one surface with
respect to the other. It consists essentially of one or more
steel rollers between upper and lower plates.
14 Rocker bearing: A bearing that carries vertical load by
direct contact between two metal surfaces and that
accommodates movement by rocking of one surface with
respect to the other. It consists essentially of a curved
surface in contact with a flat or curved surface and
constrained to prevent relative horizontal movement. The
curved surface may be cylindrical or spherical.
15 Longitudinal: Parallel with the main span direction of
the bridge.
16 Transverse: The horizontal direction normal to the
longitudinal axis of the bridge.
17 Translation: Horizontal movement of the bridge in
the longitudinal or transverse direction.
18 Rotation about the longitudinal axis: Rotation about
an axis parallel to the main span direction of the bridge.
19 Rotation about the transverse axis: rotation about an
axis parallel to the transverse axis of the bridge.
11.1.1.2 References
1 American Association of State Highway and
Transportation Officials (AASHTO):
AASHTO 2008 AASHTO LRFD Bridge Construction
Specifications, 2nd Edition, 2004, 2008
Interim Revisions.
AASHTO 2008 AASHTO LRFD Bridge Design
Specifications, 3rd Edition, 2004, 2008
Interim Revisions.
11.1.1.3 Design and Construction Standards
1 Bearings shall be designed in accordance with the
latest edition of AASHTO LRFD Bridge Design
Specifications, Sub-Section 14.7, as complemented or
modified herein.
2 Bearings shall be constructed as specified in the
latest edition of AASHTO LRFD Bridge Construction
Specifications, Section 18, as complemented or modified
herein.
3 Alternatively, the bearings may be designed and
constructed in accordance with Eurocode as described in
the following documents, as complemented or modified
herein.
i. BS EN 1337-1 Structural Bearings - Part 1:
General Design Rules.
ii. BS EN 1337-2 Structural Bearings - Part 2: Sliding
Elements.
iii. BS EN 1337-3 Structural Bearings - Part 3:
Elastomeric Bearings.
iv. BS EN 1337-5 Structural Bearings - Part 5: Pot
Bearings.
v. BS EN 1337-9 Structural Bearings - Part 9:
Protection.
vi. BS EN 1337-10 Structural Bearings - Part 10:
Inspection and Maintenance.
♦ 11-1 ♦
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 vii. BS EN 1337-11 Structural Bearings - Part 11:
Transport, Storage and Installation.
4 Definitions of bearing types and bearing components
shall be in accordance with AASHTO LRFD Bridge Design
Specifications, Third Edition, 2004, Section 14.2. Relevant
definitions are reported in Paragraph 11.1.1.1.
5 Detailed specifications for elastomeric bearings and
Pot Bearings are given in Sub-Sections 11.2 and 11.3,
these two types being the most common and most
suitable types.
6 Other types of bearings shall follow AASHTO LRFD
Bridge Design Specifications, Section 14 for design, and
AASHTO LRFD Bridge Construction Specifications for
construction requirements, as follows:
i. Disc Bearings Sub-Section 18.3
ii. Rocker and Roller Bearings Sub-Section 18.4
iii. Spherical Bearings Sub-Section 18.5
11.1.1.4 Submittals
1 The Contractor shall submit the following to be
approved by the Engineer prior to fabrication of the
bearings. Such approval shall not relieve the Contractor of
any responsibility under the contract documents for the
successful completion of the work.
i. Working drawings as defined in AASHTO LRFD
Bridge Construction Specifications Article 18.1.1.
The drawings shall, additionally, show transit
restraints and lifting points as necessary.
ii. Details of protective coatings with data sheets
and painting drawings showing the venue and
timing of the application of shop and site applied
coatings.
iii. Method statements.
iv. Evidence that the manufacturer has at least ten
years experience in manufacturing bearings
comparable with those required for the Project,
and that the proposed types of bearings have
been incorporated in structures in similar
environmental conditions.
v. Design calculations.
vi. Construction drawings of any additional or
revised reinforcement and modified concrete
details and/or steelwork details required at the
abutting structural elements.
vii. Details of fixings to superstructures and
substructures including tolerance requirements.
viii. Program of manufacture, testing and delivery,
including the name, address and accreditation of
the testing laboratory.
ix. Samples:
− All samples required to perform the tests
specified for the verification of material
♦ 11-2 ♦
quality and performance of bearings and
ancillary items.
− Records of an installation trial for each type
of bearing in accordance with the method of
installation which shall take full account of
restrictions that may be imposed on the
operations by the location of the bearings in
the Works. A photographic record of the
trial shall be made. Subject to the successful
completion of the trial the method of
installation shall not subsequently be varied
unless approved by the Designer.
x. Certificates (not older than 12 months):
− Certificates as specified in the standards in
respect of the specified materials.
− Certificates for all materials used in the
manufacture of bearings shall be obtained
from the manufacturers or suppliers. These
shall state the type and grade of material,
the relevant standard and the results of all
tests carried out.
xi. Test Reports:
− Reports of the specified material tests.
− Reports of the specified tests on bearings.
xii. Replacement procedures.
xiii. Inspection and Maintenance Plan.
11.1.1.5 Quality Assurance
1 Codes and Standards: AASHTO LRFD Bridge
Construction Specifications.
2 The Contractor shall ensure that direct site
supervision of the first of each type of bearing is provided
by an experienced technical representative of the
manufacturer and thereafter, by competent persons who
have been trained in the proper installation of bearings.
11.1.2 Materials
11.1.2.1 Steel
1 Unless otherwise specified, rolled steel shall conform
to AASHTO M 270M/M 270 (ASTM A 709/A 709M), Grade
36 (Grade 250), and shall cause no adverse electrolytic or
chemical reaction with other components of the bearing
and shall be free of all rust and mill scale.
2 Unless otherwise specified, steel laminates shall be
made from rolled mild steel conforming to AASHTO M
270M/M 270 (ASTM A 709/A 709M), Grade 36 (Grade 250),
ASTM A 1011/A 1011M, or equivalent. Laminates shall
have a minimum nominal thickness of (1.6 mm). Holes in
plates for manufacturing purposes shall not be permitted
unless they have been accounted for in the design and are
in accordance with the contract documents.
3 Cast steel shall satisfy the requirements of ASTM
A802/A802M and be free of all blow-holes and impurities
larger than 3.2 mm the inside wall of the pot in pot
bearings and the contact surface of metal rocker or roller
copy 249
bearings shall be free of blow-holes or impurities of any
size.
4 Forged steel shall satisfy the requirements of ASTM
A 788.
5 Stainless steel shall conform to the requirements of
ASTM A167, Type304 or ASTM A240/A240M, Type 304
and shall have a minimum thickness of 0.91 mm and a
surface finish in the finished bearing better than or equal
to 0.2 μm. Stainless steel in contact with PTFE sheet shall
be polished to a finish no less than 0.50 μm.
6 Where ASTM is referred, equivalent specifications,
Eurocode for example, may be accepted.
11.1.2.2 Material Testing
1 Material certification tests to determine the physical
and chemical properties of all materials shall be
conducted in accordance with the appropriate
specification governing the material. The test certificates
shall be submitted to the Engineer.
2 Material friction test for sliding surfaces shall be
conducted either on samples taken from the same batch of
materials as those used in the prototype bearings, or on
finished bearings. The testing procedure shall be in
accordance with AASHTO LRFD Bridge Construction
Specifications Article 18.1.5.2.3. The bearing or specimen
shall show no appreciable sign of wear, bond failure, or
other defects.
3 Long-term deterioration test shall either be
conducted on samples or on a pair of bearings placed
back-to-back. The testing procedure shall be in accordance
with AASHTO LRFD Bridge Construction Specifications
Article 18.1.5.2.7. The following shall be cause for rejection
of the bearing:
i. Damage visible to the naked eye on disassembly
of the bearing, such as excessive wear, cracks, or
splits in the material.
ii. A coefficient of friction which exceeds two-thirds
the value used in design.
11.1.2.3 Bedding Material
1 Bedding material shall be of the type specified in the
contract documents or as ordered or approved by the
Engineer and shall be installed to provide full bearing on
contact areas. Grout and mortar used for filling under
bearing or masonry plate shall conform to the
requirements of AASHTO LRFD Bridge Construction
Specifications Sub-Section 8.14.
2 Materials for mortar and grout shall conform to the
requirements of Sub-Section 5.1 as complemented and/or
modified herein.
3 When the width or depth of the void to be filled is
less than 20 mm, the grading of sand for use in the grout
shall be modified so that all material passes the 2.36 mm
sieve.
4 Unless otherwise specified or ordered by the
Engineer, the proportion of cement to sand shall be one to
one.
5 When nonshrink mortar or grout is specified, a
nonshrink admixture of a type approved by the Engineer
shall be used.
6 Only sufficient water shall be used to permit placing
and packing.
7 Mixing shall be done by either hand methods or with
rotating paddle-type mixing machines and shall be
continued until all ingredients are thoroughly mixed. Once
mixed, mortar or grout shall not be retempered by the
addition of water and shall be placed within one hour.
11.1.3 Construction Requirements
11.1.3.1 Manufacture
1 The manufacturer shall certify that each bearing
satisfies the requirements of the contract documents and
this Specification, and shall supply the Engineer a certified
copy of material test results. Each bearing shall be marked
in indelible ink or flexible paint. The marking shall consist
of the location in the structure, the orientation, the order
number, lot number, bearing identification number, and
elastomer type and grade number. Unless otherwise
specified in the contract documents, the marking shall be
on the face that is visible after erection of the bridge.
Bearing assemblies shall be preassembled in the shop by
the supplier and checked for proper completeness and
geometry before shipping to the site.
2 The design of the bearing shall include necessary
provision to facilitate the replacement of the bearing with
minimum interruption to traffic. The Special Specification
defines, where appropriate, the maximum lifting of bridge
decks to remove existing and install new bearings.
3 Performance for the system for protection against
corrosion shall not be less than 15 years to first
maintenance unless otherwise specified in the contract
documents. The system for corrosion protection shall be
subject to test in accordance with Table 1, Clause 5.3, BS
EN 1337-9 or other such criteria as may be additionally
recommended by the corrosion protection system
manufacturer as being adequate to demonstrate the ability
of the protection system to achieve life to first
maintenance as specified for the steelwork.
11.1.3.2 Manufacture Tolerances
1 Bearings shall be fabricated within the tolerances of
Table 18.1.4.2-1 of AASHTO LRFD Bridge Construction
Specifications. The Special Specification defines, where
appropriate, the class of tolerances A, B or C.
11.1.3.3 Testing of Complete Bearings
1 Dimension Check: the dimensions of the bearings
shall be checked in accordance with AASHTO LRFD Bridge
Construction Specifications Article 18.1.5.2.4.
2 Clearance Test: in accordance with AASHTO LRFD
Bridge Construction Specifications Article 18.1.5.2.5.
3 Bearing Friction Test: in accordance with AASHTO
LRFD Bridge Construction Specifications Article 18.1.5.2.6.
♦ 11-3 ♦
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In addition to the compression of 100 percent of the full
service dead load plus live load, the bearings shall be
checked for 50 percent and 80 percent of the full service
dead load plus live load.
4 Bearing Horizontal Force Capacity: in accordance
with AASHTO LRFD Bridge Construction Specifications
Article 18.1.5.2.8. Failure or excessive deflection of any of
the components shall be cause for rejection.
5 Vertical Load Test: bearings shall be tested for
vertical load equal to one and a half (1.5) times the full
service dead load plus live load. The test shall be applied
in five equal increments and the test load held for one (1)
hour or until deformation ceases, whichever is the greater.
The load shall then be removed in equal decrements as
the load increments. A second cycle of load increment and
decrement shall be applied with the maximum test load
being held for (30) minutes. The load-deformation graph
shall be plotted for both load cycles and the set
determined. If the set exceeds a value deemed to be
excessive by the Engineer, the Engineer may require all
bearings to be pre-loaded before installation. At the end of
the vertical load test, the bearing shall be dismantled and
the bearing surfaces examined. Damage visible to the
naked eye on disassembly of the bearing, such as
excessive wear, cracks, or splits in the material shall be
cause for rejection.
6 If one bearing of the sample fails, all the bearings of
that lot shall be rejected, unless the manufacturer elects to
test each bearing of the lot at his expense. In lieu of this
procedure, the Engineer may require every bearing of the
lot to be tested.
7 Testing of the complete bearings shall be at the
Contractor’s expense and will be witnessed by
representatives of the Engineer and the Employer. The
cost for providing facilities to the Engineer or his
representative for witnessing the test shall be borne by the
Contractor. The Contractor shall ensure access to the
manufacturer plant for the Engineer’s representatives.
8 The Engineer may waive any or all of the bearing
tests.
11.1.3.4 Packaging, Handling and Storage
1 Prior to shipment from the point of manufacture,
bearings shall be packaged in such a manner to ensure
that during shipment and storage, the bearings will be
protected against damage from handling, weather, or any
normal hazard. Each completed bearing shall have its
components clearly identified, be securely bolted,
strapped, or otherwise fastened to prevent any relative
movement, and be marked on its top as to location and
orientation in each structure in the Project.
2 All bearing devices and components shall be stored
at the work site in an area that provides protection from
environmental and physical damage. When installed,
bearings shall be clean and free of all foreign substances.
3 Dismantling of bearings at the site shall not be done
unless absolutely necessary for inspection or installation.
♦ 11-4 ♦
Bearings shall not be opened or dismantled at the site
except under the direct supervision of or with the approval
of the manufacturer.
11.1.3.5 Construction and Installation
1 Bearings shall be installed by qualified personnel to
the positions shown in the contract documents. Bearings
shall be set at time of installation to the dimensions and
offsets prescribed by the manufacturer, by the Engineer,
and as shown in the contract documents and shall be
adjusted as necessary to take into account the
temperature and future movements of the bridge due to
temperature changes, release of falsework, and shortening
due to prestressing.
2 Each bridge bearing shall be located within ±3 mm of
its correct position in the horizontal plane and oriented to
within an angular tolerance of 1 degree. Guided bearings
and bearings which rotate about only one axis shall be
oriented in the direction specified in the contract
documents to within a tolerance of 0.25 degree. All
bearings except those which are placed in opposing pairs
shall be set horizontal to within an angular tolerance of
0.25 degree, and must have full and even contact with
load plates, where these exist. The superstructure
supported by the bearing shall be set so that, under full
dead load, its slope lies within an angular tolerance of 0.25
degree of the design value. Any departure from this
tolerance shall be corrected by means of a tapered plate or
by other means approved by the Engineer. If shim stacks
are needed to level the bearing, they shall be removed
after grouting and before the weight of the superstructure
acts on the bearing.
3 Metallic bearing assemblies not embedded in the
concrete shall be bedded on the concrete with a filler or
fabric material as specified in Paragraph 11.1.2.3.
4 Where bearings are seated directly on steel work, the
supporting surface shall be machined so as to provide a
level and planar surface upon which the bearing is placed.
5 Bearings or masonry plates which rest on steel
supports may be directly installed on the supports,
provided the support is flat within a tolerance of 0.002
times the nominal dimension and is sufficiently rigid so as
not to deform under specified loads.
11.1.4 Method of Measurement
1 Measurement of bridge bearings shall be by the
number of each type of bearing furnished, installed,
completed in place and accepted. Bearings of the same
type but of different load or movement capacities shall be
measured separately.
2 Bearing tests, installation trials, bedding, nuts and
bolts, grout injection where applicable, and temporary
restraint of bearings where necessary due to the sequence
of deck construction, measuring devices for movement
and/or load, as well as plinths, downstands, masonry
plates and all elements between the substructure and
superstructure shall not be measured for direct payment
copy 249
but shall be considered as subsidiary works the costs of
which shall be deemed to be included in the rates for
bridge bearings.
11.1.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided above, will be paid for at the rate
for each type of “Bridge Bearing” as specified in the Bill of
Quantities, which rate shall be full compensation for
furnishing all materials, labor, equipment, tools, supplies
and other items necessary for proper completion of the
Work.
11.1.6 Items in the Bill of Quantities
i) Bridge bearing (type), vertical and
horizontal loads (kN), movement (mm) (nr.)
11.2 Elastomeric Bearings
11.2.1 Description
1 Elastomeric bearings as defined herein shall include
unreinforced pads (consisting of elastomer only) and
reinforced bearings with steel laminates.
2 Design of steel-reinforced elastomeric bearings shall
be in accordance with AASHTO LRFD Bridge Design
Specifications Method B defined in Article 14.7.5 or
Method A defined in Article 14.7.6 where the provisions of
the appropriate article are used.
3 Bearings shall be constructed as specified in the
latest edition of AASHTO LRFD Bridge Construction
Specifications, Section 18, as complemented or modified
herein.
4 Alternatively elastomeric bearings may be designed
and constructed in accordance with Eurocode BS EN 1337-
3 Structural Bearings - Part 3: Elastomeric Bearings.
11.2.2 Materials
1 The raw elastomer shall be either virgin Neoprene
(polychloroprene) or virgin natural rubber (polyisoprene)
satisfying the testing requirements in Tables 18.2.3.1-1
and 18.2.3.1-2 of AASHTO LRFD Bridge Construction
Specifications. Test requirements may be interpolated for
intermediate hardness.
2 Unless otherwise specified in the contract documents,
the elastomer shall be Grade 0, 60-durometer.
3 Materials for elastomeric bearings and the finished
bearings themselves shall be subjected to the tests
described in AASHTO LRFD Bridge Construction
Specifications Article 18.2.5. Material tests shall be in
accordance with either Table 18.2.3.1-1 or Table 18.2.3.1-2,
as appropriate. Frequency of testing shall be as specified
in Article 18.2.5.2.
4 Short-duration compression tests on bearings shall
be as described in AASHTO LRFD Bridge Construction
Specifications Article 18.2.5.6 except that the compression
load shall be 200 percent of the rated service load.
5 Shear testing on finished bearings shall be as
described in AASHTO LRFD Bridge Construction
Specifications Article 18.2.5.8 at constant compression
loads of 50 and 100 percent of the rated service load.
6 Where elastomeric bearings are equipped with
sliding surface of polytetrafluorethylene (PTFE) and
stainless steel mating surface, the PTFE shall be as
specified in AASHTO LRFD Bridge Construction
Specifications Article 18.8.2 and the stainless steel as
specified in Article 11.1.2.1 of these Specifications.
11.2.3 Construction Requirements
1 Installation of elastomeric bearings shall be in
accordance with AASHTO LRFD Bridge Construction
Specifications Article 18.2.6.
2 Where elastomeric bearings are equipped with
sliding surface of PTFE and stainless steel mating surface,
the fabrication requirements shall be as specified in
AASHTO LRFD Bridge Construction Specifications Article
18.8.3.
11.2.4 Method of Measurement
1 Measurement of elastomeric bearings shall be by the
number of each type of bearing furnished, installed,
completed in place and accepted. Bearings of the same
type but of different load capacities shall be measured
separately.
2 Bearing tests, installation trials, bedding, grout
injection where applicable, measuring devices for
movement and/or load, as well as plinths, downstands,
masonry plates and all elements between the substructure
and superstructure shall not be measured for direct
payment but shall be considered as subsidiary works the
costs of which shall be deemed to be included in the rates
for bridge bearings.
11.2.5 Basis of Payment
1. The amount of completed and accepted work
measured as provided above, will be paid for at the rate
for each type of elastomeric bearing as specified in the Bill
of Quantities, which rate shall be full compensation for
furnishing all materials, labor, equipment, tools, supplies
and other items necessary for proper completion of the
Work.
11.2.6 Items in the Bill of Quantities
i) Elastomeric Bearing (type), vertical and
horizontal loads (kN) (nr.)
♦ 11-5 ♦
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11.3 Pot Bearings
11.3.1 Description
1 Pot bearings shall:
i. be adequate for the design loads and
movements shown in the contract documents or
specified.
ii. be tested at the appropriate level.
2 Bearings shall be designed in accordance with the
latest edition of AASHTO LRFD Bridge Design
Specifications, Section 14.7, as complemented or modified
herein.
3 Bearings shall be constructed as specified in the
latest edition of AASHTO LRFD Bridge Construction
Specifications, Section 18, as complemented or modified
herein.
4 Alternatively, the bearings may be designed and
constructed in accordance with BS EN 1337-5 Structural
Bearings - Part 5: Pot Bearings, as complemented or
modified herein.
5 All pot bearings including sliding bearing shall be
attached to the substructure and superstructure by
mechanical fixings or other approved methods.
6 The capacity of bolts fixing the bearings to the
substructure and superstructure shall be adequate to
resist solely the entire horizontal force without
consideration of any friction forces.
11.3.2 Materials
11.3.2.1 General
1 All materials shall be new and unused, with no
reclaimed material incorporated in the finished bearing.
11.3.2.2 Steel
1. All steel except stainless steel components of the pot
and disc bearing shall conform to the requirements of
Section 6 for carbon steel or high-strength, low-alloy
structural steel for welding.
11.3.2.3 Stainless Steel
1 Stainless steel shall conform to the requirements of
Paragraph 11.1.2,1 item (5) of this Specification.
11.3.2.4 Elastomeric Rotational Element
1 The elastomeric rotational element used in the
construction of pot bearings shall contain only virgin,
crystallization-resistant polychloroprene (Neoprene),
AASHTO M251 (ASTM D4014) or virgin natural
polyisoprene (natural rubber), AASHTO M 251 as the raw
polymer. The physical properties of Neoprene and natural
rubber shall conform to the standards stated herein with
modifications as follows:
i. The Shore A durometer hardness shall be 50 ±
10 points.
♦ 11-6 ♦
ii. Samples for compression set tests shall be
prepared using a Type 2 die.
11.3.2.5 Sealant
1 The elastomer shall be lubricated between the steel
pot and the top steel bearing plate with a silicon grease
which does not react chemically with the elastomer and
does not alter its properties within the range of
environmental conditions expected at the site or as
recommended by the manufacturer.
11.3.2.6 Sealing Rings
1 The sealing rings between the steel piston and the
elastomeric rotational element of pot bearings shall be
made of brass conforming to ASTM B 36 / B 36M for rings
of rectangular cross-section and ASTM B 121 / B 121M for
circular sections. The Engineer may, at his discretion,
approve other sealing ring material on the basis of test
evidence conforming to Article 14.7.4.5 of the AASHTO
LRFD Bridge Design Specifications.
11.3.2.7 Polytetrafluorethylene (PTFE) Sheet and Strip
1 PTFE sheet and strip requirements for pot bearings
shall conform to the provisions of AASHTO LRFD Bridge
Construction Specifications Article 18.8.1 or BS EN 1337-2
Sub-Section 5.2.
11.3.2.8 Other Sliding Materials
1 Other sliding materials shall conform to the provisions of
BS EN 1337-2 Section 5.
11.3.3 Construction Requirements
11.3.3.1 General
1 Comply with AASHTO LRFD Bridge Construction
Specifications as complemented or modified herein.
2 The Contractor shall provide the Engineer with
written notification 30 days prior to the start of bearing
fabrication.
3 The finish of the mold used to produce the
elastomeric rotational element shall conform to good
machine shop practice.
4 The PTFE sheet shall be bonded to a grit-blasted steel
substrate using an epoxy resin adhesive under controlled
factory conditions in accordance with the instructions of
the adhesive manufacturer. The PTFE sheet shall be
recessed into its steel substrate for at least one-half of its
thickness. If on a vertical surface, the PTFE sheet may be
mechanically fastened to the substrate. The attachment of
the PTFE sheet to its substrate shall be done in accordance
with the manufacturing requirements of AASHTO LRFD
Bridge Construction Specifications Article 18.8.2,
"Materials”.
5 After fabrication, steel surfaces exposed to the
atmosphere, except stainless steel surfaces, shall be shop
painted or coated to protect against corrosion as specified
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in Section 7. Surface preparation shall be as AASHTO
LRFD Bridge Construction Specifications Article 18.3.3.1.
6 Stainless steel sheet shall be attached to a steel
substrate with an approved epoxy to ensure complete
contact and then sealed with a continuous seal weld. All
welding shall conform to and all welders shall be qualified
in accordance with the requirements of the current
AASHTO/AWS D1.5 M / D1.5 Bridge Welding Code. Except
as noted, all bearing surfaces of steel plates shall be
finished or machined flat within 0.0008 mm/mm. Out-of-
flatness greater than 0.0008 mm/mm on any plate shall be
cause for rejection. The bottom surfaces of lower bearing
plates (masonry plates) designed to rest on bearing pads
shall not exceed an out-of-flatness value of 0.005 mm/mm.
Oxygen-cut surfaces shall not exceed a surface roughness
value 25 m, as defined by ANSI B 46.1.
7 Gross bearing dimensions shall have a tolerance in
accordance with Paragraph 11.1.3 .2. of this specification
8 Every bearing shall have the project identification
number, lot number, and individual bearing number as
well as its location on the structure indelibly marked with
ink on a side that will be visible after erection.
9 Fabrication Requirements for the Pot:
i. The pot shall be manufactured by welding or
machining from a single piece of plate.
ii. The piston shall be machined from a single piece
of steel. The outside diameter of the piston shall
be no more than 0.760 mm less than the inside
diameter of the pot at the level of interface
between the piston and elastomeric rotational
element. The sides of the piston shall be beveled
to facilitate rotation.
iii. If guides are used, they shall be attached to the
piston by welding or bolting.
10 Fabrication Requirements for Sealing Rings: The
sealing rings shall be recessed into the elastomeric disc
and shall fit snugly against the pot wall. Rings of
rectangular cross-section shall be installed with their gaps
equally spaced round the circumference. The gap between
the ring and the wall shall nowhere exceed 0.25 mm. The
gap between the cut ends of the ring shall not exceed 1.25
mm.
11 Fabrication Requirements for Elastomeric Rotational
Element: The elastomeric pad shall have the same
nominal diameter as the pot. The elastomeric pad shall be
individually molded or cut from sheet and shall be made
of no more than three separate layers, of which none may
have a nominal thickness of less than 13 mm. The sealing
ring recess depth shall be the same as the total ring
thickness if rectangular rings are used.
11.3.3.2 Sampling and Testing
1 Lot Size: Sampling, testing, and acceptance
consideration shall be made on a lot basis. A lot shall be
the smallest number of bearings as determined by the
following criteria:
i. Shall not exceed a single contract document or
project quantity.
ii. Shall not exceed 25 bearings.
iii. Shall consist of those bearings of the same type
regardless of load capacity. Bearing types may
be fixed or sliding types. Guided and non-guided
sliding bearings shall be considered to be a
single type.
2 Material Certification Tests: The manufacturer shall
select, at random, samples for material certification tests
as defined in Paragraph 11.1.2.2 of this Specification,
bearings from completed lots of bearings for testing. The
manufacturer shall complete the required testing and
determine compliance with this specification before
submitting the lot(s) for quality-assurance inspection,
testing, and acceptance consideration. The results of the
manufacturer's tests shall be furnished to the Engineer.
Certification shall be provided for all elastomeric elements.
Their material properties shall satisfy the requirements
specified and the tests described in Paragraph 11.1.3.3.
Additional tests may be required by the Engineer.
3 Testing by the Engineer’s instruction:
i. The manufacturer shall furnish to the Engineer
the required number of complete bearings and
component samples to perform quality-
assurance testing on the expense of the
Contractor in accordance with the following:
− For Proof Load Test: one production bearing
per lot.
− For Coefficient of Friction Test: one
production bearing per lot.
− Physical Properties of Elastomeric
Rotational Element: one elastomeric
element per lot.
− Physical Properties of PTFE Sheet: one
250x400 mm sheet of PTFE material per
project.
− Bearing Horizontal Force Capacity as
Paragraph 11.1.3.3: one production bearing
per lot for each of (a) fixed type and (b)
guided sliding type (guide test).
− Vertical Load Test as Paragraph 11.1.3.3:
one production bearing per lot of each type.
ii. At least one elastomeric element shall be tested
per lot of bearings. All exterior surfaces of
sampled production bearings shall be smooth
and free from irregularities or protrusions that
might interfere with testing procedures.
iii. A minimum of 30 days shall be allowed for
inspection, sampling, and quality-assurance
testing of production bearings and component
materials.
iv. The Engineer may select, at random, the
required sample bearing(s) from completed lots
of bearings and samples of the elastomeric and
PTFE materials for quality-assurance testing.
♦ 11-7 ♦
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 v. The Contractor shall bear the cost of transporting
all samples from the place of manufacture to the
test site and back or, if applicable, to the Site.
4 Performance Characteristics for Proof-Load Test:
i. Critical dimensions shall include the clearance
between the piston and the pot and shall be
verified by the clearance test described in
Paragraph 11.1.3.3.
ii. A long-term deterioration test, as described in
Paragraph 11.1.2.2 item (3) shall be performed
on one bearing of each lot of pot bearings with
the sealing rings with rectangular cross-section
and sealing rings with circular cross-sections.
The bearing shall be load-tested to 150 percent
of the specified rated capacity at 0.02 rad. If the
size of the bearing prohibits adequate testing
with available equipment, the Engineer may
agree to test a prototype bearing with
comparable requirements.
iii. During the test, the steel bearing plate and steel
piston shall maintain continuous and uniform
contact for the duration of the test.
iv. The bearing shall be visually examined both
during the test and upon disassembly after the
test. Any resultant visual defects, such as
extruded or deformed elastomer, or PTFE;
damaged seals or limiting rings; evidence of
metal-to-metal contact between the pot wall and
the top plate; or cracked steel, shall be cause for
rejection of the lot.
5 Sliding Coefficient of Friction Test:
i. For all guided and non-guided sliding type
bearings, the sliding coefficient of friction shall
be measured at the bearing's design capacity in
accordance with Paragraph 11.1.3.3 and
additionally on the fifth and fiftieth cycles, at a
sliding speed of 25 mm per min.
ii. The sliding coefficient of friction shall be
calculated as the horizontal load required to
maintain continuous sliding of one bearing,
divided by the bearing's vertical design capacity.
iii. The test results shall be evaluated as follows:
− The measured sliding coefficients of friction
shall not exceed three percent.
− The bearing will be visually examined both
during and after the test. Any resultant
visual defects, such as bond failure, physical
destruction, cold flow of PTFE to the point of
debonding, or damaged components, shall
be cause for rejection of the lot.
− Bearings not damaged during the
testing of performance characteristics may
be used in the work.
♦ 11-8 ♦
11.3.3.3 Installation
1. Pot bearings shall be installed in accordance with the
contract documents and on the approved working
drawings. Upon final installation of the bearings, the
Engineer, in the presence of the manufacturer's
representative, shall inspect the bearing components to
assure that they are level and parallel to within 2.6 mm/m.
Any deviations in excess of the allowed tolerances shall be
corrected.
11.3.4 Method of Measurement
1 Measurement of pot bearings shall be by the number
of each type of bearing furnished, installed, completed in
place and accepted. Bearings of the same type but of
different load capacities shall be measured separately.
2 Bearing tests, installation trials, bedding and epoxy
injection where applicable shall not be measured for direct
payment but shall be considered as subsidiary works the
costs of which shall be deemed to be included in the rates
for bridge bearings.
11.3.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided above, will be paid for at the rate
for each type of “Pot Bearing” as specified in the Bill of
Quantities, which rate shall be full compensation for
furnishing all materials, labor, equipment, tools, supplies
and other items necessary for proper completion of the
Work.
11.3.6 Item in the Bill of Quantities
i) Pot Bearing (type), vertical and horizontal
loads (kN), movement (mm) (nr.)
11.4 Bridge Expansion Joints
11.4.1 Description
11.4.1.1 Scope
1 This Sub-section describes furnishing materials and
installation of expansion joints for bridge decks, all as and
where shown on the Drawings.
11.4.1.2 Types of Joints
1 The joint construction shall be as described on the
Drawings and may be one of the following types:
− Buried joint within the bridge deck
− Elastomeric sealed joints
− Modular joints using neoprene box or band
sections
− Metallic finger joints
− Asphaltic plug joint.
2 Unless otherwise shown on the Drawings, expansion
joints shall be fully waterproof type.
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3 The bedding and nosings of expansion joints shall be
considered integral parts of the joint and the joint
manufacturer shall be responsible for the supply of all
constituent materials required for bedding and nosing of
joints at the time of supplying the joint.
11.4.1.3 References
1 American Association of State Highway and
Transportation Officials (AASHTO):
AASHTO 2008 AASHTO LRFD Bridge Construction
Specifications, 2nd Edition, 2004, 2008
Interim Revisions.
AASHTO 2008 AASHTO LRFD Bridge Design
Specifications, 3rd Edition, 2004, 2008
Interim Revisions.
11.4.1.4 Submittals
1 If the type of expansion joints for a particular
application is not shown in the contract documents, the
Contractor shall submit, for the Engineer’s approval, a
report well in advance, identifying the type of expansion
joint he intends to use for every structure.
2 The Contractor shall furnish detailed drawings of the
joint and method of assembly and installation procedure
for the approval of the Engineer.
3 Material certificates, signed by manufacturers and
Contractor shall be provided, certifying that the joints are
designed in accordance with AASHTO LRFD Bridge Design
Specifications or equivalent standard and AASHTO LRFD
Bridge Construction Specifications or equivalent and that
they comply with the requirements of this specification.
11.4.1.5 Quality Assurance
1 Codes and Standards: AASHTO LRFD Bridge
Construction Specifications.
2 The Contractor shall ensure that direct site
supervision of the first of each type of joint is provided by
an experienced technical representative of the
manufacturer and thereafter, by competent persons who
have been trained in the proper installation of expansion
joints.
11.4.2 Materials
11.4.2.1 General
1 Storage of joints, jointing materials, sealants and
other associated items shall be in accordance with the
manufacturer's recommendations.
2 The elastomeric, metallic, bituminous, cementitious
and resin based components used in the joint construction
shall all be strictly in accordance with the description in
the contract documents and the manufacturer's
specifications.
11.4.2.2 Asphaltic Plug Joints
1 Binder:
i. The binder used in the construction of an
asphaltic plug joint must have the following
characteristics:
− remain flexible in cold conditions,
− be stable in hot conditions,
− be flow resistant.
ii. The following tests shall be performed by an
approved laboratory at the temperatures
expected in use,, and a test certificate issued
before the asphaltic plugs are delivered to Site:
− Extension Test,
− Softening Point Test,
− Flow Resistance Test.
2 Aggregate: The aggregate shall be single-sized 20
mm aggregate to BS 63. It shall be a clean, dry stone with
a polished stone value of 60, and a maximum flakiness
index of 25, and shall bagged to avoid contamination.
11.4.3 Construction Requirements
11.4.3.1 General
1 The positioning of holding down bolts and
anchorage systems shall be checked for accuracy and
agreed by the Engineer before the casting of the concrete
for the joint and to locate holding down bolts or
anchorage pockets. The templates or forms shall only be
removed with the Engineer's consent. Threaded parts
shall be protected, kept clean and protected from
corrosion by a grease coating.
2 Where the carriageway surfacing is removed to
accommodate the bridge joint it shall be cut to a clear
straight line for the full depth of the surfacing without
damage to the concrete substrate or the waterproofing.
3 Before installation of the joint, the concrete surfaces
shall be free from laitance, sand, clear and comply strictly
with the joint manufacturer's requirements.
11.4.3.2 Nosings
1 Construction of nosings at joints using epoxy mortar
and epoxy concrete shall be formed under the direction of
a competent supervisor experienced in the use of the
material. The work shall be carried out preferably in the
warm weather. The air temperature around the joint shall
be not less than 10 degrees C, which shall be achieved
artificially if necessary. Concrete surfaces to which
nosings are applied shall be dry, sound and free from
laitance. Before application of the primary coat, loose
material and dust shall be removed by an air jet tested to
ensure that no oil is carried over from the compressor.
2 Unless otherwise specified, surfacing shall be carried
across the joint and then cut back to accommodate the
nosing. The cutting shall be done with a diamond saw to
give a clean edge throughout the depth of the material to
be removed. Masking material shall be provided to
prevent surfacing materials adhering to the deck where
nosings are to be formed and shall be adequately located
to prevent displacement by the paving machine.
♦ 11-9 ♦
copy 249
3 A primary coat of unfilled epoxy resin composition cross the joints only by means of the ramps until the
shall be well worked in by brush to all surfaces with which bedding and nosing have reached full strength.
the nosings will be permanently in contact, at a uniform
rate of not less than 300 gm/square meter. The mortar 11.4.4 Method of Measurement
shall then be applied as quickly as possible while the
primary coat is still tacky. 1 Bridge expansion joints shall be measured by the
linear meter of each joint type and size (measured by
4 The epoxy mortar and epoxy concrete composition
movement range). Measurement shall be made from
shall be approved by the Engineer. Aggregate shall be
outside face of parapet to outside face of parapet whether
either silica sand, calcined bauxite or other approved
or not the joint types over carriageway, verges and
synthetic or natural aggregate of suitable grading. The
walkways for a particular joint type are similar. Special
particle size distribution shall be that which produces a
curb units, cover plates over walkways, epoxy mortar
mortar with adequate strength and workability and
bedding and epoxy concrete nosing shall not be measured
minimum voids. Aggregate shall be clean and completely
for direct payment, but shall be considered as subsidiary
dry. Whichever type of aggregate is used, the epoxy
works the costs of which will be deemed to be included in
mortar or epoxy concrete constituents shall be thoroughly
the unit rates.
mixed in a suitable mechanical mixer. The sequence,
duration and temperature of mixing shall be in accordance
with the manufacturer's instructions. 11.4.5 Basis of Payment
5 The mixed constituents shall be placed in position 1 The amount of completed and accepted work
within the time recommended by the manufacturer, well measured as provided above, will be paid for at the rates
worked against the primed surfaces and trowelled flush identified in the Bill of Quantities, which rates shall be full
with the adjacent road surface to form a dense solid compensation for furnishing, installing, fixing and for
nosing to the required profiles. Epoxy mortar shall materials, labor, equipment, tools, supplies and all other
generally be compacted in layers not exceeding 50 mm items necessary for the proper completion of the work.
thick. Where an underlying layer is more than one hour
old it shall, unless otherwise agreed by the Engineer, be 11.4.6 Items in the Bill of Quantities
primed with an unfilled epoxy resin priming coat before
placing the next course. (i) Buried Joint
movement range ( ) (lin.m.)
11.4.3.3 Installation
(ii) Elastomeric (waterproof) Joint
1 The gap width shall be set, in relation to the
movement range ( ) (lin.m.)
prevailing deck temperature, with the joint gap sides
parallel as described on the Drawings and within the joint (iii) Modular joint with neoprene
manufacturer's installation instructions. Seals shall insert, movement range ( ) (lin.m.)
remain in compression for the full range of joint
movement. (iv) Metallic finger joint with
2 Expansion joints shall be of uniform width and shall neoprene insert
be accurately set or finished and aligned flush with the movement range ( ) (lin.m.)
finished carriageway surface. Care shall be given to
ensure that metallic components are not bent or deformed (v) Metallic finger joint no insert
during handling and installation. movement range ( ) (lin.m.)
3 The installation process shall strictly comply with
(vi) Asphaltic Plug Joint
instructions given on the Drawings and by the joint
manufacturer. movement range ( ) (lin.m.)
4 The expansion joint and the waterproofing shall be
formed so that a watertight seal is provided. 11.5 Joint Seals and Fillers
5 During the placing and hardening of the bedding and
bonding materials, movement between the joint and the 11.5.1 Description
substrate shall be prevented.
1 This Sub-section describes requirements for
6 When one half of the expansion joint is being set, the furnishing and installing joint sealing and preformed
other half shall be completely free from longitudinal expansion joint filler materials as shown on the Drawings,
restraint. In particular, where templates are used to locate or as directed by the Engineer.
the two sides of a joint, they shall not be fixed
simultaneously to both sides. 11.5.2 Materials
7 Ramps shall be provided and maintained to protect
all expansion joints from vehicular loading. Vehicles shall 1 For preformed joint filler strips, refer to Section 5,
Paragraph 5.3.2.6.

♦ 11-10 ♦
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2 For joint sealants, refer to Section 5, Paragraph
5.3.3.7 (7).
11.5.3 Construction Requirements
1 For construction joints, refer to Section 5, Paragraph
5.3.3.6.
2 For contraction and expansion joints, refer to Section
5, Paragraph 5.3.3.7.
3 For waterstops, refer to Section 5, Paragraph 5.3.3.8.
11.5.4 Method of Measurement, Basis of
Payment and Bill of Quantities
1 No separate measurement is made for joint sealers
and fillers and no items are included in the Bill of
Quantities. The work shall be considered subsidiary to
other items of work in the Bill of Quantities.
11.6 Bridge Parapets and Railings
11.6.1 Description
1 This Sub-section describes requirements for
furnishing and installing bridge parapets and railings as
shown on the Drawings or as directed by the Engineer.
11.6.2 Materials
11.6.2.1 Materials of Construction
1 The materials of construction of the parapet shall be
aluminum alloy or structural steel or reinforced concrete.
11.6.2.2 Aluminum Alloy
1 Aluminum alloys used for bridge parapets and
railings shall conform with the requirements of AASHTO
M 193 and AASHTO M 219 or BS 1470, BS 1474 and BS
1490.
11.6.2.3 Structural Steel
1 Structural steel used for bridge parapets and railings
shall conform to the requirements of Section 6 "Structural
Steel and Other Metal Work". The anchorage system shall
be as shown on the Drawings or of a type approved by the
Engineer.
11.6.2.4 Reinforced Concrete
1 Reinforced concrete used for bridge parapets shall
conform to the requirements of:
− Sub-Section 5.1 Concrete Materials and Mixes
− Sub-Section 5.2 Reinforcing Steel
− Sub-Section 5.3 Reinforced Concrete Structures
The anchorage system shall be as shown on the Drawings or
of a type approved by the Engineer.
11.6.2.5 Anchorage System
1 The anchorage system of parapets and rails, shall be
as shown on the Drawings and shall be subject to the
approval of the Engineer. It shall be such that damaged
metal posts and rails can be readily replaced without the
need for cutting the bridge deck or copings or edge units
into which the anchorages are located.
11.6.3 Construction Requirements
1 During erection, the parapet units shall be securely
held in their correct positions until all connections and
fixings are complete and the post fixings have gained
adequate strength to develop the full holding down
moment. The assessment of the adequacy of the post
fixing shall be subject to the Engineer's approval. The
finished parapets shall be true to line and level throughout
their length.
2 Welding of aluminum shall comply with the
requirements of BS 3019 Part 1 and BS 3571 Part 1 and all
welding shall be carried out in the factory under controlled
environment. Welding of steel parapet units shall be
carried out in factory or at site in compliance with Section
6
3 The Contractor shall ensure the proper installation of
the posts and rails for metal bridge parapets by competent
persons who have been trained in the proper installation
of the type of bridge parapets to be installed, using tools
and procedures recommended by the manufacturer.
4 The rails and posts of parapets shall be closed
sections, presenting no visible seam welds or exposed
bolt heads. The shape and texture of the posts and rails
and the protective treatment to be applied shall be as
indicated on the Drawings and no deviations and/or
alterations to these shall be permitted.
5 The standard of finish of reinforced concrete parapet
units shall conform to finish of approved sample units
made before main production commences. Where minor
blemishes and discolorations occur on production units,
making good with an approved epoxy mortar compound
will be permitted only with the express approval of the
Engineer. Units which are considered unacceptable for
use in the works by the Engineer shall be destroyed.
Considerable care shall be given during erection of
parapet units to avoid cracking or otherwise damaging the
concrete unit or its finish.
11.6.4 Method of Measurement
1 Bridge parapets and railings shall be measured by
the linear meter of each type of parapet and railing, based
upon the lengths and dimensions shown on the Drawings
or ordered by the Engineer
2 Full scale dynamic testing or any other testing that
may be required, expansion joints, specially fabricated
units of posts and rails for nosing areas, special
requirements at junctions with transition walls, or guard
rails, grit blasting to produce the required surface texture
♦ 11-11 ♦
copy 249
anchorages and holding down assemblies stitching and
making good to concrete and other ancillaries, will all be
considered as subsidiary works the cost of which shall be
deemed to be included in the rates for bridge parapets and
railings.

11.6.5 Basis of Payment

1 The amount of completed and accepted work
measured as provided for above shall be paid at the rates
in the Bill of Quantities, which rate shall be full
compensation for furnishing and installing all materials,
labor, equipment, tools, tests, records and all other items
for completing the works as specified.
2 Where a concrete parapet is mounted with a metal
rail, both components will be measured as one item
completely furnished and installed.

11.6.6 Item in the Bill of Quantities

(i) Concrete bridge parapet
(state type) (lin.m.)

(ii) Concrete bridge parapet with

metal rail (state type) (lin.m.)

(iii) Steel bridge parapet (lin.m.)

(iv) Aluminum bridge parapet (lin.m.)

(v) Steel pedestrian railing (lin.m.)

(vi) Aluminum pedestrian railing (lin.m.)

♦ 11-12 ♦
copy 249
12.1  General 12-1 
12.1.1  Description 12-1 
12.1.2  References 12-1 
12.1.3  Materials 12-1 
12.1.4  Construction and Installation
Requirements 12-2 
12.1.4.1  Sub-grade and Sub-base 12-2 
12.1.4.2  Curbs 12-2 
12.1.4.3  Precast Concrete Tile Paving 12-2 
12.1.4.4  Block Paving 12-4 
12.1.4.5  Cast In-situ Concrete Paving/Curbing 12-4 
12.1.5 Method of Measurement 12-4
12.1.6 Basis of Payment 12-5
12.1.7 Items in the Bill of Quantities 12-5

♦ 12-1 ♦
copy 249
♦ 12-2 ♦
copy 249
12.1 General
12.1.1 Description
1 This Sub-section describes requirements for paving
and curbs for sidewalks and other paved areas, including
precast concrete and natural stone paving, aggregate
bases, granular sub-bases and sub-grade, all as shown on
the Drawings.
2 Paving includes, as appropriate and shown on the
Drawings, hydraulically pressed precast concrete elements,
clay pavers, granite, basalt and cobbled paving, sub-bases
and related accessories such as movement joints. In
limited cases, and only if specifically ordered by the
Engineer, cast in situ concrete paving and curbs may be
permitted, provided trial sample work is approved by the
Engineer.
12.1.2 References
1 American Association of State Highway and
Transportation Officials (AASHTO)
M-33-99 Preformed Expansion Joint Filler for
Concrete (Bituminous Type)
M 235M Standard Specification for Epoxy Resin
Adhesives
2 American Society for Testing and Material (ASTM)
D994-98 Standard Specification for Preformed
Expansion Joint Filler for Concrete (Bituminous Type)
C936M – 09 Standard Specification for Solid
Concrete Interlocking Paving Units
3 British/European Standards
BS 7533-3:2005/A1 2009
Pavements constructed with clay,
natural stone or concrete pavers. Code
of practice for laying precast concrete
paving blocks and clay pavers for
flexible pavements.
EN 1342:2001 Setts of natural stone for external
paving. Requirements and test methods
EN 1343:2001 Curbs of natural stone for external
paving. Requirements and test methods
BS 6717:2001 Precast, unreinforced concrete paving
blocks. Requirements and test methods
BS EN197-1:2000 Cement. Composition, specifications
and conformity criteria for low heat
common cements
EN 13139:2002 Aggregates for mortar
BS 882:1992 Specification for aggregates from
natural sources for concrete
EN 998-1:2003 Specification for mortar for masonry -
Rendering and plastering mortar
EN 998-2:2003 Specification for mortar for masonry -
Masonry mortar
BS 7263-1:2001 PC concrete flags, curbs, channels,
edgings and quadrants, PC
unreinforced concrete paving slabs and
complimentary fittings:- Requirements
and test methods.
12.1.3 Materials
1. Portland cement concrete shall conform to the
requirements of Section 5 and as shown on the Drawings,
including HDS Section 16, SD16.20.
2. Precast concrete curbs, edgings and channels shall
be hydraulically pressed units to conform to BS 7263,
obtained from an approved manufacturer, and of the
sections and sizes shown on the Drawings
i. Straight units shall generally be 900mm long but
shall be shorter where used for curves of radius
down to 12 meters,
ii. Radius curb units shall be used for curves of
radius less than 12 meters
3 Precast concrete paving slabs (tiles) shall be
hydraulically pressed slabs to conform to BS 7263,
obtained from an approved manufacturer, and of the sizes,
shapes, colors and surface finish shown on the Drawings.
4 Granite blocks shall conform to BS EN 1342 and 1343,
approved natural local granite with sawn finish, and be
obtained from one strata of one quarry, free from faults
and to the shapes, sizes and patterns shown on the
Drawings.
5 Basalt blocks shall be approved natural basalt sets to
BS EN 1342 and 1343 with various finishes, obtained from
one strata of one quarry, free from faults and to the
shapes, sizes, and patterns shown on the Drawings.
6 Interlocking concrete blocks shall conform to BS
6717 [ASTM C 936], precast concrete interlocking block
pavers, obtained from an approved manufacturer and to
the shapes, sizes, colors, finishes and patterns shown on
the Drawings.
7 Interlocking clay pavers shall conform to BS6677, be
obtained from an approved manufacturer and to the
shapes, sizes, colors, finishes and patterns shown on the
Drawings.
8 Stone cobbles: selected hard smooth, egg-shaped
beach or river cobble stones obtained from an approved
source and to the sizes shown on the Drawings.
9 Base, sub-base and sub-grade courses for paving
shall comply with requirements of Section 3 of these
standard specifications and as shown on the Drawings,
including HDS Section 16, SD16.20.
10 Preformed expansion joint filler shall meet the
requirements of AASHTO M-33-99 or ASTM D994-98
11 Cement-sand mortar mix for bedding of block pavers
shall, unless otherwise specified, be composed of:
i. Ordinary Portland cement to BS EN 197-1 or, if
instructed, white Portland cement to BS EN197-1.
ii. Sand to BS 882, Table 5.
♦ 12-1 ♦
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 iii. Mix composition shall be Type “ii” as BS 998
1&2, to give a 28 day compressive strength of
not less than 5 MPa. Cement sand ratio shall not
be less than 1: 3 or 1:4 by volume; submit details
of proposed mix for approval.
12 Where approved by the Engineer, factory premixed
mortar to BS EN 998-1 & 2, compressive strength at 28
days not less than 5 MPa, may be used.
13 Bedding sand for block paving shall be clean sharp
sand, free from deleterious salts and contaminants with
clay, silt and fine dust content of not more than 3% by
mass. They shall be obtained from a single source,
consistently graded according to the requirements of BS
7533-3, Table 2. Sand that will stain paving should not be
used. Bedding sand should be maintained at an even
moisture content which will give maximum compaction
during block laying.
14 Epoxy adhesive shall conform to the requirements of
AASHTO M 235M, Standard Specifications for Epoxy
Resin Adhesive, for the type of application required.
12.1.4 Construction and Installation
Requirements
12.1.4.1 Sub-grade and Sub-base
1 The sub-grade shall be excavated to the required
depth and to the width to receive sub-base and paving and
to permit installation and bracing of the forms where
needed. The foundation shall be shaped and compacted to
an even surface conforming to the sections shown on the
Drawings. All soft and yielding material shall be removed
and replaced with acceptable material.
2 Prior to commencing laying paving blocks, paving
tiles and stone paving, the prepared sub-grade surface
shall be cleared of loose and waste material and prepared
to receive sub-base as per Section 3, Clause 3.2.3.
3 Granular sub-base shall be constructed where shown
or directed by the Engineer, and shall be placed in layers
not exceeding one hundred fifty (150) millimeters in depth
and each layer shall be compacted to at least 95% of dry
density.
12.1.4.2 Curbs
1 Curb sections shall be hydraulically pressed in
approved molds under conditions of controlled
temperature and humidity. Sections shall be water or
steam cured until the concrete attains one hundred (100)
percent of specified strength. Curbs shall have a clean
finish with smooth surfaces. Segregation, honeycombing
or broken corners will not be allowed and remedial
measures will not be accepted.
2 Curbs shall be placed to the lines shown on the
Drawings or established by the Engineer. The Contractor
shall mark the location where each section is to be placed
and the marks shall be approved by the Engineer prior to
beginning work. No curb sections shall be placed over
longitudinal or transverse joints of the pavement surface.
♦ 12-2 ♦
3 Where specified or instructed by the Engineer curbs
shall be bedded in adhesive. The adhesive shall be placed
uniformly on the cleaned pavement surface or on the
bottom of the curb sections in a quantity sufficient to
result in complete coverage of the area of contact of the
curb and the pavement, with no voids present and with a
slight excess after the curb has been pressed in place. The
curb shall be placed in position and pressure applied until
firm contact is made with the pavement. Excess adhesive
around the edge of the marker, excess adhesive on the
pavement, and adhesive on the exposed surfaces of the
marker shall be immediately removed. The curb shall be
protected against impact until the adhesive has hardened.
4 Mixing of adhesive shall be performed in limited
quantities such that the curb sections shall be aligned and
pressed into place within five (5) minutes after mixing the
adhesive components. Any mixed batch of adhesion,
which becomes so viscous that the adhesive is not readily
extruded from under the curb on application of slight
pressure, shall not be used.
12.1.4.3 Precast Concrete Tile Paving
1 Tiled sidewalks shall be constructed in accordance
with the dimensions and levels shown on the Drawings or
as directed by the Engineer. All areas inside channelizing
islands shall also be provided with a sidewalk pavement,
unless otherwise shown on the Drawings or as directed by
the Engineer.
2 Precast tiles shall be manufactured by an automatic
plant of the central batch high pressure type, erected in a
special yard reserved specifically for this purpose. The
plant shall be equipped with a double feeding system, one
for the upper layer, and another for the lower layer of the
tile. Manual intervention shall be a minimum.
3 Operation of the plant shall be such that it shall first
discharge enough mortar materials into the form for the
upper layer, and after preliminary vibration and uniform
leveling, the coarse mixture for the lower layer shall then
be discharged into the tile form. The high pressure
automatic device shall be used only after a second
vibration and leveling of the material has taken place. Tiles
shall not be disturbed during setting of the concrete.
4 Curing of the tiles shall take place in a closed curing
room where the Contractor shall provide an automatic
steam curing system to be operated as approved by the
Engineer. The capacity of the curing room shall permit
acceptance and complete curing of the daily plant
production of tiles.
5 The period of curing shall be at least one full day at a
temperature of fifty-five to seventy-five degrees Celsius
(55 o to 75o C). This period may be subject to changes and
adjustments after direct tests have been made on the
production or as directed by the Engineer.
6 Tiles shall not be imperfectly finished, and shall be
free from segregation, honeycombing, broken or damaged
corners and imperfect plan faces. Correction of defects by
polishing, retouching or any other means will not be
permitted. Approval of the tiles given by the Engineer at
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any stage of the work shall not prejudice the Engineer's
right to later discard any imperfect tiles. Final approval
shall be given only after the tiles have been completely
positioned in-situ. Rejected tiles shall be removed from
the site and replaced.
7 The following tests shall be carried out on sidewalk
to tiles to ascertain their suitability for the Work:
i. Impact Strength
ii. Flexural Strength
iii. Abrasion Resistance
8 Impact Strength Test; this test establishes the
minimum height of fall of a steel ball weighing one kg.
which, when striking the tile in the middle, breaks it. The
product of the height of the fall by the weight of the ball is
taken as the Impact Strength, limiting value: 0.5 kg -meters
minimum.
9 Flexural Strength; this test is carried out by placing a
tile on two knife supports, with edges rounded with a
radius of one (1) centimeter, arranged parallel to the side
of the tile and ten (10) centimeters apart. The load is
gradually transmitted to the tile top surface, along the
centerline, by a third knife arranged parallel to the other
two.
The unit maximum bending stress = fifteen (15) Phb ,
2 with plastic or nylon sheets to avoid evaporation of water
where :
'P' is the total breaking load in kilograms, 'b' is the
width of the tile in centimeters and 'h' is the
thickness of the tile in centimeters.
The limit acceptance value for Flexural Strength shall be
thirty (30) kilograms per square centimeter minimum.
10 Abrasion Resistance; this test is carried out with a
machine composed of a horizontal cast-iron disc, rotating
about its vertical central axis at uniform speed; a
horizontal diametrical crosspiece by means of which two
samples are pressed on the disc, at such a distance from
the center of the disc that the relative speed with respect
to the disc, is one meter per second; a second horizontal
diametrical cross-piece orthogonal to the first, which is
carried at either end; appropriate devices to let the
moistened abrasive flow onto the track; two pairs of
conveniently arranged brushes to guide the abrasive that
tends to escape under the samples. The samples, pressed
against the disc, rotate by means of a special mechanical
device, around their own vertical central axis, at the rate of
one turn of the specimen for fifty (50) turns of the disc.
Carborundum grit sufficiently coated with liquid mineral
oil with an Engler viscosity between five (5) and seven (7)
at fifty degrees Celsius (50o C.) shall be used as an
abrasive. The grit shall pass Sieve No. 60 and be retained
on Sieve No. 100. Consumption of carborundum and oil
should be approximately twenty (20) and twelve (12)
grams, respectively, per minute. The square sample, with
a surface area of fifty (50) square centimeters shall be
pressed against the disc by a total of fifteen (15) kilograms
unit pressure of three tenths (0.3) kilograms per square
centimeter. The test is normally carried out with a distance
run of the grinding wheel of five hundred (500) meters. For
materials with a surface wearing layer different from the
rest of the tile, the distance run must be such that the disc
does not penetrate into the lower layer. The thickness of
the layer abraded in millimeters with a pressure of three-
tenths (0.3) kilogram per square centimeter for a distance
run of one thousand (1000) meters is taken as the
Abrasion Factor. This factor is determined by assuming
that the consumption is proportional to the distance run.
The limit acceptance value for the Abrasion Factor shall be
twelve (12) millimeters maximum
11 Tiles shall be laid with joints between tiles and
between tiles and curbs nominally 10mm wide,
completely filled with 1:2 cement/sand mortar or a grout
for the full thickness of the tile by use of proper tools,
during and after positioning of the tiles. All transverse and
longitudinal joints shall be in proper line and in the correct
pattern, to ensure a neat and workmanlike appearance.
12 As soon as the mortar or grout has partially set, the
Contractor shall rake all mortar material from the groove
formed by the two adjacent bevels, and from the first
three mm. depth of the joint, using appropriate tools.
13 When the mortar has sufficiently set, the Contractor
shall sprinkle the sidewalk with water and shall cover it
during the curing period. The sheets shall be left in place
until completion of setting of the mortar and concrete, or
as ordered by the Engineer. The Contractor shall then
remove all foreign matter, wood, concrete or mortar
lumps, etc., leaving the sidewalk in a neat, clean and tidy
condition.
14 In cases where tiles are required to be cut, due to the
presence of obstacles, poles, hydrants, etc., or in the
construction of driveways or side roads, etc., the
Contractor shall cut the tiles and/or substitute in-situ
concrete of at least the same quality as the tiles. The
Engineer shall decide, after trials, on the method to be
adopted. This operation shall be kept to a minimum. The
Contractor shall complete as much as practicable of the
sidewalk using precast tiles.
15 Where the sidewalk crosses the entrance to a shop or
a house the level of which is higher than the sidewalk, the
Contractor shall construct steps, formed by a curb and a
complete or partial tile. The steps shall be backfilled with
concrete of the same quality as specified for tile
foundations.
16 A step shall be constructed wherever the difference
in elevation between the entrance and the sidewalk is
more than three hundred (300) millimeters. The Contractor
shall submit to the Engineer, prior to commencing any
sidewalk construction, a list of locations where steps will
be required, together with design details for construction
of such steps.
17 Driveway pavements shall be constructed to the
same standards as specified for sidewalks.
♦ 12-3 ♦
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18 The tolerances for sidewalk, drive way and median
paving construction shall be plus or minus six (6)
millimeters from the designed grade elevation.
12.1.4.4 Bedded and Interlocking Block Paving
1 Bedded block paving shall be bedded in mortar and
laid to the pattern shown on the Drawings or directed by
the Engineer. A bed of stiff mortar should be spread and
leveled. Blocks shall be individually laid and hammered
down so that tops are level, leaving joints open. Joints
shall be carefully and thoroughly filled flush with the
surface of the blocks using mortar of stiff plastic
consistency. Finishing shall be neat and cleaned of any
mortar from the face of blocks before it sets. Joint widths
in stone block paving are to be a nominal 10 mm.
2 Interlocking block paving shall be laid and bedded in
accordance with the Drawings. Unless otherwise specified,
paving shall not be commenced until adjacent curbs,
edgings and channels have been installed and sufficiently
matured. Blocks shall be laid to the required pattern on the
sand bed and thoroughly compact with a vibrating plate
compactor as the work proceeds. After infilling at the
restraining edges; the same compacting effort shall be
applied over all areas, avoiding damage to edges and
adjacent work. Compaction shall not be conducted within
1 m of any working face. Un-compacted areas of paving
shall not be left at the end of working periods, except
within 1m distance of an unrestrained edge. Compacted
paving shall be checked initially and at frequent intervals
to ensure surface levels are correct. Where unsatisfactory,
blocks shall be lifted, the bedding adjusted and blocks re-
laid as necessary. Dry bedding sand shall be brushed into
the joints, followed by the re-vibration of the surfaces.
This shall be repeated until all joints are completely filled.
12.1.4.5 Cast In-situ Concrete Paving/Curbing
1 In situ concrete paving and curbing, where directed
by the Engineer, shall conform to the appropriate
requirements of Section 5.
2 Forms shall be of metal, wood, or other suitable
material and shall extend for the full depth of the concrete.
All forms shall be geometrically accurate, free from warp,
and of sufficient strength to resist the pressure of the
concrete without displacement. Bracing and staking of
forms shall be such that the forms remain in both
horizontal and vertical alignment until their removal. All
forms shall be cleaned and oiled before concrete is placed
against them.
3 Mixing and Placing Concrete. The foundation shall be
thoroughly moistened immediately prior to the placing of
the concrete. The proportioning and mixing of the
concrete shall be in accordance with the requirements for
the class of concrete specified. The concrete shall be
deposited in one course in such a manner as to prevent
segregation and consolidation by vibrators.
4 The surface of paving shall be finished with a
wooden float and light brooming. No plastering of the
surface will be permitted. All outside edges of the slab and
♦ 12-4 ♦
all joints shall be edges with a five (5) millimeter radius
edging tool.
5 Expansion joints for paving shall be in the locations
and of the dimensions specified, and shall be filled with
approved pre-molded expansion joint filler. Sidewalks
shall be divided into sections by weakened plane joints
formed by a jointing tool or other acceptable means as
directed. These joints shall extend into the concrete for
about one fourth (¼) to one fifth (1/5) of the depth and
shall be approximately three (3) millimeters wide. Joints
shall match as nearly as possible adjacent joints in curb or
pavements. Weakened plane joints may be sawed in lieu
of forming with a jointing tool.
6 Construction joints in paving shall be formed around
all appurtenances such as manholes, utility poles, etc,
extending into and through the sidewalk, drive way, or
median. Pre-molded expansion joint filler one (1)
centimeter thick shall be installed in these joints.
Expansion joint filler of the thickness indicated shall be
installed between concrete construction and any fixed
structure such as a building or bridge. This expansion joint
material shall extend for the full depth of the concrete
construction.
7 Concrete shall be cured by membrane or water in
accordance with Section 5, ‘Curing and Protection’.
12.1.5 Method of Measurement
1 Precast concrete tiled paving, concrete and clay block
paving and natural stone paving shall each be measured
separately by the square meter for each type, authorized,
completed, and accepted by the Engineer based on the
horizontal dimensions shown on the Drawings or ordered
by the Engineer.
2 In-situ concrete paving, where specifically instructed
by the Engineer, shall be measured by the square meter of
the area shown or instructed, stating the thickness. In-situ
concrete paving for irregular shapes or in locations where
other paving types are used, will not be measured
separately but will be deemed to be included in the area of
the adjacent paving.
3 In-situ concrete curbs, where specifically instructed
by the Engineer, shall be measured by the linear meter of
completed and accepted work.
4 Precast concrete curbs of each type, including all
blinding and haunching, shall be measured by linear
meters. Depressed curbs at driveway entrances and the
like will not be measured separately but will be included
as a normal length of standard curb as specified.
5 Excavation for paving and curb shall not be
measured separately for payment but will be considered
as subsidiary work, except when such excavation is a part
of, and is measured in conjunction with, the roadway
excavation. In such instances, the excavation shall be
measured and included in the quantity of roadway
excavation as per Section 2.
6 Preparation of sub-grade, supply, transport and laying
sub-base and bedding courses, concrete bases incidental
copy 249
to curbs and the like, finishing, cleaning and protecting
paving, and tests on materials shall not be measured
separately but shall be considered subsidiary work, the
cost of which is deemed to be included in the rates stated
in the Bill of Quantities for the relevant items.

12.1.6 Basis of Payment

1 The completed and accepted work, as measured
above, will be paid for at the unit rates in the Bill of
Quantities, which shall be full compensation for supply,
transport and installation of all required materials,
equipment, tools, labor, and all other items necessary for
the proper completion of the Work as specified.

12.1.7 Items in the Bill of Quantities

1 Payment for the work will be made under one or
more of the following items:
i. Precast concrete tile paving (type) (sq.m.)
ii. Block paving (type) (sq.m.)
iii. Natural stone paving (type) (sq.m.)
iv. Cast in-situ concrete paving (type;
thickness) (sq.m.)
v. Precast concrete curb (type) (lin.m.)
vi. Cast in situ concrete curb (type) (lin.m.)

♦ 12-5 ♦
copy 249
copy 249
Ref. Title Page No.
13.1 Roadside Barriers 13-1
13.1.1 Description 13-1
13.1.2 References 13-1
13.1.3 Materials 13-1
13.1.3.1 Metal Components 13-1
13.1.3.2 Concrete Components 13-2
13.1.3.3 Delineators 13-2
13.1.3.4 Other Materials 13-2
13.1.4 Construction and Installation
Requirements 13-2
13.1.4.1 Metal Guardrails 13-2
13.1.4.2 Concrete Barriers 13-3
13.1.4.3 Impact Attenuators 13-3
13.1.5 Method of Measurement 13-4
13.1.6 Basis of Payment 13-4
13.1.7 Items in the bill of Quantities 13-4

13.2 Fence 13-4

13.2.1 Description 13-4
13.2.2 References 13-4
13.2.3 Materials 13-5
13.2.4 Construction and Installation
Requirements 13-5
13.2.5 Method of Measurement 13-6
13.2.6 Basis of Payment 13-6
13.2.7 Items in the Bill of Quantities 13-6

♦ 13-0 ♦
copy 249
copy 249
13.1 Roadside Barriers
13.1.1 Description
1 This Sub-section describes roadside barriers and
fences, including crashworthy metal beam, concrete
barriers and other safety barriers, barrier terminals, and
portable and permanent impact attenuators. This Sub-
section applies also to reinstallation/retrofitting of metal
beam guardrail, concrete barriers and guardrail terminals,
impact attenuators and steel safety railings.
13.1.2 References
1 American Association of State Highway and
Transportation Officials (AASHTO)
AASHTO M160 Standard Specification for General
Requirements for Steel Plates, Shapes,
Sheet Piling, and Bars for Structural
Use.
AASHTO M180 Standard Specification for Corrugated
Sheet Steel Beams for Highway
Guardrail
AASHTO M237 Standard Specification for Epoxy-Resin
Adhesives for Bonding Traffic Markers
to Hardened Portland Cement and
Asphalt Concrete
2 American Society For Testing and Material
ASTM A36 Standard Specification for Carbon
Structural Steel
ASTM A653M Standard Specification for Steel Sheet,
Zinc-Coated (Galvanized) or Zinc-Iron
Alloy-Coated (Galvannealed) by the
Hot-Dip Process.
ASTM A576 Standard Specification for Steel Bars,
Carbon, Hot-Wrought, Special Quality
ASTM A449 Standard Specification for Hex Cap
Screws, Bolts and Studs, Steel, Heat
Treated, 120/105/90 ksi Minimum
Tensile Strength, General Use
ASTM A325 Standard Specification for Structural
Bolts, Steel, Heat Treated, 120/105 ksi
Minimum Tensile Strength.
ASTM A563 Standard Specification for Carbon and
Alloy Steel Nuts
ASTM A123M Standard Specification for Zinc (Hot-
Dip Galvanized) Coatings on Iron and
Steel Products
ASTM A153M Standard Specification for Zinc Coating
(Hot-Dip) on Iron and Steel Hardware
ASTM A413M Standard Specification for Carbon Steel
Chain
13.1.3 Materials
13.1.3.1 Metal Components
1 Metal beams, guardrail elements and backup plates
for W-beam or Thrie-beam rail shall conform to the
requirements of AASHTO M180, Class A, Type 2.
Galvanized rail elements shall be designed to be
spliced at intervals not to exceed either four (4) or
eight (8) meters and such splices shall be made at
posts, unless otherwise shown on the Drawings. Rail
elements to be erected on a radius of forty-five (45)
meters or less shall be shaped in the shop and the
radius of curvature shall be stenciled on the back of
each section of rail.
2 Posts and miscellaneous barrier rail hardware; unless
otherwise indicated on the Drawings, all steel posts,
plates, angles, channels, brackets, and anchor
assembly units shall conform to the requirements of
ASTM A 36. Cold rolled post sections shall conform
to the requirements of ASTM A 653M, Grade B.
3 Swage fittings for anchor terminals shall be
machined from hot-rolled carbon steel conforming
to the requirements of ASTM A 576, Grade 1035, and
shall be annealed suitable for cold swaging. A lock
pin hole shall be drilled through the swage fitting
head to accommodate a seven (7) millimeter, plated,
spring steel pin to retain the stud in position. The
stud shall be steel conforming to the requirements of
ASTM A 449. Prior to galvanizing, a ten (10)
millimeter slot for the locking pin shall be milled into
the stud end. The swage fitting, stud, and nut shall
develop the full breaking strength of the wire cable.
4 All bolts shall conform to the requirements of ASTM
A 307, except those designated on the Drawings as
high strength shall conform to the requirements of
ASTM A 325 or A 449. All nuts shall conform to the
requirements of ASTM A 563M, Grade A or better,
except those designated on the Drawings as high
strength shall conform to the requirements of ASTM
A 563M, Grade C or better.
5 Galvanizing for all ferrous materials for guardrail,
guardrail anchor terminals, impact attenuators, glare
screens, and delineators shall be galvanized after
fabrication unless otherwise specified. Galvanization
shall be in accordance with ASTM A 123M or ASTM
A 153M as appropriate.
6 All components shall be fabricated and galvanized
for installation without further drilling, bending,
cutting or welding. When field modifications are
approved by the Engineer, or when minor damage to
the galvanized coating occurs, the exposed surface
shall be repaired by thoroughly cleaning and
applying two (2) applications of paint as specified in
Section 7, Clause 7.2.6, "Zinc Dust-Zinc Oxide
Primer."
7 Impact Attenuators:-
i. Rail elements for Thrie beam rail (used in Guard
Rail Energy Absorbing Terminal - G.R.E.A.T.
♦ 13-1 ♦
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 Impact Attenuators) shall conform to AASHTO
M180, Class B, Type galvanized. Rail element
joints shall be fabricated to lap not less than
thirty (30) centimeters and be bolted. The rail
metal, in addition to conforming to the
requirements of AASHTO M 180, shall withstand
a cold bend, without cracking, of two hundred
(200) grads around a mandrel of a diameter
equal to two and one half (2½) times the
thickness of the sheet metal plate.
ii. Restraining chains for G.R.E.A.T. impact
attenuators shall be twelve (12) millimeter
nominal size and shall conform to the
requirements of ASTM A 413M, Grade 28.
iii. QuadGuard metal work shall be fabricated from
either M1020 Merchant Quality or ASTM A-36
steel. After fabrication, metal work shall be
galvanized in accordance with ASTM A-123M. All
welding shall be done by or under the direction
of a certified welder.
iv. The QuadGuard system shall be assembled with
galvanized fasteners. All bolts, nuts and washers
shall be Commercial Quality “American National
Standard” unless otherwise specified.
v. The QuadGuard diaphragms shall be made from
10 gauge steel Quad-beam sections. The
diaphragms shall be available in widths of 610,
760 and 910 mm [2', 2'-6" and 3']. Two support
legs shall be welded to the Quad-beam. Ski-
shaped plates shall be welded to the bottom of
the support legs. The diaphragms shall be
designed to lock onto and be guided by a
ground-mounted, center monorail support
structure.
vi. The QuadGuard fender panels shall be fabricated
from 10 gauge steel Quad-beam sections. Each
fender panel shall be drilled and slotted in
accordance with the manufacturer’s
specifications so that when assembled in the
field, the front end shall be bolted to a
diaphragm by means of the three (3) 15.9 mm
(5/8") bolts.
vii. Impact attenuation devices with cartridges filled
with liquids, such as antifreeze agents, that may
become a skid hazard when impacted, shall not
be used; replaceable cartridges with foam-filled
cardboard, lightweight concrete and similar
materials will be acceptable. All units shall be
identified by identification labels fastened at a
protected but conspicuous location.
13.1.3.2 Concrete Components
1 Concrete for post supports, buried footings, and
anchors and for concrete barriers and terminal sections
shall conform to the requirements for concrete as
described in Section 5. Types and strength of concrete
shall be as stated on the Drawings and in the Special
Specification.
♦ 13-2 ♦
2 Reinforcing steel shall be of the size and grade
shown on the Drawings and shall conform to the
provisions of Sections related to "Reinforcing Steel" in
Section 5 of these Standard Specifications.
13.1.3.3 Barrier Reflectors
1 Guardrail Reflectors: Metal W-beam and Thrie-beam
guardrail reflectors and associated hardware shall
conform to the requirements of the Drawings, Special
Specifications and M.U.T.C.D. (Manual of Uniform Traffic
Control Devices). When shown on the Drawings or stated
in the Special Specifications, reflective sheeting shall be
fixed to the approach ends of metal beam guardrail
terminals and be Type IV (microprismatic) high intensity
retro-reflective sheeting.
2 Concrete barrier reflectors shall conform to the
requirements of the Drawings, Special Specifications, and
M.U.T.C.D. Epoxy resin adhesives for bonding delineators
to hardened Portland cement concrete shall conform to
AASHTO M 237.
13.1.3.4 Other Materials
1 Other Materials: Other materials shall be as shown
in the Drawings, stated in the Special Specifications or in
the U.S. American Road Builders Transportation
Association (ARBTA) Bulletin No. 268 "A Guide to
Standardized Highway Barrier Rail Hardware.” Special
materials for impact attenuators shall be as specified by
the manufacturer.
13.1.4 Construction and Installation
Requirements
13.1.4.1 Metal Guardrails
1 Metal W-beam and Thrie-beam guardrail. shall be
installed at the locations shown on the Drawings or as
ordered by the Engineer. Posts shall be installed by
driving plumb to the required grades or set in concrete as
shown or directed by the Engineer. When the pavement is
within one (1) meter of the guardrail, the posts shall,
unless otherwise directed by the Engineer, be set before
placing the pavement.
2 If ground conditions are such that pilot holes are
necessary to prevent damage to posts during driving, all
space around steel posts after driving shall be filled with
dry sand or fine gravel.
3 When posts are set in concrete, the concrete shall be
placed against the excavated earth unless otherwise
permitted.
4 Continuous lengths of rail or cable shall be installed
and alignment checked and adjusted before final
tightening of bolts, etc. Unless otherwise specified, bolted
connections shall be torque to six (6) to seven (7)
kilogram-meters. Bolts that extend at least six (6)
millimeters but not more than twenty-five (25) millimeters
beyond the nuts shall be used. Rail elements shall be
erected in a smooth continuous line with the laps in the
direction of traffic flow.
copy 249
5 Posts may be erected by driving with approved
mechanical devices. The method of driving shall not
substantially alter the cross-sectional dimensions of the
posts or materially damage the galvanization / coating.
Battered tops shall not be accepted. Posts which, in the
opinion of the Engineer, are bent or otherwise damaged
during or after erection, shall be removed and replaced at
the Contractor’s expense.
6 Damaged galvanized surfaces may be repaired, only
if so approved by the Engineer. Such surfaces shall be
repaired by thoroughly wire brushing and then applying
two coats of primer in accordance with Section 7, Clause
7.2.6.
7 Guardrail anchor terminals shall be installed at the
locations shown on the plans or ordered by the Engineer
all in accordance with the Drawings and Special
Specifications.
13.1.4.2 Concrete Barriers
1 Construction of concrete barriers and terminal
sections shall conform to the Drawings and Special
Specification. Concrete barriers shall present a smooth,
uniform appearance in their final position, conforming to
the horizontal and vertical lines shown on the Drawings or
as ordered by the Engineer, and shall be free of lumps,
sags, or other irregularities. The top and exposed faces of
the barrier shall not vary more than more than six (6)
millimeters between any two (2) contact points when
tested with a four (4) meter straightedge laid on the
surfaces. Transverse expansion joints of one (1)
centimeter thick pre-molded filler shall be provided in all
concrete barriers at spacing not exceeding fifteen (15)
meters center to center. All transverse expansion joints
will be weather sealed with a smooth and uniform bead of
durable sealant approved by the Engineer.
2 Concrete barriers may be precast, cast-in-place with
fixed forms, or extruded with slip forms at the Contractor's
option and approval of the Engineer. Concrete barriers
constructed by casting-in-place with fixed forms shall
conform to the provisions of Section 5. Concrete shall be
Class 25 as per Paragraph 5.1.3.4.
3 Concrete barriers constructed by means of an
extrusion machine or other similar type equipment shall
be of thoroughly consolidated concrete, and the exposed
surfaces shall conform to the requirements of Section 5.
The Contractor shall furnish evidence of successful
operation of the extrusion machine or other equipment by
constructing a trial section of barrier or by other evidence
suitable to the Engineer. Concrete shall be fed to the
extrusion machine at a uniform rate. The machine shall be
operated under sufficient uniform restraint to forward
motion to produce a thoroughly consolidated mass of
concrete free from surface pits larger than two (2)
centimeters in diameter and requiring no further finishing.
The concrete shall be of such consistency that, after
extrusion, it will maintain the shape of the barrier without
support. The grade for the top of the concrete barrier shall
be indicated by an offset guide line set by the Contractor
and approved by the Engineer.
4 The forming portion of the extrusion machine shall
be readily adjustable vertically during the forward motion
of the machine to conform to the predetermined grade
line. A grade line gauge or pointer shall be attached to the
machine in such a manner that a continual comparison
can be made between the barrier being placed and the
established grade line as indicated by the offset guide line.
Other means of controlling barrier grade may be
permitted by the Engineer. Expansion joints of the width
shown on the plans shall be constructed by sawing
through the barrier section to its full width. If sawing is
performed before the concrete has hardened, the adjacent
portions of the barrier shall be firmly supported with close
fitting shields. When sawing is performed after the
application of curing compound, the exposed faces of the
barrier in the vicinity of the joint shall be treated with
curing compound after sawing the joint.
5 If stationary forms for concrete barriers are used,
they shall be removed as soon as possible after the
concrete has set enough to maintain the shape of the
barrier without support in order to facilitate finishing. The
surface shall be free from pits larger than one (1)
centimeter in diameter. The surface shall be given a final
soft brush finish with strokes parallel to the line of the
barriers. Finishing with a brush application of grout will
not be permitted. Surfaces shall be finished as necessary
to produce smooth, even surfaces of uniform texture and
appearance, free from bulges, depressions, and other
imperfections. The use of power sanders, carborundum
stones, or disks may be required to remove bulges or
other imperfections.
6 Exposed surfaces of concrete barriers shall be cured
by the "water method" in accordance with the provisions
of “curing and protection" in Section 5 Paragraph 5.3.3.12.
The Engineer may permit the concrete barriers to be cured
by use of "curing compound" in accordance with the
provisions of Section 5, Paragraph 5.3.3.12 of these
Standard Specifications.
13.1.4.3 Impact Attenuators
1 G.R.E.A.T. system and other impact attenuators shall
be installed in accordance with the requirements
/recommendations / instructions provided by the
manufacturers and all to the approval and satisfaction of
the Engineer. A copy of these recommendations and
instructions shall be furnished to the Engineer upon
delivery of the materials.
2 The QuadGuard System shall consist of crushable
cartridges surrounded by a framework of steel Quad-beam
guardrail which can telescope rearward during head-on
impacts. The QuadGuard System shall have a center
monorail which will resist lateral movement during side
angle impacts. The nose shall consist of a formed plastic
nose wrap.
3 A bay describes a section of the QuadGuard System
consisting of a cartridge, a diaphragm and two fender
♦ 13-3 ♦
copy 249
panels. Each bay shall be fitted with an energy absorbing 6 Guardrail and concrete barrier reflectors shall not be
cartridge. The outside of the cartridge shall be fabricated measured for separate payment. Their installation will be
from a weather resistant plastic. The front portion of the considered subsidiary to the construction of the guardrail
system shall be fitted with Type I cartridges. The rear or concrete barriers.
portion of the system shall be fitted with Type II cartridges. 7 Terminals, terminal end sections, and impact
All cartridges shall include a cartridge replacement attenuators shall be measured by the unit for each type
indicator. authorized, completed and accepted by the Engineer,
4 The rear end of each Quad-beam fender panel shall based on the number of units shown on the Drawings or
overlap and be connected to the diaphragm of the next ordered by the Engineer.
bay by means of a bolt and enlarged “mushroom” washer.
The bolt fits through the long horizontal slot in the forward 13.1.6 Basis of Payment
fender panel. This permits the movement, front to back, of
1 The completed and accepted work, as measured
one set of fender panels relative to the panels in the
above, will be paid for at the contract unit rates in the Bill
underlying-rearward bay. The back portion of each fender
of Quantities. There will be no separate payment for posts.
panel shall be tapered to help maximize performance
Payments in accordance with the unit rates shall be full
during wrong-way, re-directive impacts.
compensation for all required materials, transport,
5 The monorail support structure shall be made of equipment, tools, labor, and all other items necessary for
steel and be anchored to a specified concrete pad. The the proper completion of the work.
monorail shall prevent lateral movement, vertical
movement and overturning movement of the diaphragms
13.1.7 Items in the Bill of Quantities
during design impacts.
6 The nose section shall contain a nose cover and a 1 Payment for the work will be made under one or
crushable cartridge and is not counted as a bay. The nose more of the following items:
cover shall be made from a plastic material formulated to
resist weathering. The nose shall attach to the front (i) W-Beam G/rail, standard section (type) (lin.m.)
diaphragm. Standard colors shall be gray or yellow. (ii) W-Beam G/rail, transition section (type) (lin.m.)
(iii) W-Beam G/rail, terminal (end type) (nr.)
(iv) Thrie Beam G/rail, standard section (lin.m.)
13.1.5 Method of Measurement
(v) Thrie Beam G/rail transition
1 Guardrails of each type and, reinstallation of section (type) (lin.m.)
guardrails, are each measured by the linear meter along (vi) Thrie Beam G/rail, terminal( end type) (nr.)
the front face, excluding terminal sections. Measurement (vii) Concrete Barrier, single face (type) (lin.m.)
shall be based on the dimensions as shown on the (viii) Concrete Barrier, double face(type) (lin.m.)
Drawings or ordered by the Engineer. (ix) Concrete Barrier, transition
2 No separate measurement is made for posts, blocks, Section (type) (nr.)
plates, splices, bolts , nuts, screws, studs and other fixing (x) Impact Attenuator (type) (nr.)
accessories nor for excavation and concrete post bases, all (xi) Guardrail Re-installation (type) (lin.m.)
of which work is considered as subsidiary to the guardrail
and their cost is deemed to be included in the rates for 13.2 Fences
guardrail.
3 Guardrail transition sections, including hardware 13.2.1 Description
necessary to meet the requirements of the installation,
1 This Sub-section describes furnishing and installing
shall be measured separately only when the transition
fences, gates, and guards in accordance with the Drawings
section is shown on the Drawings and listed in the Bill of
and Special Specification, at the locations and to the lines
Quantities. Otherwise such work shall be considered
and grades shown on the plans or ordered by the
subsidiary to the standard guardrail section.
Engineer. The work shall include all foundation or/ and
4 Concrete barriers of each type are measured by additions needed to have a fully operational system.
linear meters, based on the dimensions shown on the
Drawings or ordered by the Engineer
13.2.2 References
5 No separate measurement is made for the barrier
base, reinforcement bars, dowel bars or concrete filling, 1 American Society For Testing and Material
Excavation for the concrete barriers shall not be measured ASTM A 392 Specification for Zinc-Coated Steel
separately but will be considered as subsidiary work Chain Link Fence Fabric
except when such excavation is part of and is measured in
conjunction with the roadway excavation. In such ASTM A 53M -07 Standard Specification for Pipe, Steel,
instances, the barrier excavation shall be measured and Black and Hot-Dipped, Zinc-Coated,
included in the quantity of unclassified excavation as Welded and Seamless
provided for in Section 2.

♦ 13-4 ♦
copy 249
ASTM A501 - 07 Standard Specification for Hot-Formed
Welded and Seamless Carbon Steel
Structural Tubing
ASTM A618M - 04 Standard Specification for Hot-Formed
Welded and Seamless High-Strength
Low-Alloy Structural Tubing
ASTM A123M-09 Standard Specification for Zinc (Hot-
Dip Galvanized) Coatings on Iron and
Steel Products
ASTM A153M-09 Standard Specification for Zinc Coating
(Hot-Dip) on Iron and Steel Hardware
2 British Standards
BS 4360 HR Steel for general engineering purposes
13.2.3 Materials
1 Chain Link Fence. Chain link fabric shall conform to
ASTM A 392 (galvanized). Mesh size shall be fifty (50)
millimeters nominal, and wire size shall be three and
seventy-six hundredths (3.76) millimeters diameter (No. 9
American Wire Gauge, AWG) before galvanizing. If
required by the Drawings or Special Specification, fabric
shall be plastic coated.
2 Tension wire for chain link fence and industrial fence
shall be a minimum of four and five tenths (4.5)
millimeters diameter. Tension wire for other fences shall
be of the minimum diameter shown on the Drawings.
3 Posts and Braces. Circular steel posts and braces
shall be galvanized, conforming to ASTM A 53M-07,
Schedule 40 and shall be of the dimensions shown on
the Drawings. At the option of the Contractor, alternate
galvanized steel shapes having the minimum equivalent
bending strength in both directions may be substituted for
circular posts and braces.
4 Rectangular hollow sections shall conform to ASTM
A 501, BS 4360 Grade 43C.
5 End corner posts, straining posts and line posts,
along with braces and stretcher bars thereof, shall be of
the sizes and dimensions indicated in the Drawings. Line
posts shall be spaced at three (3.0) meters on centers
maximum, unless otherwise directed by the Engineer.
Gate posts shall conform to the requirements of this
specification and shall be of the sizes and dimensions
shown on the Drawings.
6 Post tops shall be pressed steel, wrought iron,
malleable iron, or plastic caps to manufacturer’s standard
as approved by the Engineer, designated as a weather
tight closure cap for each post.
7 Posts and braces for high tension wire fence shall
conform to ASTM A 618M-04, Grade 1.0 Material shall be
of the shapes and dimensions shown on the Drawings and
shall be galvanized in accordance with ASTM A 123M-09.
8 All miscellaneous hardware shall conform to the
requirements shown on the plans, and shall be galvanized
in accordance with ASTM A153M-09.
9 Tie wire shall conform to ASTM A112 (withdrawn
1990 with no replacement), and shall be minimum three
and five tenths (3.5) millimeters diameter unless otherwise
shown.
10 Concrete for setting posts shall conform to the
requirements of Section 5, Sub-section 5.1.3.4.
11 Reinforcing steel shall be of the size and grade
shown on the plans and shall conform to Section 5, Sub-
section 5.2
12 Materials for gates shall be of the sizes, dimensions
and types indicated in the Drawings.
13 Gate perimeter frames shall be fabricated of tubular
members. Additional horizontal and vertical members
shall be provided to ensure proper gate operation and for
attachment of fabric, hardware and accessories. Space so
that frame members are not more than two and forty five
hundredths (2.45) meters apart.
14 Gate frames shall be assembled by welding or with
special malleable or pressed steel fittings and rivets for
rigid connections. Same fabric as for the fence shall be
used, unless otherwise directed by the Engineer. Fabric
shall be installed with stretcher bars at vertical edges. Bars
may also be used at top and bottom edges. Attach
stretchers to gate frame at not more than three hundred
eighty (380) mm on centers. Attach hardware with rivets
or by other means which will provide security against
removal or breakage.
15 Diagonal cross-bracing consisting of ten (10) mm
diameter adjustable length truss rods shall be installed on
gates, where necessary to ensure frame rigidity without
sag or twist, as approved by the Engineer.
13.2.4 Construction and Installation
Requirements
1 The Contractor shall stake all sections of fence as
shown on the Drawings or ordered by the Engineer prior
to beginning work. Top elevations of all posts shall be
computed to follow a smooth grade with curves at
transitions. Cutting the tops from posts after installation
shall not be permitted. The required line of the fence shall
be cleared of all obstacles and debris which would
interfere with the line of the fence. Minor grading may be
required to achieve a smooth line.
2 Posts shall be set plumb to the required line and
grade in concrete footings. No wire or fabric shall be
strung taut until line posts have been set for at least one
(1) day and corner posts for at least three (3) days. In
sandy areas or other areas of poor soil support, the
Contractor shall enlarge the footings as required by the
Engineer to maintain adequate fence tension.
3 Wire or fabric shall be strung uniformly at the
required tension and attached to corner posts and brace
posts before permanently attaching to line posts. Any
significant sags or de-tensioning which occurs after
installation shall be corrected by the Contractor.
♦ 13-5 ♦
copy 249
4 When fencing crosses ravines or other discontinuities
in the terrain causing gaps under the fence, the Contractor,
if so ordered by the Engineer, shall modify the installation
to the extent practical by adding strands or additional
fabric so as to provide the required access control without
interfering with drainage.
5 Galvanized gates or fencing materials which are
constructed or repaired by welding, cutting, or other work
which damages the coating shall be repaired by grinding
smooth all damaged surfaces and painting with two (2)
coats of paint specified in Section 7, Clause 7.2.6, "Zinc
Dust-Zinc Oxide Primer" .
6 The materials incorporated into the fences and gates
shall be sampled, tested and evaluated in accordance with
the standards stated in Clause 13.2.2, all to the approval
and acceptance of the Engineer. The Contractor shall
adjust, redo or complement any test result ordered by the
Engineer.

13.2.5 Method of Measurement

1 Each type of fence is measured by the linear meter,
based on the horizontal length shown on the Drawings or
ordered by the Engineer. Measurement shall be from
center to center of end or corner posts. Gates and other
gaps shall be deducted from the total length.
2 Gates shall be measured by the square meter for
each type, based on the nominal height of the gate
multiplied by the required distance between the adjacent
fence end/gate support posts.
3 No separate measurement shall be made for
excavation, backfill, grading, concrete footings /
foundations, or for any other material and work required,
all of which shall be considered subsidiary to fence or gate,
and whose costs are deemed to be included in the rates
for these items.

13.2.6 Basis of Payment

1 The amount of completed and accepted work as
measured above will be paid at the contract unit rates
specified in the Bill of Quantities, which rates shall be full
compensation for furnishing all materials, for all labor,
transport, installation, equipment, tools, supplies, and all
other items necessary for the proper completion of the
Work.

13.2.7 Items in the Bill of Quantities

1 Payment for the work will be made under one or
more of the following items:

(i) Chain Link Fence (type)(height) (lin.m.)

(ii) Pedestrian/Animal Fencing
(type) (height) (lin.m.)
(iii) Wire Fence(type) (height) (lin.m.)
(iv) Sand Dune Fence (type) (lin.m.)
(v) Gate (type) (sq.m.)

♦ 13-6 ♦
copy 249
Ref. Title Page No. Ref. Title Page No.
14.1  Traffic Signs 14-1  14.1.4.4  Sign Faces for Permanent Traffic
Signs 14-4 
14.1.1 Description 14-1 
14.1.4.5  Manufacture and Assembly of
14.1.2 General 14-1
Permanent Traffic Signs 14-4 
14.1.2.1  Standards 14-1 
14.1.4.6  Location and Erection of Permanent
14.1.3 Materials 14-1
Traffic Signs 14-4 
14.1.3.1  References 14-1 
14.1.4.7  Covering of Permanent Traffic Signs 14-5 
14.1.3.2  Sign Classification 14-1 
14.1.4.8  Temporary Traffic Signs 14-5 
14.1.3.3  General Requirements for Permanent
14.1.5 Method of Measurement 14-5
Traffic Signs 14-1 
14.1.6 Basis of Payment 14-5
14.1.3.4  Posts for Permanent Traffic Signs 14-1 
14.1.7 Items in the BilI of Quantities 14-5 
14.1.3.5  Foundations for Permanent Traffic
Signs and Signals 14-2  14.2  Road Markings 14-5 
14.1.3.6  Sign Plates for Permanent Traffic
14.2.1 Description 14-5
Signs 14-2 
14.2.2 Materials 14-5
14.1.3.7  Sign Faces for Permanent Traffic
14.2.2.1  Thermoplastic Material 14-5 
Signs 14-2 
14.2.2.2  Liquid Paint 14-7 
14.1.3.8  Manufacture and Assembly of
14.2.2.3  Testing 14-8 
Permanent Traffic Signs 14-2 
14.2.2.4  Painting of curbs 14-8 
14.1.3.9  Covering of Permanent Traffic Signs 14-2 
14.2.3 Construction Requirements 14-8 
14.1.3.10  Depth and Marker Posts
14.2.3.1  Raised Rib (Profiled) Road Markings 14-9 
(for Floodways) 14-2 
14.2.3.2  Temporary Road Markings 14-9 
14.1.3.11  Kilometer Posts (5km spacing) and
14.2.3.3  Removal of Road Markings 14-9 
Kilometer Reference Posts
14.2.3.4  Masking of Road Markings 14-9 
(1km spacing) 14-2 
14.2.3.5  Longitudinal Road Markings Lateral
14.1.3.12  Delineator Posts (for edge of
Tolerances 14-9 
carriageway or right-of-way marking) 14-3 
14.2.4 Method of Measurement 14-9 
14.1.3.13  Traffic Signs on Cantilevers
14.2.5 Basis of Payment 14-9 
and Gantries 14-3 
14.2.6 Items in the Bill of Quantities 14-9 
14.1.3.14  Preparation and Finish of Metal
and Other Surfaces 14-3  14.3  Road Studs 14-9 
14.1.3.15  Traffic Cones 14-3 
14.3.1 Description 14-9 
14.1.3.16  Flashing Beacons 14-3 
14.3.2 Materials 14-10 
14.1.3.17  Temporary Traffic Signs 14-3 
14.3.2.1  Permanent Retroreflecting
14.1.4 Construction Requirements 14-3 
Road Studs 14-10 
14.1.4.1  Posts for Permanent Traffic Signs 14-3 
14.3.2.2  Temporary Retroreflecting
14.1.4.2  Foundations for Permanent Traffic
Road Studs 14-10 
Signs and Signals 14-3 
14.3.2.3  Ceramic Buttons 14-10 
14.1.4.3  Sign Plates for Permanent
14.3.3 Construction Requirements 14-10
Traffic Signs 14-3 

copy 249
Ref. Title Page No.
14.3.3.1  Permanent Retroreflecting
Road Studs 14-10 
14.3.3.2  Temporary Retroreflecting
Road Studs 14-10 
14.3.3.3  Non retroreflecting Road Studs 14-10 
14.3.4 Method of Measurement 14-10
14.3.5 Basis of Payment 14-10
14.3.6 Items in the Bill of Quantities 14-10

copy 249
14.1 Traffic Signs
14.1.1 Description
1 This Sub-section describes requirements for supply
and erection of sign assemblies, comprising posts, clips,
post caps, gantries, sign faces and foundations.
14.1.2 General
14.1.2.1 Standards
1 All traffic signs, whether permanent or temporary,
shall be of the size, shape, color and type described in the
Highway Design Standard, Section 19, unless otherwise
approved by The Engineer. Signs that are not described in
the Highway Design Standard must be specially approved
by the Employer and the Engineer. Where the use of
temporary traffic signs is proposed, the Contractor shall
obtain the approval of the Engineer and the agreement of
the ROP and the Concerned Authority for the use of the
signs at the locations proposed.
2 Signs that are changeable by means other than
manual operation require approval of their construction
and operating mechanisms by the Engineer. This
requirement is in addition to the need for the design of the
sign to be described in the Highway Design Standards or
otherwise approved by the Employer.
14.1.3 Materials
14.1.3.1 References
1 BD 94/07 Design of Minor Structures (UK Design
Manual for Roads and Bridges).
2 BS EN 12899 Part 1 Fixed Vertical Road Traffic Signs.
3 BS 8408 Road Traffic Signs - Specification for
Microprismatic Sheeting Materials.
4 EN 1993 Design of Steel Structures.
5 EN 1999 Design of Aluminium Structures.
6 BS EN 13422 includes Cones and cylinders.
7 BS EN 12352 includes Flashing Beacons.
14.1.3.2 Sign Classification
1 The following classifications of signs apply:
i. Permanent Traffic Signs:-
Traffic signs described in the Highway Design
Standard, or specially approved by the
Employer, designed to remain in position at the
completion of the Permanent Works.
ii. Temporary Traffic Signs :-
a) Traffic signs defined in the Highway Design
Standards that comply with all the
requirements of a permanent traffic sign,
but which will not remain in position at the
completion of the Permanent Works
b) Traffic signs designed by the Contractor and
specially approved but which will not
remain in position at the completion of the
Permanent Works.
14.1.3.3 General Requirements for Permanent Traffic
Signs
1 Permanent traffic sign materials, construction,
assembly, test, location and erection shall comply with BS
EN 12899 where applicable and the requirements shown
on the Drawings or Schedules.
2 The sign plate shall be manufactured using 3mm
thick alloy aluminium sheet stiffened with alloy aluminium
rails or galvanized steel frame and designed to accept the
fastening clips. The sign face material shall be retro-
reflective sheeting applied to the aluminium sheet in
accordance with the manufacturer’s instructions. The
supporting posts may be galvanized steel or alloy
aluminium, as approved by the Engineer, specifically
designed to cope with the wind conditions of the location.
The sign plate shall be fixed to the post with stainless steel
clips and fasteners that do not pierce the face of the sign.
The posts shall be fixed to the concrete foundation as
described in Paragraph 14.1.3.5 of this specification.
3 Before the commencement of manufacture the
Contractor shall submit for the approval of The Engineer
three copies of:
i. a detailed schedule (including location) of all
traffic signs.
ii. fabrication and sign face drawings for
‘directional’ signs and ‘informative’ signs.
iii. fabrication and sign face drawings for any gantry
mounted signs.
iv. fabrication and sign face drawings for any
illuminated signs.
4 The back of each traffic sign shall have an indelible
label showing manufacturer, year of erection, sheeting
material class, sign face product. The text for the label
shall be in English and Arabic with a character height of 5
to 10mm.
5 Traffic signs shall be carefully handled at all times to
prevent damage and transported and stored in accordance
with the sign face or sign sheeting manufacturer’s
instructions.
14.1.3.4 Posts for Permanent Traffic Signs
1 Posts for permanent traffic signs shall be as shown in
the Drawings or Schedules, shall comply with BS EN
12899-1, and shall be either:
i. galvanized steel posts of tubular or rectangular
hollow section complying with EN 1993
(Design of Steel Structures).
ii. aluminium posts of tubular or rectangular
hollow section complying with EN 1999
(Design of Aluminium Structures).
2 Where, exceptionally, traffic signs are illuminated,
base compartments for electrical equipment shall be as
shown in the Drawings or schedules and shall be fitted
with vandal and weather resistant locks to the approval of
♦ 14-1 ♦
copy 249
the Engineer. Keys, in the quantities stated in the
Drawings or Schedules, shall be provided. Wherever
practicable, access doors shall be on the side of the
compartment furthest from approaching traffic. In the case
of signs supported by more than one post, the
compartment shall normally be in the post furthest from
the carriageway.
3 Flange mounted sign posts, where specified on the
Drawings or Schedules, shall have holes or slots in the
flange plate to accommodate the anchorage system.
Structural design of flange mounted sign assemblies shall
comply with Section 6 (Structural Steel and Other Metal
Work)
14.1.3.5 Foundations for Permanent Traffic Signs and
Signals
1 The type and size of foundations for permanent
traffic signs shall be as shown in the Drawings or
Schedules and shall comply with BD 94/07 (Design of
minor structures, UK Design Manual for Roads and
Bridges).
2 Posts should be flange mounted to foundations as
shown on the Drawings or Schedules.
3 Concrete foundations for multiple posts should
consist of a single long composite block.
14.1.3.6 Sign Plates for Permanent Traffic Signs
1 Permanent sign plates shall be as shown in the
Drawings or Schedules and shall comply with BS EN
12899-1
14.1.3.7 Sign Faces for Permanent Traffic Signs
1 Faces for permanent traffic signs shall be as shown
in the Drawings or Schedules, and shall comply with BS
EN 12899-1.
2 Sign face material shall comply with ASTM D4956-01
Type III (encapsulated lens sheeting) (also known as High
Intensity), or ASTM D4956-01 Type IV (microprismatic
sheeting). In locations where increased conspicuity is
required, such as chevrons and similar hazard warning
signs, sign face material shall comply with ASTM D4956-
01 Type VII material (microprismatic sheeting).
3 Testing of sign face materials shall comply with BS
8408 and BS EN 12899-1.
4 A warranty statement from the sign face sheeting
manufacturer must be provided stating that there is a
100% replacement guarantee for the effective shelf life and
performance life of the material being supplied of 9 years.
Failure to supply the warranty statement shall be cause for
rejection.
5 Deliveries of sign face material shall be accompanied
by certification that all specifications are met.
♦ 14-2 ♦
14.1.3.8 Manufacture and Assembly of Permanent
Traffic Signs
1 Manufacture and assembly of traffic signs shall
comply with BS EN 12899-1.
14.1.3.9 Covering of Permanent Traffic Signs
1 Where traffic signs are to be covered prior to use or
to show a new message, the following method shall be
adopted:
i. Permanent changes to permanent signs
A permanent self adhesive plastic film overlay
shall be used to display the new legend. The
overlay shall be compatible with the original sign
face sheeting and match the appearance of the
original sign face and shall be applied in full
compliance with the sheeting manufacturer’s
recommendations.
ii. Temporary covering of permanent signs (prior to
use)
A temporary opaque self adhesive plastic film
overlay shall be used to cover the sign face. The
overlay shall be compatible with the original sign
face and shall be applied and removed in full
compliance with the sheeting manufacturer’s
recommendations.
iii. Use of spray applications to temporarily cover
sign faces can be used, subject to the approval of
the Engineer, provided that the material is
compatible with the sign face material and is
used strictly in compliance with the
manufacturer’s instructions.
iv. Temporary changes to permanent signs
A temporary self adhesive plastic film overlay
shall be used to display the new legend. The
overlay shall be compatible with the original sign
face sheeting and match the appearance of the
original sign face and shall be applied and
removed in full compliance with the sheeting
manufacturer’s recommendations.
2 The method of application and removal of temporary
covering is manufacturer specific and their instructions
must be followed exactly to avoid damage to the
permanent sign face material.
14.1.3.10 Depth and Marker Posts (for Floodways)
1 Depth and marker posts shall be constructed to
withstand permanent immersion in water and, in other
respects, shall be constructed as for permanent traffic
signs and be installed in the locations shown in the
Drawings or Schedules.
14.1.3.11 Kilometer Posts (5km spacing) and Kilometer
Reference Posts (1km spacing)
1 Kilometer posts and kilometer reference posts shall
be constructed as for permanent traffic signs and
copy 249
materials, construction, assembly, testing, location and
erection shall be as shown on the Drawings or Schedules
and shall comply with BS EN 12899-1.
14.1.3.12 Delineator Posts (for edge of carriageway or
right-of-way marking)
1 Delineator posts shall comply with BS EN 12899 Part
3. Post construction and color and type of reflective
marker shall be as shown in the Drawings or Schedules.
14.1.3.13 Traffic Signs on Cantilevers and Gantries
1 Where traffic signs are erected on cantilevers or
gantries the sign plates and sign faces shall comply with
the requirements for permanent signs specified in this
Section and the Drawings or Schedules.
2 Cantilevers and gantries shall be in accordance with
the Drawings or Schedules. Fabricated steel gantries shall
be in accordance with Section 6 (Structural Steel and other
Metal Work) and Section 7 (Paint) of this Specification.
14.1.3.14 Preparation and Finish of Metal and Other
Surfaces
1 Permanent traffic signs (and temporary traffic signs
where specified in the Drawings and Schedules) shall be
protected against corrosion and finished in compliance
with Section 6 (Structural Steel and other Metal Work) and
Section 7 (Paint) of this Specification as applicable.
2 Posts, frames, purlins (stiffeners) and general fittings
and fixings shall be protected against corrosion as
specified, in compliance with Section 6 (Structural Steel
and other Metal Work) and Section 7 (Paint) of this
Specification.
3 To prevent specular reflection, the backs of
aluminium alloy sheets forming plate signs shall be dulled
using a method to be agreed by the Employer or be
coated as follows:
i. painted matt traffic grey, using a paint system
specified in Section 7.
ii. covered with matt grey non-retro-reflective
sheeting.
4 Electrical equipment cabinets and metal components
of electrical equipment in base compartments shall be
protected against corrosion as specified in Section15 of
this Specification.
5 Unless otherwise specified on the Drawings or
Schedules, stainless steel shall be left untreated except
where the component is visible against the sign face when
it shall be covered by a compatible material of a color to
match that part of the face.
14.1.3.15 Traffic Cones
1 Traffic cones shall comply with BS EN 13422.
14.1.3.16 Flashing Beacons
1 Flashing beacons shall comply with BS EN 12352.
14.1.3.17 Temporary Traffic Signs
1 Temporary traffic sign materials, construction,
assembly, testing, location and erection shall comply with
the requirements for permanent traffic signs, and with BS
EN 12899 as applicable, and shall be as shown on the
Drawings or Schedules.
2 Where a temporary sign is to be erected it may be
fixed or frame mounted so that it can be easily relocated
or reused. Fabricated frames shall conform to Section 6
(Structural Steel and Other Metal Work).
3 Temporary traffic signs include all vertical sign types
and bollards and marker, depth, kilometer, kilometer
reference and delineator posts.
14.1.4 Construction Requirements
14.1.4.1 Posts for Permanent Traffic Signs
1 Posts shall not protrude above the top of the sign.
2 Signs erected on a single post shall be positioned so
that the post is in the center of the sign, unless otherwise
shown on the Drawings.
3 The fasteners used for fixing the sign to the post
shall have shear heads so that the hexagonal head of the
bolt shears off when the fixing is tightened, leaving a
tamper proof fixing.
4 As an alternative for item 3 above, theft resistant
methods of fixing can, with the approval of the Engineer,
consist of welding up appropriate areas of fastening.
14.1.4.2 Foundations for Permanent Traffic Signs and
Signals
1 Pits for post foundations shall be excavated to the
sizes shown on the Drawings and cleared of all loose
material before placing of concrete and backfilling.
Concrete shall conform to the requirements of Section 5 of
these Specifications and the Drawings, and where steel
reinforcement is used, be protected with two coats of
bitumen material in accordance with paragraph 5.10.3.6 of
these Specifications
2 Posts for all traffic signs shall be installed centrally in
circular or square concrete foundations to the dimensions
shown in the Drawings or Schedules and finished with a
minimum ground cover of 150 mm.
3 Where, exceptionally, traffic signs are illuminated,
provision shall be made for cable entry through the
foundation by means of ducting as shown on the
Drawings.
4 Surfaces above foundations shall be reinstated to
match the existing surrounding surface construction and
finish in accordance with the Drawings.
14.1.4.3 Sign Plates for Permanent Traffic Signs
1 Fabricated plate signs up to 1.2m in height and 2.4m
width shall be made of a single substrate sheet. Above
this size, the number of sheets shall be kept to a minimum
♦ 14-3 ♦
copy 249
and the separate sheets shall be rectangular and of
comparable size and shape.
2 Fabricated plate signs up to 2.4m wide shall have no
vertical joints. Above 2.4m wide, joints in the stiffening
extrusions shall preferably be positioned at a vertical
support. If not, then the vertical joints in the stiffening
extrusions shall be staggered so that joints are not less
than 1.0 m apart. Only one such joint in each horizontal
stiffening extrusion shall be permitted and all joints shall
be reinforced.
3 Sign face plates shall have all corner points rounded
as shown in the Drawings. These should match cleanly
with the associated corner radius of sign face sheeting to
be fitted.
14.1.4.4 Sign Faces for Permanent Traffic Signs
1 Sign substrates shall be prepared to receive sign face
sheeting materials in compliance with the sheeting
manufacturer’s recommendations.
2 All sign face sheeting shall be fixed in accordance
with the sheeting manufacturer’s instructions.
3 Only vertical and horizontal joints shall be permitted
and all joints in plastic sheeting shall be overlapped by not
less than 6mm. The overlap in the horizontal joints shall
be from the top. Butt joints in plastics sheeting shall not
be used, except in overlay film, or if recommended by the
sheeting manufacturer.
4 All materials comprising the sign face, including the
background, border and legends shall be carefully
matched for color at the time of sign fabrication to provide
uniform appearance both by day and night. The sheeting
manufacturer’s recommendations on color matching
methods shall be observed.
5 Letters, numerals, symbols and borders shall be clear
cut, sharp edged and without cracks.
6 Any cut-out letters, numerals, symbols and borders
shall be of material compatible with the sheeting to which
they are applied. They shall be applied in accordance with
the sheeting manufacturer’s instructions.
7 Sheeting materials including letters, numerals,
symbols and borders shall be fully adhered and there shall
be no air bubbles, creases, cracks or other blemishes.
14.1.4.5 Manufacture and Assembly of Permanent
Traffic Signs
1 All sign plates, frames, purlins, posts and other
components shall have rough edges smoothed prior to
assembly.
2 Where framing and stiffening are not an integral part
of the sign plate their joints shall be welded or joined with
suitable brackets utilizing nuts, bolts and washers.
3 Where purlins are adopted they shall be attached to
each vertical member of the sign frame and the sign
stiffening and framing shall be continuous in the vertical
direction. Purlins shall be spaced equally apart.
♦ 14-4 ♦
Connections shall be made at every point where a purlin
crosses a post.
4 Where purlins are not adopted the sign stiffening and
framing shall be continuous in the horizontal direction.
5 Rivets and other devices used for fixing sign plates to
their stiffeners or framework, or in the construction of
housings, shall be of a material compatible with the
materials being joined. Spacing of rivets or other fixing
devices shall be uniform and shall not exceed 150 mm
around the outside edge of any sheet or section of sheet,
and shall not exceed 300mm on cross braces. Hollow
rivets shall not be used. Where sign plates need to be
stiffened this shall be achieved in a manner such that the
sign face material is not punctured or otherwise damaged
to accommodate the stiffening.
6 Rivets or other fixings must not protrude through the
sign face sheeting
7 An additional washer of neoprene, nylon or plastic
shall be used between the sign face and any metal nuts,
bolts, washers and screws to protect it from corrosive or
other damaging effects.
8 Where traffic sign posts are required to have flange
plates these shall be secured by anchorages and
attachment systems in accordance with the Drawings. The
bolts shall be lightly greased before final installation and
they and their anchorages shall be installed so as to
achieve the loadings, torque settings and other
requirements in accordance with the Drawings and the
manufacturer’s instructions.
9 Sheet signs shall be connected to posts (or lighting
columns where permitted) by correctly sized stainless
steel clips.
10 Where ferrous components are permitted any
drilling of them shall be completed before the application
of any finish.
11 Prior to fitting any sign to any lighting column, the
Contractor shall seek the approval of the Engineer to
ensure that the column loading is acceptable. No holes
shall be drilled in the lighting column except those whose
location and size are specified on the Drawings.
12 Traffic signs to be erected on lighting columns shall
have fixings compatible with the column cross section and
finish.
14 Variable message traffic signs shall also comply with
these paragraphs.
14.1.4.6 Location and Erection of Permanent Traffic
Signs
1 The approximate location of each traffic sign is
shown in the Drawings and Schedules. Exact locations will
be as directed on Site by the Engineer and shall be
recorded as-built.
2 All posts shall be erected plumb and where two or
more posts are provided for any one sign, the faces of the
posts shall be aligned.
copy 249
3 Signs erected on two posts shall have each post tools, and other items necessary for the proper completion
positioned so that the distance from the center of the post of the work as specified.
to the edge of the sign plate is 300mm unless otherwise
shown in the Drawings or Schedules. 14.1.7 Items in the BilI of Quantities
4 Traffic signs mounted on posts, except those on i. Highway sign, triangular, (height -mm). (nr.)
gantries, shall be erected to have their face plumb vertical ii. Highway sign, circular, (diameter -mm). (nr.)
and be orientated at 95 degrees from the carriageway iii. Highway sign, rectangular, size
centerline to reduce specular reflection. (finished sign area) (sq m).
5 The Contractor shall provide full proposals for the iv. Highway sign, octagonal,
erection of traffic signs mounted on gantries or cantilevers (height - mm) (nr.)
for approval by the Engineer. v. Sign post support assembly
6 No traffic sign shall be dismantled, re-sited or including foundation (type). (nr.)
removed without the prior approval of The Engineer. vi. Breakaway sign post support
assembly including foundation
14.1.4.7 Covering of Permanent Traffic Signs (type). (nr.)
vii. Overhead sign support including
1 Any traffic sign erected at such a time that its legend
Foundation (type). (nr.)
does not relate either wholly or in part to the traffic
movement and route in operation, shall have its sign face
covered as specified in Paragraph 14.1.3.9 until such time 14.2 Road Markings
as its legend is applicable.
2 Under no circumstances shall adhesive tape or other 14.2.1 Description
non approved adhesive material be applied to the face of
1 The Sub-section describes requirements for road
any sign.
marking consisting of white or yellow lines, chevron
3 Removal of any covering shall be carried out with the hatching, arrows, lettering and painting of curbs.
minimum disturbance to traffic.

14.1.4.8 Temporary Traffic Signs

1 Removal of temporary traffic signs shall be carried
out as soon as they become superfluous or a hazard to
traffic. Methods of removal shall ensure the minimum
disturbance to traffic consistent with safety. Making good
shall be carried out immediately after removal of the
traffic sign.
14.1.5 Method of Measurement
1 Rectangular signs shall be measured by the area in
square meters of the sign face installed. The rates shall
include sign substrate, sign face and all fixing devices.
2 Triangular, circular and other shapes of signs shall
be measured by the number of each type as installed.
3 Sign posts support assemblies shall be measured by
the number of each type installed. The rates shall include
for the foundation and all fixings and painting or other
protection.
4 Temporary signs are not measured separately. Their
cost shall be included as part of the traffic management
requirements stated in Section 1, Sub-section 1.7 of the
Specification.
14.1.6 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate for highway signs in the Bill of Quantities which rate
shall be full compensation for supplying, fabrication,
erection, painting, fixing, foundation, excavation
backfilling, and for materials, transport, labor, equipment,
14.2.2 Materials
1 The material for markings on the carriageway shall
be either of the following, as shown on the Drawings or
directed by the Engineer:
i. Thermoplastic material to British Standard BS
EN1436: 2007, or
ii. Liquid paint to British Standard BS EN1871: 2000
and BS EN1436: 2007.
14.2.2.1 Thermoplastic Material
1 Type I road markings do not necessarily have special
properties that enhance retroreflection in wet or rainy
conditions. Type II road markings, on the other hand, are
road markings with special properties intended to enhance
the retroreflection in wet or rainy conditions. Type III road
markings are profiled markings designed for use on the
edges of major, heavily trafficked highways. Type I
markings shall not be used without special instruction
from the Employer.
2 Thermoplastic road markings shall consist of binder,
resin, intermix beads, pigment, plasticizing oil and such
other constituents as necessary to reach the performance
level required. The objective of BS EN1436 2007 is to set
the performance level that the thermoplastic road marking
must reach; it does not lay down specific percentages of
binder, resin, intermix beads, pigment or other
constituents. Subject to the restrictions stated in this
Specification, the manufacturer is free to achieve the
required performance level in any way suited to his
manufacturing techniques. However, because pavement
temperatures in Oman are very high over prolonged
periods, and because hydrocarbon resins are a proven

♦ 14-5 ♦
copy 249
cause of blackening in road markings on hot pavements, White
hydrocarbon resins shall not be used. The Contractor shall
submit a certificate from the manufacturer stating that the Type I Road Markings Qd ≥ 100 mcd/m²/lx
thermoplastic road marking contains no hydrocarbon
Type II Road Markings Qd ≥ 130 mcd/m²/lx
resins.
3 The softening point of the thermoplastic road Type III Road Markings Qd ≥ 160 mcd/m²/lx
markings shall be not less than the figures shown in Table
Yellow
14.2.2.1. The flashpoint for thermoplastic materials must
o
be greater than or equal to 240 C and drying (tack free) Type I Road Markings Qd ≥ 80 mcd/m²/lx
time should be between 2 and 10 mins. dependent on
Type II Road Markings Qd ≥ 100 mcd/m²/lx
ambient road surface temperature and wind.
Type III Road Markings Qd ≥ 130 mcd/m²/lx

Type I Road Markings 95°C minimum Table 14.2.2-5: Luminance coefficient

Type II Road Markings 95°C minimum 8 The luminance factor (β) for dry road markings shall
be greater than the figures shown in Table 14.2.2.6.
Type III Road Markings 110°C minimum
Table 14.2.2-1: Softening point White

4 The skid resistance of the thermoplastic road Type I Road Markings β = 0.30 minimum
markings (assisted if necessary by the application of drop- Type II Road Markings β = 0.40 minimum
on beads) shall be not less than the figures shown in Table
14.2.2.2. (Note: Tested using the pendulum test as Type III Road Markings β = 0.50 minimum
specified in EN 1341 for external paving. Skid resistance Yellow
has no units.)
Type I Road Markings β = 0.20 minimum
Type I Road Markings 45 minimum
Type II Road Markings β = 0.30 minimum
Type II Road Markings 45 minimum Type III Road Markings β = 0.40 minimum
Type III Road Markings 55 minimum Table 14.2.2-6: Luminance factor
Table 14.2.2-2: Skid resistance
9 The luminance coefficient (Qd) under diffuse
5 The flow resistance of the thermoplastic road illumination under dry conditions, measured in
marking shall not be more than the figures shown in Table millicandellas (mcd) shall after one year in use conform to
14.2.2.3. the figures shown in Table 14.2.2.5.
10 The luminance factor (β) for dry road markings shall
Type I Road Markings 5% maximum after one year in use be greater than the figures shown in
Table 14.2.2.6.
Type II Road Markings 5% maximum
11 For the measurement of reflection under vehicle
Type III Road Markings 5% maximum
headlamp illumination, the coefficient of reflected
Table 14.2.2-3: Flow resistance luminance RL is used. RL is expressed in mcd/m²/lx. Road
markings in the dry under vehicle headlamp illumination
6 The relative density of the thermoplastic road
shall conform to the figures shown in Table 14.2.2.7.
markings, measured in grams per cubic centimeter, shall
be within the range shown in Table 14.2.2.4.
White
Type I Road Markings 1.9 to 2.1 g/cm³ Type I Road Markings RL ≥ 100

Type II Road Markings 1.9 to 2. 1 g/cm³ Type II Road Markings RL ≥ 150

Type III Road Markings 1.9 to 2. 1 g/cm³ Type III Road Markings RL ≥ 200

Table 14.2.2-4: Relative density Yellow

7 The luminance coefficient (Qd) under diffuse Type I Road Markings RL ≥ 80

illumination under dry conditions measured in Type II Road Markings RL ≥ 150
millicandellas (mcd) shall conform to the figures shown in
Table 14.2.2.5. Type III Road Markings RL ≥ 200
Table 14.2.2-7: Reflectorization under vehicle headlamp
illumination (dry)

♦ 14-6 ♦
copy 249
12 Road markings in rain under vehicle headlamp considered necessary for the acceptance of the materials
illumination shall conform to the figures shown in Table or for the control of their application.
14.2.2.8.
14.2.2.2 Liquid Paint
White
1 The daytime visibility of road marking paint shall be
Type I Road Markings RL ≥ 25 defined by the luminance factor β. The classes shown in
Type II Road Markings RL ≥ 35 Table 14.2.2.10 shall apply.

Type III Road Markings RL ≥ 50 Colour Class Luminance factor β

Yellow LF5 ≥0.30
White LF6 ≥0.40
Type I Road Markings RL ≥ 25 LF7 ≥0.50
Type II Road Markings RL ≥ 35 LF1 ≥0.30
Yellow
LF2 ≥0.40
Type III Road Markings RL ≥ 50
Table 14.2.2-10: Luminance factor
Table 14.2.2-8: Reflectorization under vehicle headlamp
2 The x, y chromaticity co-ordinates for dry road
illumination (rain)
markings shall lie within the regions defined by the corner
13 The x, y chromaticity co-ordinates for dry road points as shown in Table 14.2.2.11.
markings shall lie within the regions defined by the corner
points as shown in Table 14.2.2.9. Corner White Yellow
Point No X Y X Y
Corner White Yellow 1 0.355 0.355 0.443 0.399
Point No X Y X Y 2 0.305 0.305 0.545 0.455
1 0.355 0.355 0.443 0.399 3 0.285 0.325 0.465 0.535
2 0.305 0.305 0.545 0.455 4 0.335 0.375 0.389 0.431
3 0.285 0.325 0.465 0.535 Table 14.2.2-11: Color
4 0.335 0.375 0.389 0.431
3 The contrast ratio (hiding power) for white and
Table 14.2.2-9: Color yellow paints shall be not less than 96% for white and 90%
for yellow when tested in accordance with ISO 2814 when
14 In order to prevent cracking of thermoplastic when
applied with a doctor blade of 300μm.
the plasticizing oil content is reduced to prevent
blackening of the road marking, good quality resins (such 4 The paint shall be free from skin and settlement that
as alkyd resins, rosin esters and maleic-modified resins) cannot be reincorporated by stirring. Drying (tack free)
shall be used in the manufacture of thermoplastic material time should be between 5 and 7 minutes dependent on
instead of the hydrocarbon resins. Road markings ambient road surface temperature and wind.
showing more than minimal cracking during the 5 The skid resistance of the painted road markings
warranted life of the markings will be deemed to have (assisted if necessary by the application of drop-on beads)
failed. shall be not less than 50.
15 The Contractor shall warrant that Type I and Type II 6 For the measurement of reflection under vehicle
markings will continue to achieve all performance headlamp illumination, the coefficient of reflected
requirements of this Specification for a minimum period luminance RL is used. RL is expressed in mcd.m-2.lx-1.
of 1 (one) year from the time of application and that Type Road markings in the dry under vehicle headlamp
III markings will continue to achieve all similar applicable illumination shall conform to the figures shown in Table
performance requirements for a minimum period of 3 14.2.2.12.
(three) years from the time of application, when used on
White RL ≥ 100
the edges of the highway as yellow edge marking.
Yellow RL ≥ 80
16 In no case shall any materials be laid more than 6
mm thick. Unless specified, all white markings shall be Table 14.2.2-12: Reflectorization under vehicle headlamp
reflectorized by means of spherical glass beads to BS EN illumination (dry)
1424 premixed during compounding and additionally by
7 Road markings in rain under vehicle headlamp
spherical glass beads to BS EN 1423 wet surface applied
illumination shall conform to the figures shown in Table
during application. The glass beads shall not have more
14.2.2.13.
than 1,000 ppm of Arsenic Trioxide, 200 ppm of Lead and
1,000 ppm of Antimony. The Contractor shall supply test White RL ≥ 35
certificates showing compliance with these requirements. Yellow RL ≥ 35
17 Before delivery to site, or during the course of the Table 14.2.2-13: Reflectorization under vehicle headlamp
work, the Engineer may call for any tests that are
illumination (rain)

♦ 14-7 ♦
copy 249
8 Testing of spherical glass beads shall be done to
conform with BS EN 1423 for drop on materials and BS EN
1424 for premix glass beads. The Contractor shall warrant
that markings will continue to achieve all performance
requirements of this Specification for liquid paint for a
minimum period of 1 (one) year from the time of
application.
9 Liquid paint is unsuitable for forming raised rib edge
line markings and should not be used for this purpose.
14.2.2.3 Testing
1 Testing for liquid paint shall comply with BS EN 1436
2007. The softening point, flow resistance and density of
road marking material should be carried out by a roads
testing laboratory. The manufacturer of the road marking
material shall provide a certificate for the material stating
these values. The responsibility for the accuracy of the
figures remains with the Contractor.
2 Testing of skid resistance shall be by use of a
portable skid resistance tester designed to carry out the
Pendulum test. This is common equipment for use in the
field or in a roads testing laboratory.
3 Determination of the luminance coefficient (Qd) and
the reflectorization (RL) shall be by use of a road marking
retro-reflectometer which is a portable unit suitable for
use on site.
4 Determination of the luminance factor (β) shall be
tested using a Reflectometer which is a portable unit
suitable for use on site.
5 Before delivery to site, or during the course of the
work, the Engineer may call for any tests that are
considered necessary for the acceptance of the materials
or for the control of their application.
14.2.2.4 Painting of curbs
1 Chlorinated rubber paint for painting curbs shall be
plasticized and drying shall be solvent evaporation alone.
It shall have the properties give in Table 14.2.2.14.
Property Allowable Limits
Relative density 1.48 minimum
Viscosity at 21°C 65 to 70
Drying time Approx 10-15 minutes
Coverage 3m² per litre maximum
Luminance
80 mcd/m²/lx minimum
coefficient
Passes around 12mm diameter
Flexibility
mandrel
Chlorinated
9.0%
rubber content
Table 14.2.2-14: Paint for Curbs
14.2.3 Construction Requirements
1 Traffic shall be kept off markings until the installation
has fully cured.
♦ 14-8 ♦
2 Application of road marking material shall generally
be by mechanized spraying equipment consisting of a
motor powered self propelled machine with compressor.
A minimum line width of 100mm shall be sprayed in one
pass. The separate bead gun shall be synchronized to
spray glass spheres immediately onto the surface of the
road marking. An automatic mechanism shall be fitted to
produce broken or dotted lines as shown on the Drawings
without the need for pre-measurement.
3 If material is applied by hand methods,, the
Contractor shall provide stencils, specialized labor and all
necessary equipment to ensure that results match the
quality and finish of the sprayed work, to the satisfaction
of the Engineer. Drop on spherical glass beads shall be
hand applied to give a consistent covering over the whole
of the surface of the road marking between 350 to 400
grams per square meter.
4 All road markings shall comply with the dimensions,
angles and proportions stated in the Highway Design
Standards.
5 Where indicated on the Drawings, curbs shall be
painted alternately black and yellow to cover the entire
exposed surface. Changes in colors shall be made at joints
between curbs.
6 Obsolete or existing markings to be replaced shall be
removed by a purpose designed line removal machine
capable of operating between 600 and 2500 meters/hour. It
should not cause damage to the road surface. The working
width shall be adapted to the width of the marking line up
to a maximum of 400mm. Hand operated machines used
for removal of small areas of marking shall have a work
rate of 3 meters/minute.
7 The pavement shall be prepared in accordance with
the following:
i. Where the marking is to be applied on concrete
carriageways, the transverse texturing shall be
freed from all traces of curing compound by wire
brushing or other approved means. Prior to the
application of thermoplastic material a tack coat
compatible with the road surface and the
marking material shall be applied in accordance
with the manufacturer’s instructions.
ii. On surface dressed carriageways, all loose
chippings where the marking is to be applied
shall be removed prior to application. The
surface to be marked shall be clean and dry.
8 Road marking materials shall only be applied to
surfaces which are clean and dry. Markings shall be free
from raggedness at their edges and shall be uniform and
free from streaks. Longitudinal road markings shall be laid
to a regular alignment.
9 Pre-marking shall be carried out manually on straight
lines and curves using a 100m long string. On straights the
pre-marking shall consist of 1 dot mark every 3m, and on
curves every 1m. The pre-marking dot shall be a circle of
40mm diameter cut into 2 equal parts by a gap of 10mm.
copy 249
Longitudinal changes in line types shall be within 300mm BS 7962. The total thickness of original and masking
of the location specified on the Drawings. materials shall not exceed 6 mm.

14.2.3.1 Raised Rib (Profiled) Road Markings 14.2.3.5 Longitudinal Road Markings Lateral Tolerances

1 Raised rib road markings shall only be used on 1 For longitudinal road markings, the lateral tolerance
National and Arterial roads with full width hard shoulders shall be within ± 25mm from the designed position. Any
or other high speed roads (both single and dual discontinuities between road markings shall be replaced
carriageway) with at least 1 meter wide hard strips. with a smooth taper from one road marking to the other.
2 Raised rib road markings shall be yellow lines which The length of the transition shall be derived from Table
are continuous over the sections where they are specified 14.2.3.1.
on the Drawings. Gaps shall be provided for drainage
Speed (km/h) Taper
purposes only where specified on the Drawings.
3 Raised rib road markings shall be in accordance with Up to 60 1 in 40
the Highway Design Standards. Spacing of the transverse
80 1 in 45
raised ribs shall be 500 mm.
4 Raised rib road markings shall not be used adjacent 100 1 in 50
to hatched areas or central reserve crossings.
120 1 in 55
14.2.3.2 Temporary Road Markings
Table 14.2.3-1: Marking transition taper
1 Temporary road markings shall only be adopted with
2 Where studs are to be placed within the line the
the prior approval of the Engineer. They shall comply with
centre line of the marking and the center line of the studs
the same clauses as permanent road markings, or if
must not be displaced by more than 15mm.
required to be removable, be constructed only from a
proprietary preformed road marking material complying
with BS EN 1790.
14.2.4 Method of Measurement
2 When temporary road markings are used on surfaces 1 Road markings of each type shall be measured by
that will continue to be used by public traffic after their square meters marked. Removal of road markings shall be
removal, any shadow trace remaining after their removal measured by square meters removed.
shall be permanently obliterated. Preformed materials
shall not be used for this obliteration. 14.2.5 Basis of Payment
3 Temporary road markings constructed from a 1 The amount of completed and accepted work
proprietary preformed road marking material shall only be measured as provided for above will be paid for at the unit
adopted in locations and on types of road surface as rate for Road Marking in the Bill of Quantities which rate
shown on the Drawings and shall comply with any other shall be full compensation for supplying, applying, surface
requirement therein. The marking material shall be new preparation, and for materials, labor, equipment, tools,
and together with any primer shall be stored and installed supplies and other items necessary for the proper
in accordance with the manufacturer’s instructions and completion of the work as specified.
within the recommended shelf life.
4 Temporary preformed road markings shall only be 14.2.6 Items in the Bill of Quantities
applied to surfaces that are clean and dry. Upon removal
i. Traffic lines (type) (material)
they shall be disposed of off Site and if any making good
(mechanical application). (sq.m.)
is necessary to the road surface it shall be satisfactorily
ii. Raised rib road markings. (sq.m.)
carried out before the road is opened to traffic to the
iii. Special road markings
satisfaction of the Engineer.
(type), (material) ;(hand applied). (sq.m.)
14.2.3.3 Removal of Road Markings iv. Curb painting (sq.m.)
v. Removal of road markings (sq.m.)
1 The removal of road markings on surfaces that will
continue to be used by traffic shall be undertaken in a
manner that will avoid damage to the surface. The
14.3 Road Studs
removal of road markings shall be by mechanical means
only. The Contractor shall submit details of the system he 14.3.1 Description
proposes to use to the Engineer for approval. 1 This Sub-section describes requirements for the
supply and installation of road studs.
14.2.3.4 Masking of Road Markings

1 When black masking materials are required to cover

existing permanent road markings, they shall comply with

♦ 14-9 ♦
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14.3.2 Materials studs shall be removed from the carriageway on
completion of the Works to the satisfaction of the Engineer.
14.3.2.1 Permanent Retroreflecting Road Studs
14.3.3.3 Non retroreflecting Road Studs
1 All retroreflecting road studs shall comply with BS
EN 1463-1 and 1463-2, and shall be installed in accordance 1 All non retroreflecting road studs shall be installed in
with the manufacturer’s instructions accordance with the manufacturer’s instructions in
2 Retroreflecting road studs and components which do locations, and complying with any other requirements, as
not fall into a category of BS EN 1463, but which have type shown on the Drawings.
approval of the Employer may be used if specifically
permitted by the Engineer. 14.3.4 Method of Measurement
3 The bodies of the studs shall be aluminium or high 1 Road studs of each type shall be measured by the
impact plastic and shall incorporate an integral plug at number of studs installed.
least 60mm deep.
4 Fixing of studs shall be by epoxy resin adhesive in 14.3.5 Basis of Payment
accordance manufacturers requirements.
1 The amount of completed and accepted work
5 The Contractor shall submit details of the road studs measured as provided for above will be paid for at the unit
he proposes to use together with the method of fixing to rate for Road Studs in the Bill of Quantities which unit rate
the Engineer for approval. shall be full compensation for supplying, fixing, surface
preparation, and for materials, labor, transport, equipment,
14.3.2.2 Temporary Retroreflecting Road Studs
tools, and other items necessary for the proper completion
1 Temporary retroreflecting road studs shall be of the of the work as specified.
fluorescent yellow type to BS EN 1463-1.
14.3.6 Items in the Bill of Quantities
14.3.2.3 Ceramic Buttons
i. Reflecting road studs (type/color). (nr.)
1 Ceramic buttons may be used only in exceptional
ii. Non-reflecting road studs. (nr.)
circumstances to supplement road marking only with the
approval of the Employer and Engineer.

14.3.3 Construction Requirements

14.3.3.1 Permanent Retroreflecting Road Studs

1 Traffic shall be kept off studs until the resin adhesive

has fully cured.
2 Permanent retroreflecting road studs shall be
installed in the locations and to any other requirements as
shown on the Drawings.
3 Road studs shall be fixed so that the displacement to
the left or right of the correct line does not exceed 10mm.
The angular displacement of road studs shall not exceed
5°.
4 Where studs are to be placed within the line the
centre line of the marking and the centre line of the studs
must not be displaced by more than 15mm.
5 Studs shall be installed after the completion of the
wearing course and the installation shall be carried out to
accordance with the manufacturer’s instructions and as
agreed by the Engineer.
6 Studs shall be applied on clean, sound, dry surfaces.
Air temperature shall be greater than 5° at the time of
installation and when it will remain above 5° for the time
taken for the adhesive to cure.

14.3.3.2 Temporary Retroreflecting Road Studs

1 They shall not be used for a second application.

Adhesive used for the temporary retroreflecting road

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Ref. Title Page No. Ref. Title Page No.
15.1 General 15-1 15.3.4 Method of Measurement 15-7
15.3.5 Basis of Payment 15-7
15.1.1 Scope 15-1
15.3.6 Items in the Bill of Quantities 15-7
15.1.2 Design 15-1
15.1.3 Regulations and Standards 15-1 15.4 Package Medium Voltage
15.1.4 Factory Tests 15-1 Switching Stations 15-7
15.1.5 Field Tests 15-1
15.4.1 Description 15-7
15.1.5.1 General 15-1
15.4.2 Materials 15-8
15.1.5.2 Insulation Resistance Test 15-2
15.4.3 Construction Requirements 15-8
15.1.6 Lighting Columns Tests – Pre-shipment 15-2
15.4.4 Method of Measurement 15-8
15.1.7 Switchgear Tests 15-2
15.4.5 Basis of Payment 15-8
15.1.8 Completed Tests 15-2
15.4.6 Items in the Bill of Quantities 15-8
15.1.9 General Technical Conditions 15-2
15.1.10 Approval 15-3 15.5 33kV and 11 kV Pole Mounted
15.1.11 Erection 15-3 Transformer Sub-Stations 15-8
15.1.12 Manuals 15-4
15.5.1 Description 15-8
15.1.13 Handling 15-4
15.5.2 Materials 15-8
15.1.14 Spares 15-4
15.5.3 Construction Requirements 15-9
15.1.15 Road Lighting 15-4
15.5.4 Method of Measurement 15-9
15.1.16 Sign Lighting 15-4
15.5.5 Basis of Payment 15-9
15.1.17 Medium Voltage and Substation Work -
15.5.6 Items in the Bill of Quantities 15-9
Generally 15-5
15.1.18 Method of Measurement 15-5 15.6 Feeder Pillars 15-9
15.1.19 Basis of Payment 15-5 15.6.1 Description 15-9
15.1.20 Items in the Bill of Quantities 15-5 15.6.2 Materials 15-9
15.2 Medium Voltage Intake 15.6.3 Construction Requirements 15-11
Switching Stations 15-5 15.6.4 Method of Measurement 15-11
15.6.5 Basis of Payment 15-11
15.2.1 Description 15-5
15.6.6 Items in the Bill of Quantities 15-11
15.2.2 Materials 15-5
15.2.3 Construction Requirements 15-6 15.7 Electrical Cables 15-11
15.2.4 Method of Measurement 15-6
15.7.1 Description 15-11
15.2.5 Basis of Payment 15-6 15.7.2 Materials 15-12
15.2.6 Items in the Bill of Quantities 15-6
15.7.2.1 Low Voltage Cables 15-12
15.3 Package Sub-stations 15-6 15.7.2.2 Medium Voltage (M.V) Cables 15-12
15.7.2.3 Metal Gland Parts 15-12
15.3.1 Description 15-6
15.7.2.4 Cable Trays 15-12
15.3.2 Materials 15-6
15.7.3 Construction Requirements 15-12
15.3.3 Construction Requirements 15-7
15.7.3.1 Cable Jointing and Termination 15-13

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Ref. Title Page No. Ref. Title Page No.
15.7.3.2 Field Quality Control 15-13 15.11.2.2 Controllers 15-21
15.7.3.3 Earthing 15-13 15.11.2.3 Signal Equipment 15-22
15.3.4 Protection 15-14 15.11.2.4 Signal Operation 15-23
15.7.4 Method of Measurement 15-14 15.11.3 Construction Requirements 15-23
15.7.5 Basis of Payment 15-14 15.11.3.1 Cables 15-23
15.7.6 Items in the Bill of Quantities 15-14 15.11.3.2 Controller Root 15-23
15.11.3.3 Ducts 15-23
15.8 Road Lighting Masts, Columns
15.11.3.4 Draw Pits 15-24
and Luminaires 15-14
15.11.3.5 Pole installation 15-24
15.8.1 Description 15-14 15.11.3.6 Miscellaneous 15-24
15.8.2 Materials 15-14 15.11.3.7 Completion 15-24
15.8.2.1 Masts and Columns - General 15-14 15.11.4 Method of Measurement 15-24
15.8.2.2 Columns 15-15 15.11.5 Basis of Payment 15-25
15.8.2.3 High Masts 15-15 15.11.6 Items in the Bill of Quantities 15-25
15.8.2.4 Road Lighting Luminaires and Lamps 15-16
15.12 Overheight Vehicle Detection
15.8.2.5 Flood Lights 15-18
System 15-25
15.8.3 Construction Requirements 15-18
15.8.4 Method of Measurement 15-19 15.12.1 Description 15-25
15.8.5 Basis of Payment 15-19 15.12.2 Design Criteria for Materials
15.8.6 Items in the Bill of Quantities 15-19 and Components 15-25
15.12.3 Operational Requirements 15-25
15.9 Overhead Sign Illumination 15-19
15.12.4 Physical Requirements 15-26
15.9.1 Description 15-19 15.12.5 Construction Requirements 15-27
15.9.2 Materials 15-19 15.12.6 Method of Measurement 15-27
15.9.3 Construction Requirements 15-19 15.12.7 Basis of Payment 15-27
15.9.4 Method of Measurement 15-20 15.12.8 Items in the Bill of Quantities 15-27
15.9.5 Basis of Payment 15-20
15.13 Emergency Roadside
15.9.6 Items in the Bill of Quantities 15-20
Telephone System 15-27
15.10 Under Bridge Lighting 15-20
15.13.1 Description 15-27
15.10.1 Description 15-20 15.13.2 Regulations and Standards 15-28
15.10.2 Materials 15-20 15.13.3 Definitions and Mode of Operation 15-28
15.10.2.1 Surface Mounted Luminaires 15-20 15.13.4 Products and Materials 15-29
15.10.2.2 Recessed Mounted Luminaires 15-20 15.13.4.1 Pillar Design and Manufacture 15-29
15.10.3 Construction Requirements 15-21 15.13.4.2 Pillar Dimensions and Weight 15-29
15.10.4 Method of Measurement 15-21 15.13.4.3 Frangibility 15-29
15.10.5 Basis of Payment 15-21 15.13.4.4 Pillar Materials and Color 15-29
15.10.6 Items in the Bill of Quantities 15-21 15.13.4.5 IP Rating 15-29
15.13.4.6 Vibration and Shock 15-29
15.11 Traffic Signals 15-21
15.13.4.7 Wind 15-29
15.11.1 Description 15-21 15.13.4.8 Temperature 15-29
15.11.2 Materials 15-21 15.13.4.9 Lightning Protection 15-30
15.11.2.1 General 15-21 15.13.4.10 Vermin Ingress 15-30

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Ref. Title Page No. Ref. Title Page No.
15.13.4.11 Vandalism 15-30 15.16.3.1 Labeling 15-37
15.13.4.12 Pillar Identification 15-30 15.16.3.2 Testing and Commissioning 15-38
15.13.4.13 Concrete 15-30 15.16.4 Method of Measurement and Basis
15.13.4.14 Steelwork 15-30 of Payment 15-38
15.13.5 Power Supply 15-30
15.17 Civil Works for Electrical
15.13.5.1 Power Supply 15-30
Installations 15-38
15.13.5.2 Battery 15-30
15.13.5.3 Battery Charging 15-30 15.17.1 Description 15-38
15.13.5.4 Solar Panel 15-30 15.17.2 Materials 15-38
15.13.6 Construction Requirements 15-31 15.17.3 Construction Requirements 15-39
15.13.6.1 Drawings 15-31 15.17.3.1 Bases for Poles and Equipment 15-39
15.13.6.3 Anchor Bolt Assembly 15-31 15.17.3.2 Cable Trenches and Ducts 15-39
15.13.6.4 Pillar Mounted Telephone 15-31 15.17.4 Method of Measurement 15-40
15.13.6.5 Grouting of Pillar Base 15-31 15.17.5 Basis of Payment 15-40
15.13.7 Method of Measurement 15-31 15.17.6 Items in the Bill of Quantities 15-40
15.13.8 Basis of Payment 15-31
15.13.9 Items in the Bill of Quantities (Unit) 15-31

15.14 Public Lighting Management

and Control System 15-31
15.14.1 Description 15-31
15.14.2 General Requirements 15-31
15.14.3 Detailed Technical Specification 15-32
15.14.4 Remote Control Management Software 15-33
15.14.5 Hardware 15-35
15.14.6 Method of Measurement 15-35
15.14.7 Basis of Payment 15-35
15.14.8 Items in the Bill of Quantities 15-36

15.15 Earthing 15-36

15.15.1 Description 15-36
15.15.2 Materials 15-36
15.15.3 Construction Requirements 15-36
15.15.4 Earth Resistance Test 15-37
15.15.5 Method of Measurement 15-37
15.15.6 Basis of Payment 15-37
15.15.7 Items in the Bill of Quantities 15-37

15.16 Labeling, Testing and

Commissioning 15-37
15.16.1 Description 15-37
15.16.2 Materials 15-37
15.16.3 Construction Requirements 15-37

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♦ 1-0
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15.1 General
15.1.1 Scope
1 This Sub-section describes general requirements for
electrical systems, including medium voltage substations,
packaged substations, cables and feeder pillars, road and
under-bridge lighting, traffic signals, illuminated signs,
detection system and emergency telephone system, and
all associated work. Specific requirements for each system
are given in the relevant Sub-sections of this Section.
2 Subsidiary (complementary) items which are not
expressly specified but are necessary for completion of
the work shall be supplied and installed by the Contractor
and their costs are deemed to be included in the rates and
prices for the relevant work.
3 The power supply connection for the lighting
systems shall be coordinated with and obtained from a
nearby source assigned by the concerned local power
authority.
4 The Contractor shall pay all power connection
charges and fees imposed by the Local Power Authorities
and Municipalities, including execution of all civil works
(trench, ducts).
5 The work shall be complete in every respect for
satisfactory operation in compliance with the
specifications and standards laid down by the respective
authority and as given herein.
15.1.2 Design
1 The location of light fittings, poles, feeder pillars,
distribution transformers and cables, etc. are shown for
guidance on the Drawings. Final locations shall be subject
to the road configuration, lighting calculations and
approval by the Concerned Authorities.
2 The Contractor shall coordinate with the Engineer
and shall determine the exact position and location of all
lighting and electrical equipment with respect to other
services and site requirements.
3 The Contractor shall be responsible for proper
lighting distribution on the road surface from the
proposed luminaires and other equipment after
installation and commissioning and shall be fully
responsible for maintaining the entire road lighting
system during the maintenance period of the Works.
15.1.3 Regulations and Standards
1 The Contractor shall comply with the regulations and
requirements of the concerned authorities, and shall get
all necessary approvals of the shop drawings from the
respective authority after obtaining approval of the
Engineer. If the road lighting works are executed by a Sub-
Contractor, the Contractor has to ensure that the Sub-
Contractor is approved by the Concerned Authority.
2 The quality of equipment shall be of the best grade
for each type as approved by the Engineer, even though
such quality may not be stated specifically in this
Specification.
3 All materials and products shall be new and
manufactured by manufacturers approved by the
concerned authority. Furthermore, they shall be sound
and uniform in quality, size, shape, color and texture and
free from cracks, warpage or other defects.
4 All warranties as applicable that are available from
the manufacturers shall be submitted to the Engineer in
original documents.
15.1.4 Factory Tests
1 All equipment and materials shall be subject to pre-
shipment inspection and testing at the manufacturers’
premises. The Contractor, in coordination with the
manufacturers of relevant materials shall arrange for the
pre-shipment inspection and testing by the authorized
representative of the Engineer at the manufacturers’
premises.
2 The Contractor shall make all necessary
arrangements and pay all expenses in this regard
including representation, travelling and transportation,
boarding, lodging and any other associated cost for the
pre-shipment inspection procedures and witnessing of
the tests at the manufacturer’s premises. In lieu of the
above tests the Engineer, at his sole discretion, may
accept test certificates by an approved laboratory of
international standards.
3 The Contractor shall obtain from the manufacturer
and submit to the Engineer for approval, the complete
details of tests to be performed describing the procedures,
test observations and expected results. All test certificates
shall be in compliance with recognized international
standards as approved by the Engineer and the Concerned
Authority.
4 The Contractor shall ensure availability of all tools,
instruments, test equipment, materials etc., and all
qualified personnel required for the testing, setting and
adjustment of all equipment and materials including
putting the same into operation.
5 The Contractor shall inform the Engineer of the date
and time of test for each piece of equipment at least two
weeks in advance. The witnessing of tests by the Engineer
or his representative shall not absolve the Contractor from
his responsibility for the proper functioning of the
equipment, and for furnishing the guarantees. All test
results shall be supplied in triplicate.
15.1.5 Field Tests
15.1.5.1 General
1 Upon completion of the installations, the Contractor
shall perform field tests on all equipment, materials and
systems. All tests shall be conducted in the presence of
the Engineer for the purpose of demonstrating equipment
and system’s compliance with the Specification. The
Contractor shall submit for Engineer’s approval, complete
♦ 15-1 ♦
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details of tests to be performed, equipment used,
describing the procedure, test observations and expected
results.
15.1.5.2 Insulation Resistance Test
1 Before making connections at the ends of each cable
run or joint between cables, the insulation resistance test
of each cable section shall be made. Each conductor of a
multicore cable shall be tested individually with each of
the other conductor of the group and also with earth. If
insulation resistance test readings are found to be less
than the specified minimum in any conductor, the entire
cable shall be replaced and tests repeated on the new
cables. If cable joints are provided, then each cable
section shall be tested and joints made only after the tests
have been made satisfactorily. Finally the completed
cable length including the joints shall be tested.
2 All switchgear shall be given an insulation resistance
test after installation, but before any wiring is connected.
Insulation tests shall be made between open contacts of
circuit breakers, switches and between each phase and
earth. Refer to Sub-section 15.16 for details.
3 If the insulation resistance of the circuit under test is
less than the specified value, the cause of the low reading
shall be determined and rectified. Corrective measures
shall include dry-out procedure by means of heaters, if
equipment is found to contain moisture. Where corrective
measures are carried out, the insulation resistance
readings shall be taken after the correction has been made
and repeated twice at 12 hours interval.
4 The maximum range for each reading in the three
successive tests shall exceed 20% of the average value.
After tests have been made, the equipment shall be
reconnected as required.
15.1.6 Lighting Columns Tests – Pre-
shipment
1 The tubular steel columns shall be tested and the
results recorded for each test by the manufacturer in the
presence of an authorized representative of the Engineer
in the manufacturer’s premises. The material weight and
dimensions of columns as specified shall be certified by
the manufacturer. The columns shall be inspected for
compliance and will be rejected if they are found to be
outside the specified tolerances.
2 Loading Test:
The columns shall be cantilevered horizontally, rigidly
supported at base plate and loads applied at right angle to
the axis of the pole at the required point, i.e. at some
distance from top. Tests shall be as follows:
• Deflection test.
• Permanent set test
• Breaking load test
A sample comprising four columns shall be selected at
random out of each lot of 1000 and subjected to deflection
test. One column per thousand shall be tested for
♦ 15-2 ♦
permanent set test and breaking load test. When the
columns in the Works are limited in number, the
manufacturer may supply result of tests already done for
prototype testing on such columns, or supply calculation
based results, in lieu of carrying out deflection, permanent
set and breaking load tests.
3 Passive Safety of Support Structures:
If requested by the Concerned Authority, tests shall be
carried out on each type of column in accordance with BS
EN12767: 2007 level 4. Costs of such tests for
columns/high masts will be included under separate items
in the Bill of Quantities.
15.1.7 Switchgear Tests
1 Each circuit breaker shall be operated electrically and
mechanically or only mechanically if it is not electrically
operated. All interlocks and control circuits shall be
checked for proper connections in accordance with the
wiring diagrams furnished by the manufacturer and
approved by the Engineer
2 The Contractor shall properly identify the phases of
all switchgear and cables for connections to give proper
phase sequence.
3 Trip circuits shall be checked for correct operation
and rating of equipment served. The correct size arid
function of fuses, disconnect switches, number of
interlocks, indicating lights, alarms and remote control
devices shall be in accordance with approved
manufacturer drawings. Name plates shall be checked for
proper designation of equipment served.
15.1.8 Completed Tests
1 After any equipment has been tested, checked for
operation, etc., and is accepted by the Engineer, the
Contractor shall be responsible for the proper protection
of that equipment so that subsequent testing of other
equipment does not cause any damage to the already
tested equipment.
15.1.9 General Technical Conditions
1 Electrical work shall include the submission by the
Contractor of shop drawings and calculations required by
the Specification, as well as the provision of literature and
samples for the approval process.
2 All plant and equipment shall be supplied with the
necessary fittings, accessories and parts for the complete
installation, irrespective of whether all such fittings and
accessories are listed in the Specification and Drawings.
3 Installations shall be complete, tested, ready for
operation and fully integrated with other parts of the
construction and the utility supply. The Contractor shall
make available facilities for utility providers during
commissioning.
4 Electrical work shall comply with the concerned
authority rules and regulations, and be carried out in
accordance with the recommendations of the International
copy 249
Electro-technical Commission (IEC) and in compliance
with the following:
i. Relevant standards issued by the appropriate
authorities in the Sultanate of Oman including
the Ministry of Transport and Communications
(MOTC).
ii. BS 7671:2008, Requirements for electrical
Installations; (IEE Wiring Regulations (UK) as
published by the Institution of Electrical
Engineers, London, 17th Edition (or the latest
edition).
iii. Engineering and safety recommendations of G39
‘Model Code of Practice’ of the IEE.
iv. Recommendations for the Lighting of Roads for
Motor and Pedestrian Traffic – CIE-115 or
equivalent and equal standards.
5 Electric power will be supplied by the concerned
power authority at a defined voltage, 3-phase, 3 or 4 wires,
50Hz. It shall be distributed from sub-station feeder pillars
at 415/240 V, 3-phase, 4-wire having solidly grounded
neutral at the transformer neutral point. Single phase
equipment shall be connected between phases and
neutral in a way to balance the three phases.
6 The voltage at any point in an installed power
distribution network shall not deviate from nominal
voltage level by more than 5% under normal system
operating conditions.
7 The equipment shall be capable of giving continuous
and trouble-free service in the conditions given in Table
15.1.9-1. It shall be designed and constructed to withstand
full load operation when exposed to sun, dust storms,
corrosive agents, occasional heavy rain and a high level of
ultra violet radiation.
Maximum ambient shade
50°C
temperature
Minimum ambient
-2°C
temperature
Maximum temperature of
80°C
metal surface in direct sunlight
Humidity 100%
As per project
Altitude
requirement
Table 15.1.9.1: Operating Conditions for Equipment
8 The component parts of each electrical system or
piece of equipment shall be the latest product of a single
manufacturer, of standard design and dimensions, and
similar parts shall have been in satisfactory service for at
least two years
9 The maximum gust speed at 10m above ground level
in open level country for a 1 in 50 year return period shall
be taken as: 55m/s (198 km/h)
10 PVC sleeves where used, shall be of the long chain
high molecular mass type capable of reducing the loss of
plasticizer and shrinkage of the PVC due to high
temperature (uPVC).
15.1.10 Approval
1 Details of the manufacturers of proposed plant and
equipment shall be submitted for prior approval of the
Concerned Authority and Engineer. Approval of any
manufacturer will not constitute approval of his products.
The Contractor shall ascertain that the approved
manufacturers are capable of supplying the required
equipment and in conformity with the Specification.
2 The Contractor shall submit to the Engineer for his
approval, in particular, the following luminaire criteria
before placing an order:
i. Detailed literature on each luminaire, lamp and
control gear including manufacturer’s name,
catalogue number, rating, material specification,
overall dimensions, operating characteristics and
principles
ii. Details of changes to standard luminaires if
proposed for adaptation to conditions of
installation or to meet the Specification
requirements.
iii. Photometric data for lighting calculations
including polar light distribution curves,
coefficient of utilization, glare classification,
efficiency, depreciation factors etc.
iv. Calculations of luminance and illumination levels
and glare, as recommended, using approved
software and methods
3 Fully equipped samples of any item requested by the
Concerned Authority or Engineer shall be delivered as
soon as possible to the Concerned Authority before
placing of orders for the material or products, without
hindering the planned program and progress of work.
4 The Contractor shall not order any electrical
equipment or part, plant or fitting before receiving
approval for it. The Engineer may verify the performance
and quality of the samples submitted by instructing tests
to be carried out. Approval of samples shall not relieve
the Contractor of his obligations regarding the suitability
of the equipment and their performance, once installed.
5 The Contractor shall submit for prior approval by the
Engineer detailed working drawings and shop drawings
showing the physical layout of equipment, location of
masts and columns, foundation details, erection and
installation details, and wiring diagrams. Details shall
include bolts, nuts, brackets, rods and any small or large
item that is necessary for the construction, all to the
satisfaction of the Engineer and Concerned Authority.
15.1.11 Erection
1 The Contractor shall submit to the Engineer a
schedule of the parts and equipment to be erected. If
requested by the Engineer the Contractor shall open up for
inspection before erection any plant or equipment which
has been delivered to the Site partly assembled.
♦ 15-3 ♦
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2 The Contractor shall satisfy himself as to the
correctness of the electrical and mechanical connections
to plant and equipment installed before it is
commissioned.
3 Operation of plant and equipment still under the
control of the Contractor but which is made live shall be
subject to a ‘Permit to Work’ procedure in a format agreed
with the Engineer and the respective authorities.
15.1.12 Manuals
1 Prior to the final acceptance of the installation the
Contractor shall submit to the Engineer six sets of
operation and maintenance manuals for the installed plant
and equipment. The manuals shall be A4 size in loose leaf
binders containing the following:
15.1.15 Road Lighting
1 The Contractor shall provide detailed computerized
calculations to demonstrate that the luminaires proposed
meet the criteria for illumination and luminance given in
the Specification, standards and shown on the Drawings.
2 Upon completion of a lighting installation as
specified the Contractor shall carry out measurements of
the illumination levels on the Site in accordance with
clause 15.16 and submit the results to show that the
design levels and uniformities have been achieved. The
maintained illumination and luminance levels shall be as
given in Table 15.1.15.1.
3 Illumination lighting levels shall be measured for all
the traffic lanes.

Secondary

Distributor
i. Single line diagrams of the complete network

National

Arterial

Access
Routes

Routes

Routes

Routes

Routes
properly labeled
Characteristic
ii. Control, protection and circuit diagrams for all
equipment.
iii. Setting up, commissioning and operating
Average
instruction.
Luminance level
iv. Trouble shooting procedures. 2 2 1.5 1.5 0.75
Lav (cd/m2)
v. Maintenance instructions including schedules for (maintained)
preventative maintenance. Overall
vi. Complete recommended spare parts list uniformity 0.4 0.4 0.4 0.4 0.4
including part numbers and the manufacture’s UO = LMin/ Lav
name, address, telephone and fax numbers. Longitudinal
vii. Name of the manufacturer’s local authorized uniformity
0.7 0.7 0.7 0.7 0.6
of each lane
representative and service agent.
UL = LMin/LMax
Maximum
15.1.13 Handling threshold 10% 10% 15% 15%
-
Increment (TI)
1 The Contractor shall provide slings, lifting tackle and
Road surface
cranes for the safe handling of items supplied and shall be
characteristics
responsible for obtaining and keeping up to date the R3* R3 R3 R3 R3
CIE classification
necessary test certificates for this handling equipment. with qo = 0.07
Protection of surfaces and floors during installation shall Average
be the responsibility of the Contractor. Horizontal
Illuminance 35 35 25 25 12
15.1.14 Spares E av. (Lux)
(maintained)
1 Spare parts indicated in the Bill of Quantities shall be Illuminance
supplied suitably packed for transportation to Site and Uniformities 1:3 1:3 1:3 1:3 1:3
long term storage. They shall include fastenings, lugs, and EMin/Eav
screws needed for their attachment. Identification labels EMin/EMax 1:6 1:6 1: 6 1: 6 1: 6
shall be attached to the outside and also enclosed within
*(R3: asphalt road surface with rough texture, slightly
the storage case.
specular)
2 Spares for routine maintenance shall be listed and
Table 15.1.15.1: Maintained Road Illumination and
supplied in quantities equal to 5% (rounded up to the next
Luminance Levels
whole unit) of installed quantities of each type of column,
cable, joint, lamp, control gear, circuit breaker, fuse,
luminaire, luminaire cover and associated bolts, nuts, 15.1.16 Sign Lighting
lampholders, etc. 1 The illuminance level and uniformity shall be
3 Any additional spare parts recommended by the calculated and measured on the sign surface at the
manufacturers, but not named above, shall be included in vertices of the grids defined by dividing it into 1m x 1m
the list. squares and shall be better than the following:
Average illuminance (EAV) : 200-400 lux
Uniformity (EMin: EMax) : 1:6

♦ 15-4 ♦
copy 249
2 The luminaires or floodlights shall be of purpose i. Danger High Voltage.
built design incorporating the specified size and type of ii. Keep Out.
lamps.
iii. Telephone number of emergency
3 The luminaires or floodlights shall be of pleasing contact.
aesthetic appearance with high quality finish, and shall
Additionally, instruction plates shall be posted inside high
comply with BS EN 12899-1, IEC 60598-1, IEC 60598-2-3,
voltage rooms and shall help operating staff to evacuate in
IEC 60598-2-5 and other related parts of this standard as
case of emergency.
applicable.

15.1.18 Method of Measurement

15.1.17 Medium Voltage and Substation
Work - Generally 1 The provision of power supply from the Concerned
Authority to the assigned position of the feeder pillar,
1 Medium-voltage switchgear and control gear
including cable, (KWh-meter), connections at both ends
standards and substation work, equipment and
and all necessary related civil works shall be given as a
component parts are to comply with the following
unit.
standards:
Common specifications: IEC 62271-1 2 Spare parts for routine maintenance and any special
Metal-enclosed switchgear and control gear for rated spare parts ordered by the Engineer shall each be given as
voltages above1 kV and up to and including 52kV items.
IEC 62271-200
High-voltage alternating current circuit- breakers 15.1.19 Basis of Payment
IEC 62271-100 1 The provision of power supply to the feeder pillar
Insulation coordination IEC 60071 shall be paid by number of units, which shall include
Alternating current switch-fuse combinations coordination with the Concerned Authority and for them
IEC 62271-105 to provide power supply to the feeder pillars, including
High-voltage A C. disconnectors and earthing switches subscription fees, supply and installation of breakers,
IEC 62271-102 cables, KWh metering, execution and completion of all the
Switches for rated voltages above 1 kV and less than related civil works.
52 kV IEC 62271-103
2 Spare parts shall be paid for according to the
Metering and protective current transformers (CTs)
completely delivered items by type and quantities as per
IEC 60044-1
the approved list.
Metering and protective voltage transformers (VTs)
Capacitive IEC 60044-5(IEC 60186)
Inductive IEC 60044-2 15.1.20 Items in the Bill of Quantities
Relays IEC 60255 i Power supply connection to the feeder pillar. (nr)
Surge arrestors IEC 60099-5
ii Spare parts (5% as per the approved list. (L.S)
Reading instruments IEC 60051
Watt-hour meters IEC 60521, 62052-11
62053-21,-22,-23 15.2 Medium Voltage Intake Switching
Power transformers IEC 60076, 60354, Stations
60076-11,-10
60156 15.2.1 Description
Insulating oil IEC 60296
1 This Sub-section describes requirements for
Sulphur hexafluoride IEC 60376
supplying, installing, testing and putting into operation the
Fuses IEC 60282-1
M.V. switchgear which shall be in accordance with
Climate conditions IEC 60721-3-3
concerned authority specifications and approval, at
and IEC 60721-3-4
locations indicated on Drawings.
Neutral earthing resistance (when required)IEEE std 32.
For all substations, switching and package stations, the 15.2.2 Materials
short circuit capacity rating, the low voltage control and
1 Medium voltage intake and switching units shall
power supply where needed or other provisions, have to
comprise panels containing the following equipment as
be coordinated with the Concerned Authority and
shown on the Drawings and as required by the concerned
provided accordingly.
authority:
2 Contractor shall provide danger signs in both Arabic
i. Circuit breakers for network control.
and English according to Omani standards made of heavy
ii. Circuit breakers for outgoing circuits.
duty corrosion proof metal, each of not less than 200mm x
300mm installed on all sides of substations, to clearly The panels shall be equipped with floor mounting
indicate to approaching people the hazard. These signs framework, skid bases, internal wiring, labels and cable
shall include:

♦ 15- 5♦
copy 249
sockets. The assembly shall allow for cable access from
below without dismantling any structural members.
2 The network control circuit breakers shall be
manually charged, spring operated, fitted with integral
earthing of the characteristics given by the Concerned
Authority.
3 Voltage transformers shall be installed and
connected to the primary side of the breaker, to supply the
lighting and small power for the switching station.
Voltage transformers shall be isolatable and fused on
primary and secondary sides.
4 The outgoing circuit breakers shall be manually
charged, spring operated, fitted with integral earthing of
the characteristics given by the concerned authority and
as shown on the drawings.
5 Tripping of breakers shall be by direct acting primary
trip coil or by current transformer operated direct acting
trip coils. A neon indicator connected to a voltage
capacitor divider indicating voltage presence shall be
fitted on each circuit breaker.
6 Intake stations shall be supplied with the necessary
accessories to form complete operating installations,
including the following:
i. Rubber gloves
ii. Rubber mat extending the full length of the
equipment
iii. KV potential testers
iv. Spare fuses
v. Test plugs
vi. Safety and operating instructions
vii. Framed and glazed medium voltage line
diagrams
viii. Wall mounted cupboards, with mortice lock and
three keys each.
15.2.3 Construction Requirements
1 The Contractor shall coordinate with and get
approval from the selected manufacturer of the switching
plant on the proposed civil works before starting
construction.
2 The construction of the buildings shall comply with
the requirements of Subsection 15.17.
3 The equipment shall be lifted into position within the
station upon prepared foundations. The station
switchboards may be installed complete or in sections.
The units shall then be tested before and after incoming
and outgoing cables are connected.
15.2.4 Method of Measurement
1 The approved work shall be measured by the number
of medium voltage intake switching stations, installed in
station building (excluding building) and put into
operation after testing, and acceptance by the concerned
authority.
♦ 15- 6♦
15.2.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate stated in the Bill of Quantities and shall be full
compensation for equipping, supplying materials,
installation, testing and putting into operation, labor,
transport, equipment, tools, spare parts and other items
necessary for the proper completion of the work.
15.2.6 Items in the Bill of Quantities
i Medium voltage intake switching station
(type) (voltage) (rating) (reference drawings) (nr)
15.3 Package Sub-stations
15.3.1 Description
1 This Sub-section describes requirements for
supplying, installing, testing and putting into operation,
factory assembled package sub-stations and connecting to
the medium voltage supply and the low voltage
distribution network.
15.3.2 Materials
1 Package sub-stations shall be completely self-
contained, factory assembled in a totally enclosed, vandal
and weather resistant housing, ready for placing into
position upon a concrete base pad.
2 Package sub-station shall comprise of a single
integrated metal housing, with three totally segregated
compartments, accommodating MV switch-gear, MV/LV
distribution transformer and LV switchgear. Degree of
protection shall be IP 54 for switchgear (MV or LV)
enclosures and IP 23 for transformer housing. MV and LV
connections to corresponding transformer terminals are to
be insulated and inaccessible without the use of tools.
3 The MV live parts shall be completely enclosed in
lockable compartments, which shall be segregated for
maximum safety, but give the necessary access for
cabling and connections, IP5X minimum, in accordance
with IEC 62271. Cables shall enter and leave the
compartments from below. A chain link fence 2m high
shall be provided around the sub-station with a lockable
gate.
4 The medium voltage switchgear shall consist of two
(2) ring main SF6 switches and one switch-fuse (sealed for
life), with fuses mounted in a separate compartment.
Handle design is to ensure delay between closing and re-
opening of main switch or earthing switch, to provide an
anti-reflex operation. It shall be impossible to move earth
switch inadvertently into or from earth position except
when main switch is in the open position. Indication of
switch position shall be mechanical, directly connected to
moving contacts. Each switch shall have a padlocking
device in the open, closed and earth positions. Semaphore
type indicators shall be provided to indicate on, off, earth-
on earth off positions, protected with polycarbonate
copy 249
covers. The fuse access shall be interlocked to prevent it
being opened unless the switch is off and earthed at both
ends.
5 The ring main switches shall be fitted with cable
boxes and glands. The cables shall be connected to the
fixed mating contacts by flexible connectors provided with
a slotted hole.
Alternatively, MV switchgear compartment cable terminal
connectors shall be conical stress-relieving, epoxy sealed
end, bolted, straight/elbow, molded rubber, plug-in, or
other type, complete with all accessories as may be
suggested by manufacturer and approved by the
concerned authority.
6 MV switchgear compartment potential indicators
shall be neon indicators, provided at front of each unit,
one per phase, using capacitive potential divider to
indicate voltage at switch-disconnector cable terminals.
7 MV switchgear compartment accessories are to
include the following:
i. Two N.C. and two N.O. auxiliary contacts on
each switch.
ii. Earth fault indicator, operated by core-balance
type current transformer, located near and
outside cable box/ terminations with indicator
visible from the front and with automatic reset.
iii. Shunt trip release on switch-fuse combination.
8 The transformer feeder switch shall have a trip
button or shall trip automatically by fuse operation. An
interlock shall be provided so that the switch-fuse cannot
be put back into service until the faulty fuse has been
replaced.
9 The low voltage switchboard shall be a separately
enclosed metal compartment with lockable doors within
the package housing and shall be of equal construction to
the feeder pillar. It shall consist of a triple pole and neutral
manually operated main circuit breaker of the molded
case pattern of the required ampere interrupting capacity.
Overload and short circuit release mechanisms
comprising thermal and magnetic trips and earth leakage
protection (30mA), shall be provided.
10 Three ammeters fitted with selector switch,
maximum demand indicator and current transformers
shall be incorporated along with a voltmeter with selector
switch and protection fuse.
11 A single phase socket outlet of 16-250 DIN rating
complete with plug top and a 12W fluorescent lighting
fitting of the integral battery/inverter emergency type, with
switching facility to allow emergency light to be initiated
shall be mounted adjacent to the low and medium voltage
switchgear panels and shall be prewired at the factory.
12 The low voltage panel circuits serving the lighting
shall be supplied through triple pole circuit breakers and
triple pole contactors (one set per circuit) which shall be
dual photo-electric cell controlled. The low voltage panel
and components shall meet the requirements specified in
Subsection 15.6. The package sub-station shall be fitted
with a compartment housing the accessories to form a
complete operating installation as follows:
i. Rubber gloves.
ii. Spare fuses.
iii. Safety and operating instructions.
iv. Medium voltage line diagram.
v. Low voltage circuit diagram with designations.
vi. kV potential tester
vii. Kilowatt hour metering as per requirements
Additionally, instruction plates shall be posted inside high
voltage rooms and shall help operation staff to evacuate in
case of emergency.
15.3.3 Construction Requirements
1 The Contractor shall agree with the selected
manufacturer of the package sub-station on details for the
proposed civil works and shall have shop drawings
approved before construction starts.
2 The Contractor shall install the package sub-station
unit upon the concrete base using the appropriate lifting
gear to prevent damage. When correctly located, the unit
shall be bolted in position and tested before and after
connecting the incoming and outgoing cables.
15.3.4 Method of Measurement
1 Package sub-stations shall be measured by the
number of complete units supplied, installed, tested, put
into operation and accepted by the Concerned Authority,
including time switch and connection.
15.3.5 Basis of Payment
1 The amount of completed and accepted work measured
as provided for above will be paid for at the unit rate
stated in the Bill of Quantities and shall be considered as
full compensation for supplying and installing the sub-
station, testing, putting into operation, handing over,
including all materials, labor, transport, equipment, tools
and other items necessary for the proper completion of
the work.
15.3.6 Items in the Bill of Quantities
i Package sub-station (type) (reference)
(rating) (voltage) (nr)
15.4 Package Medium Voltage
Switching Stations
15.4.1 Description
1 This Sub-section describes requirements for
supplying, installing, testing and putting into operation
factory assembled package medium voltage switching
stations, and connecting to the medium voltage electrical
supply network.
♦ 15- 7♦
copy 249
15.4.2 Materials
1 Package switching stations shall be self-contained;
factory assembled conforming to MV Switchgear
specification in Sub-section 15.3.
2 The switching station shall contain 3 extensible SF6
switch units with space for one additional SF6 switch. The
switches shall be fitted with cable boxes and glands
suitable to receive the incoming cables and shall have
operating positions at the front of the unit. The switching
mechanisms shall be independent manual type.
Engineer. The transformers and all accessories shall
conform to the requirements, standards and specifications
of the concerned authority and the Contractor shall obtain
all necessary approvals from the Concerned Authority in
this regard.
15.5.2 Materials
1 Metal work shall be hot-dipped galvanized to BS EN
ISO 1461 and ASTM A123 and ASTM A153, whichever is
more stringent, after fabrication.

3 Switching stations shall be supplied with accessories
as for sub-stations with the exception of the low voltage
circuit diagrams.
4 Emergency lighting if required by the Concerned
Authority, shall be coordinated with the Concerned
Authority and be provided as specified in Sub-section 15.3,
Clause 15.3.2 (11).
15.4.3 Construction Requirements
1 Construction requirements shall be as specified in
Sub-section 15.3, Clause 15.3.3.
2 Transformers shall be painted by the manufacturer.
Standard identification plates shall be fixed.
3 Bushings and insulators shall have a minimum
Creepage value of 40mm/kV.
4 The transformer station supports shall be ‘H’ type
construction, using 11m long, preservative treated,
wooden (Pinus Sylvestris) poles type. The support system
shall be fitted with 4 stay sets, each comprising tubular
stay-rods, wood stay insulators, galvanized steel wire of
minimum diameter 4mm and pole clamps. The poles
shall be fitted with galvanized mild steel cross arms to
support the transformer.

15.4.4 Method of Measurement 5 The 11kV fuse units shall be 3 phase expulsion drop-
out type with 900mm phase to phase spacing and fitted
1 Package medium voltage substations work shall be with re-wireable fuse elements.
measured by the number of units supplied, installed, put
6 The 33kV switch fuse units shall be 3 phase, vertical
into operation, accepted by and handed over to the
mounting, with 1050mm phase to phase spacing. The
concerned authority, including connection to the MV
switch shall include a treated wooden, insulated,
supply, fees, and the cost of power connection from the
operating handle at 1.2m from ground level. The fuses
assigned source.
shall be of the expulsion drop-out type, fitted with re-
wireable fuse elements.
15.4.5 Basis of Payment
7 The transformers shall be the pole mounted type
1 The amount of completed and accepted work with outdoor bushings on both medium and low voltage
measured as provided for above will be paid for at the unit sides and shall have the characteristics given in Table
rate stated in the Bill of Quantities, which rate shall be full 15.5.2-1.
compensation for supplying, installing the station, testing 8 The low voltage units shall be 3 outdoor pole mount
and putting into operation, connection labor, transport, porcelain cut-outs fitted with appropriately rated HRC
equipment, tools and other items necessary for the proper fuses.
completion of the work.
Rating As indicated on drawings
15.4.6 Items in the Bill of Quantities Phases 3
i Package medium voltage switching Winding Connections: Delta 3 wire primary
station (type) (reference) (voltage). (nr) Star 4 wires sld earthed
neutral secondary
15.5 33kV and 11 kV Pole Mounted Tappings Dyn 11
Transformer Sub-Stations Impedance Medium voltage off-circuit
+5% to -5% in 2.5%steps
15.5.1 Description
Cooling Oil filled natural
1 This Sub-section describes requirements for
Temperature Rise:
supplying, installing, testing and putting into operation
pole mounted transformer sub-stations and connecting to Oil 40°C
the medium voltage supply on one side and the low Windings 50°C
voltage distribution network on the other side. Table 15.5.2.1: Pole Mounted Transformer Characteristics
2 The capacity of pole mounted transformers shall be
as shown on the Drawings and or as directed by the

♦ 15- 8♦
copy 249
15.5.3 Construction Requirements
1 The Contractor shall coordinate and agree the
location of pole mounted transformer stations with the
Engineer prior to commencing the installation. The poles
shall be installed in concrete at 2.2m centers for the 33kV
system and 1.8m centers for the 11kV system.
2 The Contractor shall install the equipment using the
appropriate lifting gear to prevent damage. The medium
and low voltage connections shall be made only after the
equipment is correctly installed and tested.
15.5.4 Method of Measurement
1 Pole mounted transformer sub-stations shall be
measured by the number of units supplied, installed, put
into operation and accepted by the Concerned Authority.
2 The rate shall include for transformer, 11m long
preservative treated supporting wooden poles, platform
for mounting transformer, galvanized mild steel cross
arms, stay sets, insulators, post insulators and support
assembly, 4mm diameter galvanized steel wire, 33kV or
11kV fuse units, low voltage HRC fuses and all other
necessary hardware, GI guards and anti-climbing device,
earthing with or without chamber, 33kV or 11kV
connections, connection to the medium voltage supply
and low voltage distribution network and all other
accessories.
15.5.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate stated in the Bill of Quantities, which rate shall be
considered full compensation for supplying and installing
the complete sub-station, including supporting poles and
platform, earthing, testing, connecting, putting into
operation, and for materials, labor, transport, equipment,
tools, supplies and other items necessary for the proper
completion of the work as specified.
15.5.6 Items in the Bill of Quantities
i Pole mounted transformer sub-station,
(…KVA), 33KV/415V/240V, 3-phase, 4-wire,
solidly earthed neutral, (Ref. as
shown on dwgs). (nr)
ii Pole mounted transformer sub-station,
(…KVA), 11KV/415V/240V, 3-phase,
4-wire, solidly earthed neutral,
(Reference as shown on drawings). (nr)
15.6 Feeder Pillars
15.6.1 Description
1 This Sub-section describes requirements for
supplying, complete feeder pillar(s), installing, mounting,
testing and putting into satisfactory operation feeder
pillars for road lighting networks as shown on Drawings.
2 The Contractor shall submit data for approval,
including but not limited to the following:
i. Construction details, standards to which pillars
comply, current carrying capacities of bus bars,
de-rating factors employed for breakers and bus
bars.
ii. Manufacturer’s catalogue cuts for all
components.
iii. Dimensional and electrical characteristics and
samples of breakers used
3 The Contractor shall submit drawings for approval,
including but not limited to the following:
i. External dimensions of feeder pillars
ii. Details of base foundation
iii. Details of breaker ratings, bus bars
iv. Glands, joints, etc
v. Mounting details
15.6.2 Materials
1 Feeder pillars shall comply with IEC 60439-1 and /or
other equally approved standards
2 The feeder pillar shall be a totally enclosed cabinet,
fully self-contained, dust proof, weather proof, vermin
proof and suitable for mounting outdoors exposed to dust,
rain and direct sunlight (IP55).
3 The cabinets shall be reinforced free standing
structures, manufactured from 2mm thick steel with bolted
reinforced corner construction. They shall be of the dwarf
type with a bolting down base for mounting on a pre-
formed concrete pad suitably furnished for all incoming
and outgoing cables from below ground level within a
duct system.
4 Cabinets shall have two hinged lockable doors to
provide full front access. The roof of the cabinets shall be
slanted and have water drip edges.
Moulded case Four pole, equipped with overload
Circuit Breakers andshort circuit release mechanism
MCCB’s comprising thermal and magnetic
(to IEC 60947-2) trips(IEC 60947-2 sequence III).
Triple-pole, magnetic type , to
Contactors
interrupt an inductive load equal
(to IEC 60947-4-
to the indicated rating.
1)
Utilization Cat. AC-5a and AC- 5b
Fully insulated, rated 1.25 the main
incoming molded case breaker frame
size at 50 degrees C, with three
Bus bars, 3 ammeters each fitted with maximum
phase + full demand indicator with associated
neutral current transformers, and voltmeter
with selector switch and protection
fuse.
PVC/PVC single core 1000 v grade,
Internal
with copper conductors, rated as
Cabling
required and suitably laced or clipped.
Table 15.6.2.1: Feeder pillar fittings
♦ 15- 9♦
copy 249
5 Feeder pillars shall be complete with equipment and
fittings incorporating molded-case circuit breakers
controlling the main supply and the outgoing circuits.
Feeder pillars shall have the fittings given in Table 15.6.2.1.
6 Equipment, busbars, and conductors within the pillar
shall be fully insulated such that there are no live parts or
connections exposed. The feeder pillar shall have a 50mm
x 6mm high conductivity copper main earth bar for
grounding purposes. A distribution diagram showing
circuit connections, MCCB ratings, cables sizes and
references shall be suitably fixed to the inside of the
cabinet door. Feeder pillars shall be secured against
unauthorized access by means of wedge locks protected
by brass plugs and operated by a special key.
7 A single phase socket outlet of 16-250 DIN rating
complete with plug top and a 12W fluorescent lighting
fitting of the integral battery/inverter emergency type, with
switching facility to allow emergency light to be initiated
shall be mounted adjacent to the low panels and shall be
prewired at the factory.
8 Feeder pillars shall be finished with the following
internal and external treatments:
i. De-rust.
ii. De-grease.
iii. One coat of sprayed zinc chromate primer.
iv. Two coats exterior paint, dark grey to BS 381C
shade 632.
9 The low voltage distribution circuits serving the
street lighting installation shall be supplied through a
triple-pole contactor which shall be dual photo-electric cell
controlled by two photocells connected and mounted in
parallel with a timer .as specified below. An override
facility shall be provided for maintenance.
a) Contactors shall be, electro-magnetic type,
class AC 5a or AC 5b to IEC 60947-4, designed
to withstand large initial currents of discharge
lamps or tungsten lamp loads respectively, and
rated not less than overload setting of
protective device upstream. Contacts are to be
double break, silver cadmium plated, having
self-cleaning wiping action. Control is to be
provided by phase-neutral (maximum 240 V)
split-coil, for on/off activation by local and/or
by remote direct-wired means. Contactor is to
be mechanically latched. Control circuit is to
be fused. Auxiliaries are to include local pilot
lights, parallel remote indicating circuit, 2 N.O.
and 2 N.C. auxiliary contacts.
10 Circuit breakers shall be totally enclosed, molded
case, (MCCBs) constructed from high quality, high
temperature resistant, tropicalized, moulded insulating
materials, for normal operation at 70 deg. C within
enclosures, to approved standards, provided with quick-
make, quick-break, trip-free switching mechanism
manually operated by front toggle type handle and
automatically tripped under overcurrent conditions. Multi-
pole breakers shall have common integral trip bar for
simultaneous operation of all poles. Contacts shall be non-
♦ 15- 10♦
welding silver alloy with arc quenching metallic devices of
approved construction. Cable terminals shall be solderless
anti-turn box lug or clamp type with set screws suitable
for copper or aluminum cables.
11 MCCBs generally shall be thermal-magnetic type for
ratings below 600 A frame size, unless otherwise shown
on the Drawings. MCCBs 600 A and larger shall be
electronic solid-state trip type. All circuit breakers shall be
3-pole unless otherwise shown on Drawings.
12 Thermal magnetic circuit breakers shall include, on
each pole, a bi-metallic inverse time-delay over-current
trip element for small overloads and instantaneous
magnetic over-current trip element for operation under
short-circuit conditions. Circuit breakers 250 A frame size
and larger shall have adjustable instantaneous trips.
13 Thermal over-current trips shall be compensated to
allow for ambient temperature higher at breaker than at
protected circuit or device. Compensation shall be
applicable between 25 and 50 deg. C. Where thermal
settings are adjustable, range of adjustment shall not
exceed maximum trip rating shown on the Drawings.
14 When tripped automatically by over-current
condition, operating mechanism of circuit breaker shall
assume an intermediate position clearly indicated by the
handle between on and off positions.
15 Circuit breakers 250 A to 600/630 A frame size shall
have interchangeable thermal and electronic trip units.
16 Non-interchangeable trip circuit breakers shall have
sealed covers. Circuit breakers with interchangeable trips
shall have trip unit covers sealed to prevent tampering.
17 Circuit breaker ratings shall be non-current limiting,
fully rated (100%) with continuous duty at site conditions,
and with frame size and interrupting capacity to IEC 60947-
2, sequence III (rated ultimate short-circuit breaking
capacity), and maximum trip rating as shown on the
Drawings. Interrupting capacities at specified voltage and
frequency shall meet IEC 60947-2 test sequence I, II, III and
IV for circuit breakers of utilization category B.
18 Circuit breaker design shall allow addition of
electrical operator, control and interlocking functions,
under-voltage release, shunt-trip coils, alarm and auxiliary
switches, padlocking devices, key-lock devices, and the
like. Such accessories shall be provided where shown on
the Drawings.
19 The photo-electric control shall consist of omni-
directional cadmium cell thermal relay of high quality,
employing solid state photo-variable conductance
elements giving a 2:1 on/off ratio with sensitivity to switch
on lights when the daylight illumination reduces to 70 lux.
This allows for the high pressure sodium lights striking
time, taking into account of the rather fast rate of daylight
intensity drop off in the region.
The photo electric cells shall be mounted at the top of the
nearest column or high mast or at the top of the feeder
pillar and connected to the feeder pillar.
20 A solar dial time switch shall be of the quartz,
electronic type, capable of operating for at least 100 hours
copy 249
in case of power failure. Timer shall be of settable type
once throughout the year and to be set at definite periods
for switching on and off.
21 Instruments shall be housed in enameled, square,
metal cases for flush installation. Scale and markings shall
be protected and sealed. Accuracy of instruments shall be
within 2% unless otherwise specified.
22 Voltmeters shall be the moving iron type, with centre
zero adjuster, range 1.25 times nominal system voltage 90
degree angle, size 76x76 mm.
Voltmeter selector switch shall be 7-position rotary type.
23 Ammeters (Number = 3) shall be moving iron type,
with centre zero adjuster, range 2 times nominal circuit
amperage, 90 degree angle size 76x76mm.
Ammeter selector switch shall be 7-position rotary type.
24 Current transformers, shall be suited to the nominal
current of plant protected, short circuit level and burden.
Current transformers shall be of the indoor dry type, rated
secondary 5A. Rated primary current core size and
accuracy shall be determined from circuit data.
25 Voltage transformers shall be provided where
required, complete with primary and secondary fuses and
disconnecting device.
26 The feeder pillar shall have a separate compartment
containing a three phase kWH meter.
27 Wiring
i. Wiring shall be modular and neatly arranged on
master terminal boards with suitable numbering
strips and appropriate cartridge type fuses where
required
ii. Connections shall be made at front of terminal
board and with no live metal exposed.
iii. Metal cases of instrument, control switches,
relays, etc… shall be connected, by bare copper
conductors not less than 2.5 mm2 section, to
nearest earthing bar.
iv. Control wiring shall be copper, PVC insulated, 85
degrees C, 600V grade, and PVC sheathed
cables. Finely stranded copper conductor, silicon
rubber insulated cables shall be used in
proximity to higher temperature components
and as flexible cable.
v. Wires shall be fitted with numbered ferrules of
approved type at each termination
28 Anti-condensation heaters with disconnect switch
and pilot lamp shall be provided in feeder pillars
controlled by thermostat and/or humidistat where
required.
15.6.3 Construction Requirements
1 Construction requirements shall be as specified in
Sub-section 15.3, Clause 15.3.3 for package substation
work.
15.6.4 Method of Measurement
1 Feeder pillars shall be measured by the number of
units supplied, installed, put into operation after testing
and acceptance by the concerned authority.
15.6.5 Basis of Payment
1 The amount of completed and accepted 'work
measured as provided for above will be paid for at the unit
rate stated in the Bill of Quantities which rate shall be full
compensation for supplying, installing feeder pillar,
testing, putting into operation the pillar, and for labor,
transport, material, equipment, tools, photo-electric cells,
timer, supplies and other items necessary for the proper
completion of the work as specified.
15.6.6 Items in the Bill of Quantities
i Feeder pillar, (size, rating (A))
(No. of ways, type and reference)
(415/240V). (nr)
15.7 Electrical Cables
15.7.1 Description
1 This sub-section describes requirements for
supplying and installing cables into trenches or through
pre-installed ducts, including connecting, terminating and
circuit testing.
2 The Contractor shall submit data for approval
including, but not limited to, the following:
i. Constructional details, standards to which cables
comply, current carrying capacities, derating
factors for grouping and temperature.
ii. Manufacturer's catalogue cuts.
iii. Dimensional and electrical characteristics.
iv. Samples of each cable and wire and, if requested
by the Engineer, other accessories.
v. Voltage drop calculations for each circuit in
schedule form.
3 Unless otherwise specified or shown on the
Drawings, cables and other feeders shall have copper
conductors. Cable conductors shall be stranded for
sections 4 mm2 and above, based on IEC 60228 Class 2.
Signal and control cables shall have solid conductors
unless otherwise specified. Flexible cords shall have
finely stranded conductors. Conductors of single-core
cables 25 mm2 and above shall be compacted. Multi-core
cables 35 mm2 and above shall be sectoral shape.
4 Conductor sizes shall be as shown on the Drawings.
Conductors with cross-sectional area smaller than
specified will not be accepted.
5 Wiring insulation shall be color coded or otherwise
identified as required by the applicable regulations as
follows:
Neutral: blue.
Protective earth: green-and-yellow striped.
♦ 15- 11♦
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 Phase colors: brown, black and grey as appropriate.
6 Maintain color coding throughout installation.
Phase-conductors for which outer jacket is not color-coded
shall have engraved alphanumeric marks (L1, L2, L3) or
color coded heat-shrinkable sleeves.
15.7.2 Materials
15.7.2.1 Low Voltage Cables
1 Unarmored cable shall be PVC insulated and shall
comply with BS 6004. Conductors shall be not less than
2.5mm² cross section.
2 Single core PVC insulated (85 deg. C.) non-sheathed
single conductor cables for wiring in conduit shall have
annealed copper conductors, compacted, generally with
concentric strands and insulated with flame retardant,
moisture and heat resistant PVC/C to IEC 60227 and
IEC60332-1, suitable for wet locations and for conductor
temperature of 85 deg. C. 450/750 V grade.
3 Multi-core PVC insulated (85 deg. C.) cables (0.6/1
kV): shall have annealed, copper conductors, compacted,
insulated with PVC/C to IEC 60227, moisture and heat
resistant, suitable for wet locations and fully rated
conductor temperature of 85 deg. C, laid up, bedded with
suitable filler and sheathed with flame retardant PVC/ST2,
general purpose sheathing to international standards (IS
5831: 1984 and IEC 60502-1).
4 Cables within lighting columns, high masts and
signs shall comply with BS 6004 and shall have separate
PVC (green striped yellow) insulated earthing cable
installed. Cables for recessed lighting shall be 3 core
copper, utilizing one core for earthing.
5 Armored cable shall be PVC/SWA/PVC to BS 6346 or
BS 5467 and IEC60502-1, IEC 60811 and IEC 60332-1.
Directly buried cables shall be armored type unless
otherwise indicated on the Drawings.
6 Armored cables shall have single layer of galvanized
steel wire armor with flame retardant PVC/ST2 over-
sheath. Armoring shall comply with BS 1442 and shall
provide 50% conductivity of phase conductor conductivity
as a minimum.
7 Cable covers for underground directly buried cable
protection shall be to BS 2484, with sand cushion around
cable and a layer of 200 mm wide protective concrete
bricks over the sand along the entire route of the cable.
The bricks shall be laid in such a way as to provide equal
margin of cover on both sides of the cable. A warning tape
shall be laid throughout the length of the trench.
8 Cables shall be terminated at equipment
switchboards, and isolators, using mechanical cable
glands, in accordance with the manufacturer's
recommendations.
9 Buildouts with cable lengths are required from
designers.
♦ 15- 12♦
15.7.2.2 Medium Voltage (MV) Cables
1 Medium voltage cables, insulation and rating shall
comply with BS 6622 and IEC 60502-2 for voltages up to 33
kV and IEC 60840 for voltages above 30kV up to 150 kV
(Um=170 kV). MV cables shall be capable of a conductor
operating temperature of 90°C under worst ambient
conditions at full load rating. Each phase shall be
identified by a distinctive marking on the cable. The cable
insulation grade (voltage designation) and manufacturer
shall be embossed on the cable over the sheath. The
semi-conductive layer shall be removable without the use
of tools.
2 MV cables shall be in accordance with the concerned
authority specification (MEW Standard OES 2 -
Underground Cable Installations).
15.7.2.3 Metal Gland Parts
1 Metal gland parts shall be brass, bright dipped, and
shall have a polychloroprene inner sheath, sealing ring,
armor clamping cone, armor nut and captive
polychloroprene outer sheath sealing ring. During
assembly the gland shall not induce torque in the cable
sheath or armor. A polychloroprene shroud shall be fitted
over the gland.
15.7.2.4 Cable Trays
1 Medium cable trays shall be galvanized steel, flanged
with heavy duty folded reinforced edge, and slotted. Cable
channel shall be galvanized steel.
15.7.3 Construction Requirements
1 Before any underground and ducted cabling is
installed, copies of the test certificates from the
manufacturer shall be submitted to the Engineer for
approval. The certificate shall show that the supplied
cable satisfies the appropriate standards.
The sizes of low voltage copper conductor cables shall be
as shown on the Drawings. Care shall be taken so that
voltage drop at the far end of the cable does not exceed
5% of the nominal voltage. Cables manufactured only by
reputed firms shall be used, provided they fulfill all the
requirements of the Specification and the concerned
authority standards.
2 Cable joints and terminations shall be completed
with the correct specified materials, tapes, stress cones,
glands, sleeves and bonds. Joints shall be made in
accordance with the cable manufacturer's
recommendations and BS 6910-1. No through joints shall
be allowed in low voltage cables where adequate
manufacturer's lengths are available.
3 A sample site-constructed cable termination and
through-joint shall be submitted to the Engineer prior to
any jointing commencing on site.
4 Termination of cables shall be either crimped or
soldered. Through-joints shall be complete with
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manufacturer's recommended metal sleeves and shall be
located in a cable draw-pit
5 For underpass luminaires PVC insulated, PVC
sheathed, SWA cable shall be pulled through already
laid/buried uPVC ducts or conduits in underpass slabs or
concrete structures.
6 The pulling of cables through ducts or conduits shall
be started only after the conduit (uPVC) system is
completely installed and all outlet boxes, junction boxes
etc. are fixed in position.
7 The contractor where not in conflict with these
Specifications shall carry out the requirements and abide
where necessary with Series 1400 (Electrical Work for
Road Lighting and Traffic Signs) and Series 1500
(Motorway Communications) of the DMRB found under
UK Standards for highways.
15.7.3.1 Cable Jointing and Termination
i. Through joints will not be allowed in feeder
cables where adequate manufacturer's lengths
are available. Where a joint is necessary, it shall
be made inside boxes, handholes or manholes.
ii. Through joints and terminations shall be carried
out strictly in accordance with cable
manufacturer's recommendations, and made
with correct specified materials, boxes, tapes,
compounds or mixtures, stress cones, glands
and bonds as applicable.
iii. Qualifications of operatives shall be submitted to
the Engineer prior to work commencing on site.
Joints are to be filled with epoxy resin after
taping unless contrary to cable manufacturer's
recommendations. Sample site constructed
cable terminations and through-joints shall be
submitted to the Engineer prior to commencing
work on site. Samples are to be constructed in
the presence of the Engineer and shall be
available for test and inspection in accordance
with manufacturer's recommendations.
iv. Cutting tools for jointing and terminating cables
are to be purpose made, to prevent damage to
insulation in general, and to cable shielding of
MV cables.
v. Cleaning of lacquer on conductors shall be by
use of non-scratch scouring sponge and white
spirit or equal approved.
vi. Tighten electrical connectors and terminals,
including screws and bolts, in accordance with
manufacturers published torque-tightening
values. Where manufacturer’s torque
requirements are not indicated, tighten
connectors and terminals to comply with
international standards.
15.7.3.2 Field Quality Control
1 Cable tests shall be carried out in accordance with
the requirements of the applicable regulations and
standards.
2 Perform the following in advance of independent
tests:
i. Test cables insulation resistance.
ii. Test circuits continuity.
iii. Furnish a set of applicable specifications and
manufacturer’s recommendations to test
organization.
iv. Make power available at test locations.
3 Schedule tests and notify Engineer at least one week
in advance of schedule for test commencement.
4 Provide megger testers of various ranges as
applicable, and HV test equipment as necessary for testing
MV installations. Use 1000 V megger on installations with
nominal voltage over 500 V up to 1000 V, and 5000 V
megger for initial checks on MV installations (up to 15 kV).
5 On installations of medium-voltage cables and before
electrical circuitry has been energized, demonstrate
product capability and compliance with requirements.
6 MV Cable Testing: Provide cable test set with D.C.
output voltage and ampere range sufficient to test MV
cables. Cables are to be laid in position (trench or duct
bank), jointed where applicable, but left uncovered, with
ends free of equipment and clear of ground.
7 MV Cable Testing: D.C. test voltage is to be applied
between core under test and the screen in steps, pausing
one minute or more each step (first step being the A.C.
rms rated voltage of the cable, followed by two equal
steps) up to maximum test voltage. At each step, and for
the last 5-15 minutes duration at maximum test voltage,
the ammeter (normally a micro-ammeter) is to be
monitored closely and recorded. If, except as voltage is
increased, the current starts to increase, test is to be
stopped and the installation inspected and tested for the
fault.
i. Each cable/core is to be tested independently.
Maximum D.C. test voltage for grounded neutral
system is to be 3 times rated A.C. rms voltage of
cable.
ii. Alternative test if approved by the Engineer, is to
apply A.C. rms voltage up to 1.5 times A.C. rms
rating of cable (26 kV for 17.5 kV cable), applied
for 15 minutes, by an approved A.C. test set.
Readings are to be within same range and in
accordance with IEC 60502.
iii. Replace or correct malfunctioning cables and
accessories at Project site, and retest to
demonstrate compliance until reaching
satisfactory conditions as per international
standards/ regulations; otherwise, remove and
replace with new units and retest.
15.7.3.3 Earthing
1 The armoring on cables shall be bonded to the
metalwork and to the earthing system in accordance with
the applicable regulations.
2 Shielded cable shall be earthed at terminations,
splices and separable insulated connectors. Earth metal
♦ 15- 13♦
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bodies of terminators, splices, cable and separable
insulated connector fittings and all hardware to be in
accordance with manufacturer’s written instructions.
15.7.3.4 Protection
1 Provide final protection and maintain conditions, in a
manner acceptable to manufacturer and installer, to
prevent entrance of moisture into the cables and to ensure
medium-voltage cables are without damage or
deterioration at hand-over.
15.7.4 Method of Measurement
1 Road lighting cable shall be measured in linear
meters for each size and type of cable as shown on the
Drawings or as directed by the Engineer, installed in duct
(excluding duct) or directly buried in trench (excluding
trench), complete with required accessories, including all
types of cable jointing and terminations, accessories such
as clamps, channels, clips, connectors, tugs, tapes and any
other item which is not stated above but is considered
necessary for completion of the work.
2 Underpass lighting cable shall be measured in linear
meters for each size and type of cable as shown on the
Drawings or as directed by the Engineer, complete with
required accessories including cable trays, pulling of cable
in already installed/buried conduit or uPVC ducts in slab,
all type of jointing and terminations and any other item
which is not stated above but is considered necessary for
completion of the work.
3 The approved cable work shall be measured by the
linear meter of cable installed plus an allowance of 2m at
each end for termination and jointing.
4 Trenches, ducts, warning tapes, and markers for
cables are measured separately under Sub-section 15.17.
15.7.5 Basis of Payment
1 The amount of completed and accepted cable work
as provided for above will be paid for at the unit rates
stated in the Bill of Quantities which rate shall be full
compensation for supplying materials, installing, testing,
putting into operation, and for labor, transport, equipment
tools, supplies and other work items necessary for the
proper completion of the work as specified.
15.7.6 Items in the Bill of Quantities
i Electrical cable (type) (voltage) (size) (lin.m)
15.8 Road Lighting Masts, Columns
and Luminaires
15.8.1 Description
1 This Sub-section describes requirements for supply,
erection upon prepared foundations and putting into
service road lighting masts and columns complete with
operating mechanisms, brackets, luminaires, control gear
and cabling.
♦ 15- 14♦
15.8.2 Materials
15.8.2.1 Steel Masts and Columns - General
1 Steel Masts and columns shall be fabricated from
steel, in accordance with Section 6, and hot dip galvanized
to BS EN ISO 1461 (inside and outside) or in accordance
with ASTM A123 and A385 to Engineers approval. They
shall be in sections not less than 10m in length, and shall
be joined on site by pressure over-lapping or slip joints
which shall have a minimum length of 1.5 times the
diameter of the joint. Columns up to 12m high shall be
supplied in one piece.
2 The walls of columns shall be a minimum thickness
of 3mm with a minimum ultimate strength of 370N/mm²
and a minimum yield strength of 240N/mm². Masts and
columns over 13m in height shall have a minimum wall
thickness of 4mm, a minimum ultimate strength of
520N/mm² and a minimum yield strength of 360N/mm².
3 Masts and columns when installed and fully
equipped, shall have safety factors in accordance with
Technical Report No. 7 of the Institution of Public Lighting
Engineers (UK): 2003 or latest edition. They shall be
capable of withstanding the gust wind velocity stated in
Clause 15.1.9 blowing in the most unfavorable direction at
a height of ten meters above ground level. The deflection
at the top of the mast or column shall not exceed 1/40 of
the height.
With a wind velocity of 198km/hr on the full projected area
of column, bracket and luminaire(s) a factor of safety of 3
on minimum tensile strength shall be maintained and
horizontal deflection at lantern position shall not exceed
1/40.
4 The Contractor shall submit to the Engineer detailed
manufacturer’s design calculation sheets and supporting
data to show that the masts and columns and foundation
designs respectively are safe and meet the above
requirements. The submitted calculations shall include the
following:
i. The deflection at the top of the mast or column at
the designed wind speed.
ii. The natural frequency of the mast or column.
iii. The critical wind speed for resonance.
iv. The damping characteristics of the mast or
column.
v. The steel stresses under resonant conditions.
vi. The value of acceleration at the top of the mast
or column under resonant conditions.
vii. Welding procedure details.
viii. Procedure details ensuring that the flange plate
is not laminated.
ix. Details of the joints between the mast or column
sections and between the bottom section and
flange plate.
x. Details of the base compartment with the
method of reinforcement at the door area and
means adopted for making the door
weatherproof and tamper-proof.
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 All the above shall be submitted for approval by the
Engineer before manufacturing commences.
Delivery shall not be done until factory tests are
completed to the satisfaction of the Engineer.
5 A hot dip galvanized steel flange base plate of
sufficient (20mm minimum) thickness, free from
laminations, shall be welded to the base of the mast or
column, fully developing the strength of the section.
Supplementary gussets shall be provided between the
bolt holes drilled in the flange, if necessary. The underside
of the flange and the inside of the pole to a height of
500mm shall be painted with bitumen. The outside of the
pole and the flange if under ground level shall also be
painted with bitumen up to ground level.
6 A door shall be provided in the masts and columns to
permit access to the circuit breaker assembly, junction box,
and winch (where provided) mounted on a backboard
made of durable non-hygroscopic material. The door shall
be weatherproof and fitted with a heavy duty lock. A
stainless steel 12mm diameter earthing bolt shall be
welded inside near the access door.
7 Where indicated on drawings and covered in the
BOQ. masts and columns shall be painted with two (2)
coats of epoxy resin paint to an approved color or high
gloss finish as required by the Concerned
Authority/Engineer.
8 The Contractor shall produce a certificate from a
structural engineering authority that columns and masts
meet the above requirements. In addition, an agreed
official testing authority’s certificates shall be presented to
guarantee the life-time and resistance of the products
under worst climatic conditions.
9 The Contractor shall submit a guarantee from the
manufacturer stating that the design lifetime of the
columns and masts is a minimum of twenty five (25) years
after installation under the worst site conditions in Oman.
If any column or mast or any part thereof fails within the
guarantee period, subject to corrosion, the Contractor
shall replace them free of charge. Without this guarantee
the lighting columns and/or masts will not be
approved/accepted.
15.8.2.2 Steel Columns
1 Columns shall carry either single or double
luminaires or any combination up to six luminaires as
shown on the Drawings and shall be of circular cross
section. Any special requirement for octagonal cross
section will be shown on Drawings or in design schedules.
2 The luminaires shall be rigidly fixed and bolted to the
column or column arms to prevent wind rotation or
vibration.
3 Columns with one or two luminaires shall be
connected over one phase and neutral. Columns with
three or more luminaires shall be connected over 3 phases
and neutral, unless otherwise shown on the Drawings.
Bolted terminals and cable lugs of the sizes shown on
Drawings shall be provided with 3 phase and neutral
terminals, and for incoming and outgoing 3 phase 4 wire
cable. Terminal blocks shall be high temperature, non-
inflammable, non-toxic material with high quality fixing
screws and individual terminal for each termination.
4 One circuit breaker, single pole 15 A shall be
provided for each phase leading to a luminaire. Circuit
breakers shall be compensated and rated for 50 deg. C
ambient temperature with interrupting capacity as
specified under other Sub-sections of the Specification,
and shall be mounted in weatherproof enclosure at
baseboard. Wiring shall be PVC insulated 3 core or 4 core
85 deg. C conductor temperature. Cable shall be at least 4
mm² copper conductor.
15.8.2.3 Steel High Masts
1 Masts shall be of the height specified on the
Drawings, hot dipped galvanized of multi-sided cross-
section with a continuous taper made of formed sheet
steel, electrically welded. They shall be delivered to site in
sections and be the slip joint type. Masts shall be
assembled on site by means of pressure over-lapping or
slip joints which shall have a minimum length of 1.5 times
the diameter of the joint. Site welding will not be allowed.
2 The luminaire rings or brackets shall be constructed
of galvanized steel in accordance with Section 6. Where
necessary, they shall be in two halves joined by bolted
flanges to permit removal. For masts with a moveable
luminaire ring, rollers with a serf canting mechanism shall
be provided made of water resistant non-marking material
with oil-impregnated bronze bushings.
3 The weatherproof wiring chambers shall have
terminal blocks, neutral bars, grounding bolts for electrical
connections, and facilities on the luminaire ring to allow
testing of luminaires while in the lowered position.
Cabling shall be in accordance with Sub-section 15.7. The
high mast cables shall conform to Technical Report No. 7
as given in Paragraph 15.8.2.1, Item 3.
4 The luminaire raising and lowering lead assembly if
fitted shall be manufactured of non-corrosive metals and
the operating cable sleeves shall be enclosed and run on
stainless steel shafts. The luminaire ring or bracket shall
be supported by a 3-cable winching system. Flexible
stainless steel stranded aircraft cables entirely suitable for
the application, with factor of safety 5 times safe working
load of the winch, shall support the luminaire ring
assembly. Nylon or similar stops installed on the steel
cable shall support the luminaire ring assembly in extreme
lower position to within 900 mm above the base of the
mast. Provisions shall be made to prevent the power cable
from winding around the steel hoisting cable.
Arrangements shall be provided for the electricity and
support cables to be separated before passing over their
respective pulleys, and close fitting guides shall be
provided so that the cables cannot disengage from the
pulleys during operation. A steadying system shall keep
the luminaire ring in the correct top position preventing
rotation around its vertical axis.
♦ 15- 15♦
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5 Winching systems shall have a lifting capacity of at
least double the weight of the luminaire ring assembly
and shall be fitted with an approved safety system to
control the ring assembly in the event of a suspension
cable failure.
6 Winches shall be capable of normal operation using
either a portable power tool or by hand, and shall
incorporate a torque limiter which can be adjusted and
locked. Winches shall be self-sustaining without brakes or
clutches which require maintenance and shall be totally
enclosed and self-lubricating.
7 Termination of winch cables shall not involve
distortion or twisting of the cable structure. One full layer
of turns shall remain on the drum when the luminaire ring
is fully lowered or alternatively the drums shall be
grooved to ensure a tidy cable lay.
8 The head frame shall be covered by a shaped
protective aesthetic canopy as shown on the Drawings
and designed to give a coordinated appearance of head
frame with the luminaire ring when the latter is in the
raised position.
9 Two red aircraft obstruction lights within cast
aluminium bodies shall be fitted at the top of each high
mast attached to the luminaire ring and arranged to
project through the canopy. A transformer and relay shall
automatically connect the second lamp in the event of
lamp failure.
10 High mast distribution equipment shall be mounted
in a weatherproof enclosure on the baseboard of the lower
compartment of the high mast and shall comprise a back
plate chassis complete with:
i. 1 x 60 Amperes triple pole main incoming
molded case circuit breaker (MCCB) and neutral
assembly for luminaire circuits.
ii. 1 x 20 Amperes single pole MCCB and neutral
assembly for each luminaire circuit.
iii. 1 x 15 Amperes single or triple pole MCCB and
neutral assembly connected to the incoming
supply and serving a 16A-250V DIN or 16A-415V
DIN socket outlet complete with 3-pin plug to suit
the raising and lowering mechanism.
iv. A multi-pin plug and socket outlet with guard
ring.
11 The breakers shall be designed, manufactured and
tested in compliance with IEC 60947-2 sequence III,
calibrated at 50 degrees C. The breakers shall have
interrupting capacity exceeding 10 kA.
12 The 16A-250 V or 16A-415 V socket outlet for supply
to the portable raising and lowering power tool shall be
connected to the MCCB via a flexible connection to ensure
accessibility.
13 Each high mast supplying ground sign lighting shall
be equipped with an additional 15 amp circuit breaker to
supply the sign lighting installation. The circuit breaker
shall be installed inside the mast distribution box.
14 Masts shall be equipped with a lightning protection
air terminal of the correct height to provide the required
♦ 15- 16♦
zone of protection for the mast head frame and luminaires.
The terminal shall be bonded to the mast to ensure the
discharge is dissipated via the earth and ground terminal
without damage to the steel winch cables or electric cable.
15.8.2.4 Glass Reinforced Polyester (GRP) Columns
1 This specification is for columns applicable to coastal
roads in general, where heights of 4m to 14m are required
and as shown on layout drawings.
2 GRP columns shall be manufactured by the
centrifugal casting process and shall withstand wind
speeds up to 220km/hr.
3 GRP columns shall be highly resistant to impact,
deflection and bending, and shall be highly safe in case of
a collision, fire resistant (using special resins), electrically
non-conductive and safe without grounding.
4 GRP columns shall be corrosion proof, resistant to
chemical reactions, with UV protection against
weatherability and shall have a guaranteed lifetime of 25
years. A reinforced lockable hinged access door of
minimum height of 300mm at a height from ground level
of 600mm shall be provided.
5 The columns shall be either of the burial type or the
flanged base type, with suitable cable access as shown on
drawing/details. Flanged base plates shall be of galvanized
steel equal in construction to flange plates used on steel
columns (15mm to 20mm thickness) with four anchor
bolts and convenient cable entry, bitumen coated on the
inside and outside. Pigment color range shall be
submitted with the proposal and color shall be selected by
the Engineer before approval is granted on the
manufacturer.
6 Standards for GRP columns shall be as follows:
i. Specific Gravity: 1.65 Kg / dm3 (UNI 7092/72)
ii. Glass Fiber Content (% by weight): 45-55 %
iii. Water Absorption: 0.5 % (UNI ISO 62)
iv. E-Modulus: 22000 ± 2000 MPa (UNI 5819/66)
v. Tensile Strength: 400 ± 50 MPa (UNI 5819/66)
vi. Flexural Strength: 350 ± 50 MPa (UNI 7219/73)
vii. Compressive Strength: 200 ± 50 MPa (UNI
4279/72)
viii. Impact Strength: > 180 kJ / m2 (UNI 6062/67)
ix. Dielectric Strength: 3 – 7 kV / mm (UNI 4291/72)
x. Surface Insulation Resistance: 1010 – 1013 (UNI
4288/72)
xi. Thermal Conductivity: 0.2 – 0.3 kCal / m⁰C (UNI
7891)
xii. Coefficient of Linear Expansion: 15 – 17
1/(⁰C*106) (UNI 6061/67)
xiii. Temperature Class: F
xiv. Overall Length: 3 – 14 m
xv. Top Diameter (3 – 7 m poles): 60 mm
xvi. Top Diameter (8 – 14 m poles): 94 mm
xvii. Conicity (slope to determine the bottom): 18 mm
per linear meter length
xviii.Steel fortification (at the top): required
xix. Steel base plate: optional
xx. GRP base plate cover: available
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7 Tests and approvals for GRP columns shall conform
to the following Standards:
i. General Outdoor Lighting Pole Specifications:
ASTM – D4923-01
ii. Tensile Strength: DIN EN ISO 527-2
iii. Elongation: DIN EN ISO 527-2
iv. Flextural Test. (bending): DIN EN ISO 14125
v. Impact Bending Test: DIN 53435
vi. Rate of Burning: ASTM – D635-03
vii. Dielectric Breakdown Voltage: ASTM – D149-97a
viii. DC Resistance: ASTM – D257-99
ix. Outdoor Weathering: ASTM – D1435-99
8 Mechanical properties for GRP columns shall
conform to the following Standards:
i. Tensile Strength: DIN EN ISO 527-2
ii. Elongation at break: DIN EN ISO 527-2
iii. Bending Strength: DIN 53390
iv. E-modulus: DIN EN ISO 14125
v. Impact Strength: DIN 53435
15.8.2.5 Road Lighting Luminaires and Lamps
1 Luminaires shall be of the totally enclosed type,
complying with IEC 60598-1, IEC 60598-2-1, and IEC 60598-
2-3 (or latest version), dust protected and splash proof,
divided into two compartments. The first compartment
shall be protected by clear glass or acrylic polycarbonate
sealed to the frame and hinged and shall house the optical
system with polished and anodized pressed aluminum
reflector, conforming to at least degree IP 66 of IEC 60529,
under all operating conditions. The second compartment
shall consist of the electrical accessories (control gear),
cable feed terminals and side entry mounting socket to at
least IP 54.
2 Luminaires shall be shock resistant and specially
designed to house required lamps, electrical gear and
accessories. Body shall be corrosion resistant, extruded,
pressure die-cast or fabricated aluminum alloy, optically
sealed, mechanically strong and easy to maintain.
Luminaire housing made from glass reinforced plastic or
other synthetic material shall not be acceptable.
3 Luminaire bodies constructed of fiber reinforced
polyester or pressed aluminum may be accepted subject
to approval of the Engineer and the quality of the product
and its resistance to heat from direct sunlight and/or heat
emitted from the lamp/control gear. The decision of the
Engineer in this respect is final and not subject to
discussion.
4 Exposed metal parts of luminaires shall be factory
finished, stove enamelled, with suitable corrosion
resisting paint capable of resisting heat emitted by lamp
during continuous operation, and under full sunlight
conditions. Color shall be agreed with the Engineer.
5 Mirror reflectors shall be single piece, with 99.5%
purity, anodized and glazed aluminium or die cast with
super-purity aluminium vapor-deposited, and coated with
transparent layer of silicon protection against wiping.
6 Luminaire protectors shall be heat and shock
resistant glass, mounted into suitable frame assembly
fixed to body by captive screws, and secured by extra
safety clamps to allow replacement of protector and
reflector, for maintenance purposes without danger of the
cover falling to the ground. Ozone resistant ethylene
propylene or approved equivalent rubber shall ensure
sealing of the front glass, to maintain the required degree
of protection IP65.
7 Lamp sockets shall be high grade porcelain, mounted
in support brackets with provision to adjust lamps
vertically and axially. Lamp support and locking system
shall grip and prevent lamp movement in operation.
8 Ballast and control gear shall be mounted in
luminaire in separate compartment isolated to protect the
electrical accessories from the direct radiant heat emitted
by the lamp, and with enclosed terminal blocks fitted with
quick-disconnect electrical leads. Where required, control
gear shall be contained in the prewired box, having an
enclosure of IP 54, and mounted on luminaire ring
separately from luminaires.
9 Control gear shall be plug in type for operation at 240
V, A C. single phase, 50 Hz. Ballast shall be tropicalized
class H insulated, specially selected for particular type of
lamp used, and lamps shall be able to start with at least +/-
10% variation of nominal voltage and continue in normal
operation with dips attaining 20% for four seconds.
Control gear losses shall not exceed 10% of normal lamp
wattage. RFI suppression device shall be provided. Refer
to CISPR. Power factor shall be compensated to at least
0.9 lagging or better.
10 Control gear (choke, capacitor, ignitor, etc.) shall be
suitable to stand up to 85 degrees C. ambient temperature
of the enclosure.
11 Internal connections shall be with high quality heat
resistant wire insulated for 105 deg. C and with porcelain
connectors. Control gear shall comply with the IEC 60947-
3 or relevant equivalent British Standard specification or
other acceptable International equivalent.
12 HRC fuse cartridges, suitably rated and conforming
with IEC 60269, shall be provided, complete with base, for
protection of the luminaire. Fuse shall be rated to
withstand starting current and shall be preferably located
in control gear enclosure.
13 Terminal blocks shall be of the suitable screw-tunnel
type, clearly marked with arrangement to facilitate
maintenance, quick replacement and easy disconnection
of individual components.
14 Types of lamps are to be as follows:
a) High pressure sodium lamps shall be type
SON-T (tubular), in accordance with IEC60662
for dimensions and characteristics, and IEC
62035 for safety, with guaranteed average
rated life (down to 80% output) above 12,000
hours, and having initial luminous output equal
to or above the following:
i. 16500 lumens for 150 W lamps.
♦ 15- 17♦
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 ii. 31500 lumens for 250 W lamps. and to the luminance and illuminance results achieved.
iii. 55000 lumens for 400 W lamps. The decision of the Engineer in this respect is final and not
iv. 135000 lumens for 1000 W lamps subject to discussion.
17 Luminaires shall provide a distribution generally in
b) High pressure mercury vapor lamps shall be to accordance with IEC 60598-1, IEC 60598-2-2, IEC 60598-2-3,
IEC 60188, and shall include quartz discharge cut-off or semi-cut-off classification, as required by the
tube in an internally coated ovoid outer tube. design standards for type and class of road.
Coating shall be ytrium vanadate phosphur
with color temperature of 3300 deg. K. 15.8.2.6 Flood Lights
Guaranteed rated life (down to 80% output)
1 Flood lights shall be totally enclosed type, weather,
shall be above 8000 hours and initial luminous
dust and shock resistant, IP 65 to IEC 60529, and shall
output above the following:
conform to the requirements and types shown on
i. 3800 lumens for 80 W lamps drawings or be of approved equal make.
ii. 6500 lumens for 125 W lamps 2 Housing shall be of high pressure die-cast aluminium
iii. 14000 lumens for 250 W lamps. alloy, closed on front by hinged framed glass protector
highly resistant to thermal and mechanical shocks, and set
c) Metal halide lamps shall comprise quartz
in position by at least eight heavy duty stainless steel
discharge tube enclosed in clear tubular hard-
spring clamps with silicon rubber sealing gasket.
glass outer bulb, operating on same principle
Enclosure shall be in accordance with IEC Publication
as all gas discharge tubes with iodide additives,
60598-2-5.
indium, thalium and sodium in the mercury
discharge, to increase intensity in three 3 Reflectors shall be high purity (over 99% reflectance)
spectral bands; blue, green and yellow-red with anodized aluminium, secured in precision aligned internal
high color rendering. Lamps up to 150 W shall tracks to provide beam distribution required.
be provided with electronic ballast. Lamps shall 4 Connection box shall be located at rear of floodlight
be to IEC 61167 with E40 base. Guaranteed 2
body with gland connections to accept 4 mm PVC/PVC
average life shall not be less than 10000 hours three core cables. Lamp and control gear shall be
and luminous outputs, after 100 hours burning, mounted in two separate and isolated compartments.
shall be above the following:
5 Control gear shall be plug-in type, 240 V, 50 Hz,
i. 32500 lumens for 400 W lamps power factor compensated to at least 0.9 lagging. Ballasts
ii. 90000 lumens for 1000 W lamps and ignitors shall be of type specially adapted for make of
iii. 190000 lumens for 2000 W lamps lamps selected. Ignitors shall be electronic thyristor type.
Lamp shall be able to start with at least +/-10% from line
d) Low pressure sodium lamps shall be type SOX voltage, and with normal operation dips up to 20% for four
or SOX (E) and shall conform to IEC 60192:2001, seconds. Compensation shall ensure that there is no large
with guaranteed average life above 18000 hrs increase in operating current during starting. Control gear
and having initial luminous output equal to or losses shall not exceed 10%. Cables for internal wiring in
above the following: control gear compartments shall be single core 2.5 mm2
SOX type: copper conductors with suitable high temperature
insulation and sheath.
i. 4800 lumens for 35W lamp
ii. 8100 lumens for 55W lamp 6 Exposed metal parts of floodlights shall be painted
iii. 13500 lumens for 90W lamp with corrosion and heat resistant paint, resisting operating
iv. 22500 lumens for 135W lamp temperatures attained in direct sunlight while lamp is
v. 33000 lumens for 185W lamp burning.
7 Floodlights shall be located as shown on the
SOX E type:
Drawings and mounted on specially designed brackets to
i. 1800 lumens for 18W lamp allow swiveling in any desired direction and locking firmly
ii. 3600 lumens for 26W lamp in final position. Protractor scale shall be provided for
iii. 5800 lumens for 36W lamp accurate setting.
iv. 10500 lumens for 66W lamp 8 Bolted earthing terminal shall be provided in each
v. 17000 lumens for 91W lamp fitting.
vi. 26000 lumens for 131W lamp

15 Permissible base temperature shall not be greater 15.8.3 Construction Requirements

than 250 deg. C, and maximum bulb temperature not 1 Lighting masts/columns shall be handled,
greater than 550 deg. C. Lamp burning position for 2000 transported and erected in such a way so as to avoid any
W, 240 V lamp is to be possible up to 75 degrees. damage. Any damage to pole or galvanizing shall be made
16 Multi-piece mirror reflectors may be accepted subject good to the satisfaction of the Engineer.
to satisfaction of the Engineer of the quality of the product,

♦ 15- 18♦
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2 The lighting masts/columns shall be stored clear of
soil, ground water or other rust producing materials. The
fixing of poles shall be carried out in accordance with
manufacturer’s instructions and good engineering practice.
3 Masts/columns shall be bolted to concrete bases
constructed in accordance with Sub-section 15.17 and
erected in accordance with the mast manufacturer's
instructions. The column or mast shall be vertical to within
0.1% of its height. Final setting and adjustment of the
luminaires shall be carried out after the masts are erected
and operational.
4 The Contractor shall be responsible until final hand-
over for correcting the alignment of any column or bracket
to its original position except where it is due to vehicle
impact.
5 Where lighting columns/masts are to be installed in
the vicinity of overhead power lines, the Contractor shall
inform the Engineer and act as directed. He shall maintain
clearances from the power lines as the Concerned
Authority’s requirements.
6 Masts/columns shall be erected to the height and
with the luminaires as shown on the Drawings. Each
luminaire shall house the required lamp oriented to give
the illumination and luminance on the road surfaces as
stated in Clause 15.1.15, (3) and Table 15.1.15.1.
7 Luminaires on columns shall be aligned parallel with
the longitudinal profile of the road and set at 90° to the
centre line.
8 High masts incorporating mobile luminaire rings
shall be capable of supporting a portable personnel cage
for maintenance. The Contractor shall provide the cage
which shall be capable of safely carrying two persons plus
servicing equipment.
9 The Contractor shall number all the columns/masts
with high quality paint using stencil for 50mm high
lettering. The numbering shall be at 1200mm from the
bottom of pole towards the road. The numbering shall be
in a manner as directed by the Engineer.
15.8.4 Method of Measurement
1 Each type of high mast assembly and lighting
column shall be measured separately and shall include
brackets luminaires/ floodlights, lamps, terminal blocks,
circuit breakers and switchgear, internal wires and cabling,
control gear, obstruction lights (if needed), and earthing,
cable entries, mounting brackets/arms, complete as
specified, erected, tested and put into operation.
2 Testing of high masts and lighting columns, at the
factory and on Site, is given as an item, to cover for all
tests and reports and test certificates.
15.8.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rates stated in the Bill of Quantities which rate shall be full
compensation for supplying, installation, testing, putting
into operation, and for erecting material, labor, equipment
tools, supplies and other work items necessary for the
proper completion of the work as specified.
15.8.6 Items in the Bill of Quantities
i. High mast assembly (type) (height) (No
and type of luminaires) (reference dwg.) (nr)
ii. Lighting columns (type) (number
of arms) (height) (type of luminaire)
(reference drawing.) (nr)
iii. Column/high mast testing (Lump Sum)
15.9 Sign Illumination
15.9.1 Description
1 This Sub-section describes requirements for
supplying, installing and putting into operation the
illumination of overhead and roadside signs where shown
on the Drawings or directed by the Engineer.
15.9.2 Materials
1 Luminaires where used to illuminate signs shall be
wide angled floodlights of the totally enclosed type
conforming to IEC 60598-1, -2-5( Luminaires – Floodlights)
and BS EN 12899-1:2001 (Fixed Vertical Road Traffic Signs,
Fixed Signs). The body of the floodlight shall be
composed of an extruded aluminum alloy box closed on
the front by a protector of vandal resistant glass. The
protection rating shall be IP 65 to IEC 60529.
2 The lamp and control gear shall be mounted in two
separate compartments. Alternatively, the control gear
may be housed remotely. Power factor compensation
shall be 0.9 or better.
3 Photo-electric control units shall be of the plug-in
type. The control unit losses shall not exceed 10% of the
nominal lamp wattage. A device shall be provided for the
suppression of radio and television interference to CISPR
15 requirements.
15.9.3 Construction Requirements
1 The signs shall be adjusted and set correctly relative
to the vertical plane and the road axis before the electrical
installation work is started. Floodlights and associated
fixings shall not obstruct the sign face viewed from the
road. Screening shall be added to the top or bottom
edges of the sign to prevent glare to oncoming traffic.
2 Sign supports and gantries are specified in Sub-
section 14.1.
3 Overhead gantry or cantilever sign lighting shall be
located and mounted as shown on the drawings.
Mounting shall be provided for each floodlight allowing it
to be swiveled in any direction and locked.
4 Feeder cable shall be routed via a duct in the
supporting frame or gantry up to platform height and
terminated into a non-automatic isolator switch. A circuit
♦ 15- 19♦
copy 249
breaker board within the enclosure shall distribute power
to the individual floodlights.
5 Roadside sign lighting shall be as described in Items
3 and 4 above, but with the adjustable mountings on top
of support poles. The poles shall be positioned 1.8m in
front of the signs and parallel with the sign face and shall
be checked and shimmed to be perpendicular before
tightening down.
6 The cable from the sub-station or feeder pillar shall
be routed into the pole via the duct in the base and looped
into a circuit breaker located behind the pole access cover.
7 Lighting where required for signs located in
sidewalks in urban areas shall be mounted on the top of
the sign supporting poles, projecting in front of the top
edge of the sign and braced.
8 The earth of the cables shall be bonded to the earth
terminal of each enclosure.
15.9.4 Method of Measurement
1 Each type of overhead or roadside lighting assembly
shall be measured separately by the number of complete
floodlight installations supplied, erected and put into
operation, complete with lamps, supporting steel work,
switchgear, control gear, interconnecting cables and
earthing as necessary.
15.9.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rates stated in the Bill of Quantities which rates shall be
full compensation for supplying, installation, testing,
putting into operation, for materials, labor, transport,
equipment tools, supplies and other work items necessary
for the proper completion of the work as specified.
15.9.6 Items in the Bill of Quantities
i. Overhead sign lighting (gantry or cantilever)
(reference drawing.) (nr)
ii. Roadside sign lighting (sign ref. no.)
(reference. drawing.) (nr)
15.10 Under Bridge Lighting
15.10.1 Description
1 This Sub-section describes requirements for
supplying, and installing under bridge surface luminaires
and/or recessed lighting in prepared cutouts such as in
concrete structures.
15.10.2 Materials
15.10.2.1 Surface Mounted Luminaires
1 The fitting shall be totally enclosed, dust and jet
proof, conforming to at least IP65 of IEC 60529, and
conforming with IEC 60598-1, shock resistant and specially
designed to house the required lamps, electrical gear and
♦ 15- 20♦
accessories. Body shall be one piece extruded aluminium
(magnesium - silicon alloy) having a wall thickness of not
less than 2.5 mm.
2 Exposed metal parts of luminaires shall be factory
finished, stove enamelled, with corrosion resisting paint
capable of resisting heat emitted by lamp during
continuous operation. The whole assembly shall be
treated against corrosion by anodizing the aluminium.
3 Mirror reflectors shall be 99.5% purity, polished
aluminium reflectors and coated with transparent layer of
silicon protection against wiping.
4 Control gear shall be mounted on a "plug-in" type
control gear tray, and shall be housed in a self contained
sealed box.
5 Earth wire shall be connected through the plug and
socket connector to ensure that the earth potential is
maintained on the gear tray when it is being removed
from the luminaire for maintenance purposes.
6 Luminaires shall have a hinged front glass with at
least 2 hinges assembly which shall comprise a clear
toughened glass plate, not less than 5.0 mm thick, capable
of swinging to the vertical position. The front glass
assembly shall seat on to a neoprene non rotting type
gasket and once seated shall provide the required degree
of protection. Glass used shall be shatter proof (of the type
which once broken, no part of the glass will fall on the
carriageway). Each luminaire shall have an HRC fuse for
protection.
7 Luminaires shall be complete with their mounting
accessories and shall be supported from uni-strut
galvanized steel channel fixed to the soffit of the bridge.
Fixing details shall be submitted to the Engineer for
approval.
8 Lamp sockets shall be high grade porcelain, mounted
in support brackets with provision to adjust lamps
vertically and axially. Lamp support and locking system
shall grip and prevent lamp movement during operation.
9 Ballast and control gear shall be mounted in
luminaire in separate compartment isolated from the lamp
and with enclosed terminal blocks fitted with quick-
disconnect electrical leads. Where required, control gear
shall be contained in the prewired box, having an
enclosure of IP 65, and mounted on luminaire ring
separately from luminaires. Control gear shall be plug in
type for operation at 240 V, A.C. single phase, 50 Hz.
Ballast shall be specially selected for particular type of
lamps used, and lamps shall be able to start with at least
+/-10% variation of nominal voltage and continue in
normal operation with dips attaining 20% for four seconds.
Control gear losses shall not exceed 10% of normal lamp
wattage. RFI suppression device shall be provided. Power
factor shall be compensated to at least 0.9 lagging.
15.10.2.2 Recessed Mounted Luminaires
1 Luminaires shall comply with IEC 60598-1, IEC 60598-
2-2, and IEC 60598-2-3
copy 249
2 Luminaires shall be recessed flush mounted 15.11 Traffic Signals
weatherproof type including lamps, a frame for the
concrete opening and a housing for the control gear. 15.11.1 Description
3 The luminaire body shall be made from epoxy 1 This Sub-section describes requirements for the
powder coated galvanized sheet steel or from extruded or design, supply, installation, commissioning and
pressure die-cast corrosion resistant aluminium alloy. monitoring/review of traffic signal installations and all
Aluminium shall be anodized and painted grey. associated signal equipment.
4 Luminaires within 4m of finished ground level shall 2 The terms used are as defined in the Highway Design
be vandal resistant. Standards.
5 The luminaires shall have a hinged front glass
assembly of prismatic toughened glass, not less than 15.11.2 Materials
6.5mm thick, fixed and sealed into a metal frame which
15.11.2.1 General
shall have a rapid closing device They shall be fitted with
'trimming plates' to provide a flush appearance. 1 The equipment shall function satisfactorily for an
6 The protection rating shall be IP65 to IEC 60529 for all input voltage of 240v ±15% and input frequency 50Hz ±4%.
luminaires in the underside of bridge superstructures and If required a form of automated stabilizer shall be
luminaires in walls. incorporated.
7 The optical system, electrical control gear and lamp 2 All signal equipment should be suitable for operation
shall be mounted on a 'plug-in' type reflector gear tray. in the climatic conditions of Oman. The equipment should
The ground wire connection shall be taken through the be operational between -15°C and +60°C, and resistant to
plug and socket connector. dust/sand contamination. A minimum of 5 years operation,
with routine maintenance, should be expected from any
15.10.3 Construction Requirements installed equipment.
3 The equipment shall comply with the requirements
1 The luminaire shall be fixed surface mounted or flush
of the Highway Design Standards for timings, signal
with the concrete surface into a preformed non- corrodible
sequence and associated detectors.
framed opening as pertaining to the lighting unit specified.
4 All signal equipment shall comply with the
2 Wiring shall be ducted in conduits embedded in the
interference limits given in BS EN 55015:2006 (Limits and
structure or hidden from view within the structure and
Methods of Measurement of radio disturbance
shall loop in and out of conduit boxes serving the
characteristics of electrical lighting or similar equipment).
luminaires.
15.11.2.2 Controllers
15.10.4 Method of Measurement
1 Controllers shall be fully programmable and modular
1 Each type of lighting assembly shall be measured in design to allow the replacement of faulty components
separately by the number of lighting units (luminaire, or the addition of extra circuit boards and features as and
lamp, control gear, terminal blocks) supplied, installed and when required.
put into operation.
2 Controllers should have at least the following inbuilt
modes of operation available for use:
15.10.5 Basis of Payment
i. Manual
1 The quantity of completed and accepted work
ii. Fixed time
measured as provided for above will be paid for at the unit
iii. Vehicle actuated
rates stated in the Bill of Quantities which rate shall be full
iv. Urban traffic control
compensation for supplying, installing, testing and putting
v. Pedestrian fixed vehicle period
into service, and for materials, labor, equipment, tools,
vi. Pedestrian vehicle actuated
supplies and other work items necessary for the proper
vii. Bus/light rail transit priority
support and completion of the work as specified.
viii. Part-time
ix. Cable-less linking facility
15.10.6 Items in the Bill of Quantities x. Hurry call
i. Under bridge surface mounted luminaire xi. Emergency priority
(type) (reference drawing.) (nr) xii. Standby software flash mode
ii. Under bridge recessed lighting luminaire
(type) (reference drawing) (nr) 3 Controllers shall utilize solid state lamp switching
cards, with a maximum load per lamp switch card of 20A.
The switch cards should be able to support both ELV and
LV configurations.
4 Standard 240v Low Voltage (LV) Controllers:

♦ 15- 21♦
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 i. Shall be able to support between 24 and 36
phase outputs, arranged on up to 4 separate
phase driver cards, used as required.
ii. Shall be able to support dimming facilities of
120v, 140v or 160v RMS.
iii. Each output lamp switch shall be able to support
a 4A load, with a maximum total lamp load on
the controller of 20A - 30A.
5 Extra Low Voltage (ELV) controllers:
i. Shall be able to support between 24 and 36
phase outputs, arranged on up to 6 separate
phase driver cards, used as required.
ii. Each output lamp switch shall be able to support
a 2A load, with a maximum total lamp load on
the controller of 20A - 40A.
iii. Shall have a lamp supply voltage of 48v RMS
with a signal dimming option of 27.5v RMS
6 Controllers shall provide visual displays of the
current mode of operation and current stage / timings.
7 Controllers shall have the facility to allow testing to
be carried out via a handset port. This shall allow minor
amendments to the controller configuration to be made,
and allow artificial demands and extensions to be placed
in the controller for testing purposes.
8 Controllers shall have the facility to allow for on-site
adjustments to be made to the signal timings, via the
connection of a handset. These timings should include,
but not be limited to, VA maximum green times,
intergreens, detector extension timings, detector fault
management (DFM) values, and the controller’s timetable.
All signal timings inputted this way shall be subject to pre-
determined limits, imposed for safety reasons during the
initial design.
9 It shall not be possible, through any hardware or
software failure of any component of the controller, to
give a right of way to two conflicting signal phases.
10 The controller shall have the facility to monitor all
equipment connected to it, reporting failures as and when
they occur.
11 The controller shall have an integral lamp monitoring
unit that allows safety critical signal aspects to be
monitored for lamp failure and appropriate reporting
action taken when this occurs.
12 Should any single approach suffer a single red lamp
failure, then the controller shall report a red lamp failure
warning (RLF1)
13 Should two or more red lamps fail on any single
approach, the controller shall report a second red lamp
failure (RLF2) and inhibit conflicting pedestrian phases
from gaining right of way. On standalone pedestrian
crossings, the facility shall shut down all signals when this
condition arises.
14 A single red lamp failure condition can be self-reset if
the controller detects the lamp to be working again,
however a two or more red lamp failure condition shall
♦ 15- 22♦
require manual on-site intervention of a maintenance
engineer before normal operation is resumed.
15 The controller shall have a fused master switch to
isolate the controller. This fuse shall be of a rating
calculated from the cumulative load of all signal
equipment attached to the controller and done on a site by
site basis. A fault on any signal circuit shall not cause
damage to the controller.
16 The electrical supply to the controller shall have its
own fused system which should not be isolated by the
controller switch.
17 It shall be possible to isolate all signal lamps by use
of a switch and fuse whilst retaining supply to the
controller.
18 Controller cabinets shall be housed in weather
resistant, dust resistant corrosion resistant cabinet. The
front of the cabinet shall have a full length locking door to
allow access to the control equipment. A swing frame
shall be provided to allow access to the rear wiring of
components. Smaller flap doors can be used to give
access to manual panel, telecommunication and electricity
connections as required.
15.11.2.3 Signal Equipment
1 Signal poles shall be constructed of galvanized steel,
covered by seamless high density polythene. A terminal
block assembly shall be mounted on the top of the mast,
covered by a polythene cap.
2 Standard signal poles shall be 4m in length. 4.75m
poles may be used when the extra height would enable
better signal visibility.
3 6m poles, with two signal heads mounted at different
heights, may be used on roads with high speed limits or
where a 4m or 4.75m pole would not provide sufficient
signal visibility. However, they should not be considered
as a preferred solution for signal installations where other
options exist.
4 Short 2m poles may be used at crossing points to
house a single pedestrian push button.
5 Signal heads shall meet the requirements set out in
BS EN 12368:2006. They shall be lightweight, modular
designs with a minimum lens diameter of 200mm to
300mm. All signal heads shall contain anti sun-phantom
technology. LED signal heads may be utilized as well as
traditional tungsten bulbs.
6 Backing boards shall be provided on all signal heads
with an East-West alignment, to enhance signal visibility.
On other alignments backing boards are recommended
and shall be provided if instructed by the Concerned
Authority.
7 For vehicle detection purposes on a vehicle actuated
control strategy, above ground vehicle detectors may be
used instead of inductive loop facilities.
8 Where the 85th percentile approach speed is over
4km/h, it is recommended that microwave, radar or optical
devices be utilized. For stop-line detection of vehicles,
copy 249
pedestrian detection or where the 85th percentile speed of However, stage skipping must not occur to service a
vehicles is below 4km/h, infra-red or optical detection is demand, unless the stage is demand dependant. In the
recommended. event of a stage being terminated by the expiry of a
9 Inductive loops may be utilized where it is felt that maximum green period, a revertive demand shall be
above ground detection is not suitable for site operation. introduced for that stage.
Where loops are to be installed they shall be 2 meters 8 In fixed time mode, the controller shall cycle through
apart in the direction of traffic flow, and consist of 3 cable all (or pre-defined) stages in a pre-set timing sequence.
turns. 9 In manual control mode, the operation of the stage
buttons shall cause the controller to move to, and to
15.11.2.4 Signal Operation
remain on, the selected stage (subject to the expiration of
1 The signal timing ranges shall be as stated in Table the minimum green period of the current stage and the
15.11.2.1. associated inter-green). An indicative light shall be
provided to show the current state of the controller under
Standard Period Length (s) manual mode.
Minimum Green 4 – 50 (in 1s steps)
15.11.3 Construction Requirements
Vehicle Extension 0.4 – 31.8 (in 0.2s steps)
15.11.3.1 Cables
Maximum Green 0 – 255 (in 1s steps)
1 The wiring of all cables shall meet the IEE Wiring
Leaving Amber 3 (fixed)
Guidelines, 17th Edition (BS 7671).
Starting Amber 2 (fixed)
2 All signal heads on a single traffic phase shall not be
Inter-greens 0 – 254 (in 1s steps) connected to the traffic signal controller on the same cable
Starting Inter-green 8 – 12 (in 1s steps) run.

Phase Delays 0 – 20 (in 1s steps) 3 For new cable runs, 16 core cables with 1.5mm2
cores shall be used for both ELV and LV applications. In all
Pedestrian Blackout 3 – 20 (in 1s steps)
cable runs, 4 cores should be left disconnected for
Table 15.11.2.1: Traffic Signal Timing Ranges redundancy purposes.

2 Provision shall be made for inter-green times
between stages, and the circuitry shall include safety
features to prevent simultaneous display of conflicting
green indications.
3 Manual operation may override all modes, except
UTC control. If manual operation is required at a UTC
controlled site, then the UTC computer shall remotely
disconnect its link with the controller.
4 The modes of operation available by manual
selection shall be:
i. Cableless linking facility (CLF)
ii. Vehicle actuated (VA)
iii. Fixed time
iv. Manual
5 Under vehicle actuated mode, when there is an
absence of demands, it shall be possible to revert to an all
red condition, flashing ambers, or a specified stage.
4 All cables shall be tagged in the controller to easily
identify which equipment or pole a cable is connected to.
5 Cable tags shall be colored red for cables carrying a
low voltage (LV) and yellow for cables carrying an extra
low voltage (ELV).
15.11.3.2 Controller Root
1 The controller cabinet shall be set on a concrete
plinth, if it is above ground, or in a waterproof pit if below
ground. Design of the plinth or pit shall be submitted to
the Engineer for approval before the plinth or pit is
constructed. The cabinet shall be secured to the plinth or
pit base by suitable anchoring devices. Provision shall be
made for ducts and conduits embedded in the plinth or pit
for easy access for cables. Adequate permanent protection
shall be provided to keep the cabinet and its contents free
from damp, dust, vermin and any other harmful
conditions.

6 If the flashing amber is to be used during periods of
low or no demand, such as night-time, then the flashing
mode shall be preceded by a steady amber and the other
vehicle and pedestrian signals extinguished. The flashing
rate shall be between 55 and 85 per minute, with equal on
and off intervals. The flashing mode sequence shall be
ended by the signals reaching an ‘all red’ period for 3
seconds, followed by the normal start up sequence
leading to a right of way being shown on a pre-defined
start up stage.
7 Under vehicle actuated mode the controller shall
honor vehicle demands as and when they appear.
2 Alternative materials may be proposed for the
Engineer’s approval, such as standard heavy duty plastic
underground pits and precast concrete plinths, which
satisfy the requirements for stability and proof against all
environmental conditions.
15.11.3.3 Ducts
1 A system of ducting shall be provided so that all the
signal poles and the controller are inter-connected by a
duct network. Duct paths should be straight lines, linking
each draw pit in the network. Where a straight line is not

♦ 15- 23♦
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possible, due to sub-surface obstructions, a radius bend of
no more than 35° may be used.
2 Ducts shall be laid a minimum of 600mm below the
carriageway surface or 450mm below the footway surface.
3 Whenever a duct network crosses a road, at least 3
ducts shall be provided under the carriageway.
4 Ducts shall be 100mm internal diameter as standard,
however, separate 50mm internal diameter ducts may be
used to carry the electricity supply and telecommunication
cables to the controller, but no other cables shall be
installed inside these ducts.
5 Spur ducts to the signal pole location, from the
nearest draw-pit shall be provided. These can be 50mm or
100mm diameter depending on the number of cables to
be installed.
6 Polypropylene draw cords, break weight 5.5kN shall
be provided in each duct; these draw cords shall be
continuous over their entire length with no joints or knots
and shall extend one meter from each end of the duct.
They shall be replaced on each cable draw through so that
they can be reused.
7 Cable duct route identification markers in accordance
with MEW Standard OES 2 shall be provided at 25m
maximum spacing throughout the entire installation and
at terminations and bends in the route.
8. Refer to subsection 15.17 – civil works for electrical
and communication installations for any other conditions.
15.11.3.4 Draw Pits
1 Draw pits shall be either constructed of pre-cast
concrete rings; brick built or reinforced high density
polyethylene. Draw pits shall comply with BS EN 124.
2 Draw pits shall not be placed in the carriageway. If
this is unavoidable, then a higher specification draw pit
shall be used, capable of withstanding the loading of
traffic.
3 A master draw pit, minimum size 600mm x 600mm x
600m deep, shall be constructed in front of the controller
location to allow the cables to be easily fed into the
controller housing.
4 When ducts cross a road, draw-pits, size 1200mm x
900mm x 900mm deep, shall be installed on either side of
the carriageway and in central islands and medians, to
assist with cable pulling. They should not be installed in
the carriageway or installed in a location that would
interfere with any pedestrian movement.
5 On longer cable runs, draw pits shall not be more
than 50m apart.
6 Where possible, drawpits shall be located adjacent to
signal poles to allow cables to be spurred off to the pole
installation easily.
15.11.3.5 Pole installation
1 Standard 4 meter high poles shall normally be set in
a concrete base minimum 600mm x 600mm x 650mm
deep. The depth shall be increased for longer poles. Cable
♦ 15- 24♦
ducts shall be fixed within the base to connect to the
signals.
2 Where conditions prevent construction of the pole
base as stipulated above, the Contractor shall provide
poles with welded steel base plates and anchor bolts to
provide stability, all as approved by the Engineer.
3 For high masts, the design of the concrete base and
anchoring devices shall be proposed by the Contractor,
based on structural calculations for the ambient conditions,
and shall be approved by the Engineer before construction.
15.11.3.6 Cantilevers and Gantries
1 Where traffic signals need to be mounted on
cantilevers or gantries, those structures should be in
accordance with the drawings and schedules. Fabricated
steel structures shall be in accordance with Section 6
(Structural steel and other metal work) and Section 7
(Paint) of this Specification.
15.11.3.7 Miscellaneous
1 Upon completion of the work the controller base
shall be filled with a base sealant that dries hard to
prevent vermin infestation into the controller cabinet.
2 Ducts shall be sealed with a foam substance or wire
wool to prevent vermin infestation through the duct
network.
3 Road markings at all installations shall be in
accordance with the Oman Highway Design Standards
and Section 14 of these Specifications.
4 On approaches to all pedestrian crossing points,
special anti-skid road surfacing shall be laid 50m from the
crossing studs in the direction of on-coming traffic. The
surfacing shall have a minimum skid resistance value of
55 when tested in compliance with BS EN 3262-12:2001.
15.11.3.8 Completion
1 All signal equipment shall be assessed on site after
installation is completed by use of a commissioning check
list to ensure that the installation is complete and
complies with the quality and functional requirements of
the Specification.
2 The Contractor shall submit final close-down
paperwork, to include:
i. Site layout drawings (as installed)
ii. Timing sheets
iii. Signals hand-over certificate, including test and
commissioning reports
iv. Operation and maintenance manuals.
15.11.4 Method of Measurement
1 Traffic signal installations shall be measured by the
number of completed sets of signaling equipment and
materials installed, modified or modernized at any one
location and shall cover all requirements including
controllers, sensors, signal poles, signal heads, cables,
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drawpits, ducts, foundations, all completely installed and
commissioned.
2 Cantilever and Gantry supports for traffic signal
heads shall be measured by type and number installed,
and shall include foundations, fixings and mounting.
3 The unit rates shall be deemed to cover for all work
at each installation location, including design, submission
of drawings, obtaining approvals from all Concerned
Authorities, the supply, construction and installation,
transport, and all civil work and miscellaneous items and
close-out procedures.
15.11.5 Basis of Payment
1 The amount of completed and accepted work as
provided for above, will be paid for at the unit rate stated
in the Bill of Quantities, which rate shall be full
compensation for supplying materials, installation, testing
and putting into operation, for labor, transport, equipment,
tools supplies and other items necessary for the proper
completion of the work.
15.11.6 Items in the Bill of Quantities
i Traffic Signal Installation
(location and designation
shown on drawings) (Lump Sum)
ii Overhead Traffic Signal Support
including foundation (type) (nr)
15.12 Overheight Vehicle Detection
System
15.12.1 Description
1 This Sub-section describes requirements for the
design and installation of the system to detect over-height
vehicle/trucks approaching underpass and to display a
warning to alert drivers not to enter the underpass.
15.12.2 Design Criteria for Materials and
Components
1 The equipment shall be designed to operate on A.C.
240 volts single phase 50 Hz with a voltage variation of
plus 15 percent or minus 20 percent and frequency
variation of plus or minus four percent. If the equipment is
sensitive to voltage fluctuations within the above stated
limits, an automatic voltage stabilizer shall be
incorporated in the system, along with a stand-by
uninterruptible power supply system for maintaining
system memory.
2 Equipment shall be designed and derated for
continuous operation under operating conditions
stipulated in Sub-section 15.1. The variation in light
intensity caused by the shadow of passing clouds shall not
interfere with the proper operation of the equipment. The
equipment shall be suitable for uninterrupted full load
operation exposed to sun, dust storms, corrosive elements
and the adverse climatic conditions at the location.
3 Electronic equipment shall use components of
assessed quality in accordance with the system outlined in
BS 9000 General Requirements for a System for Electronic
Components of Assessed Quality, or other approved equal.
4 All equipment shall be to the approval of the
Concerned Authority. It shall have a proven in service
record, and documentary evidence of this shall be
submitted. Full environmental tests shall be carried out
on a production sample by an independent testing
authority and a certificate supplied to show the suitability
of the equipment for use in the specified environment.
5 Materials and components shall be the latest
technology and best of their respective kind and modern
practice, selected and treated so that no corrosion will
occur during the lifetime of the installation estimated at 20
years.
6 All wiring shall be neatly and securely fixed in
position in an approved manner. The wiring shall be in
high temperature PVC insulated cables or silicon rubber,
color coded for ease of identification. All terminals shall
be of adequate size.
7 NEMA 3R (IP 66 of IEC 60529) rated metallic
equipment enclosures shall be provided with terminals for
attachment of ground safety circuit.
8 Masts shall be designed and constructed to provide
adequate support and stability for the sign and shall be
suitable to support more than one assembly. They shall
be complete with base compartment and pole top
compartment complete with terminal chambers for
connecting incoming cables.
9 Masts shall be constructed from seamless steel,
tubular, with a wall thickness not less than 4.5mm and a
tensile strength of 520 MN/sq.m hot dipped galvanized.
No machining operation shall be allowed after completion
of the galvanizing process. Masts shall be painted with 2
coats of epoxy resin paint to an approved color finish after
completion of the galvanizing process as required by the
Concerned Authority / Engineer.
10 Signs shall be mounted on -brackets supporting both
top and bottom of the sign. Attachment shall be of
stainless steel clamps and mounting brackets which shall
incorporate a wiring duct for the sign wiring. The
attachment shall allow vertical and angular adjustment of
the sign assembly and shall be suitable for the sign
presentation.
11 Mounting heights of sign, the type of sign and the
signal presentation shall be as will be detailed by the
Concerned Authority.
15.12.3 Operational Requirements
1 All over-height vehicles or vehicle loads traveling
toward the tunnel shall be detected and a warning signal
given. Vehicles traveling away from the tunnel shall be
ignored by the detection equipment. Detection of vehicles
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traveling toward the tunnel shall be counted and recorded
on an installed electronic counting device.
2 The detection system shall consist of visible red or
infra red source(s) spectrally matching detector(s)
mounted on poles positioned on opposite sides of the
approach roadway. The alignment and height of the
visible red or infra red beam shall be preset to identify
vehicles over 4.25m above the roadway at the line of
detection or as requested by the Concerned Authority.
3 Positive measures shall be introduced to warn
drivers of a potential accident if they proceed and to
instruct them not to continue, whilst causing the least
possible disturbance or distraction to other motorists.
4 Warning and instructions for drivers of over-height
vehicles shall be stated on the face of the warning sign
which shall be illuminated internally, i.e., nature of danger
“OVERHEIGHT” and action to be taken (“STOP” or “TURN
RIGHT” or “EXIT RIGHT” or “USE RIGHT (LEFT) LANE,” or
“DO NOT ENTER” etc) if the driver proceeds. The action
must cause the driver to become alert to the extent that he
should react as instructed.
5 Warning Sub-system shall consist of a flashing light,
an audible alarm, and an electronic message board.
Upon receiving the control signal from the detection
subsystem, this warning subsystem is to be activated and
shall respond by alerting the driver to either stop the
vehicle or take an alternative route. The warning
subsystem shall comprise the following:
i. Warning message on LED display
ii. Loud audible alarm, 111 dB@ 3m
iii. Flashing Red warning light
15.12.4 Physical Requirements
1 The detector unit shall be solid state with printed
circuit boards and regulated power supply. The unit shall
be of modular construction. It shall have an effective
range of 3m to 38m with a reaction speed range of one
(1)MPH (1.61 km/h) to seventy-five (75) MPH (121 km/h) for
a 2 inch (5 cm) diameter object 1 inch (3 cm) above the
detection height. It shall provide a fault reporting output
upon loss of space/detector power or total failure.
2 Sensors are to have NEMA 6P rated enclosures,
direction selection to be from a selection switch. No tools
or adjustment is required.
3 Four LEDs and meter shall be provided for ease of
alignment and testing. Provision shall be made for the
elimination of the effect of ambient light and an internal
environmental control element that reduces operational
failure from fog, condensation and insects. Dimensions
shall not exceed a maximum overall size of 18 x 15 x 10
inches (46 x 38 x 25 cm). The housing shall be of high
grade extruded aluminum and sheet aluminum of not less
than 1/8 ″ thickness, and weather sealed for rugged
durability and extended life. The mounting shall allow for
directional adjustment and aiming after initial installation.
♦ 15- 26♦
4 Two 1/8 inch (.32 cm) boresight holes are to be
located at Top-Middle of each housing. Front and rear
screws are to be installed in these holes so as to insure a
weather tight enclosure, and should be removed to allow
alignment of units. Looking through boresight hole from
rear of unit so as to see through the boresight hole in front
of unit gives the installer a basic means of aiming the unit
in the proper direction. Focusing the unit on opposite
sides of the road in the center of the front boresight while
looking through the rear boresight hole ensures that a
general alignment is accomplished. This step should be
done from both Transmitter and Receiver Unit locations.
Fine tuning of alignment can then be done electronically.
5 The transmitter unit and the receiver units shall each
be provided with a barrier to protect the operating
equipment. The enclosure shall maintain its structural
integrity for the operational life of the equipment and shall
allow ready access for control adjustment and electrical
interconnection without the use of any tools except a
Phillips head screwdriver.
6 Each of the equipment units shall be provided with
means for rigidly attaching the unit to a vertical cylindrical
pole without requiring any machining operation. The
attachment means shall not stress or deform the unit and
shall prevent the movement of the unit in any direction by
the force developed by wind. The mounting means shall
allow adjustment of the vertical position on the pole. The
mounting means for the transmitter unit and the receiver
unit shall have the capability of adjusting the angular
orientation of the optical axis in both the horizontal and
vertical plane over an angular range of plus or minus five
degrees from horizontal. The transmitter and receiver unit
shall be mounted to detect the presence of vehicles that
exceed the specified vertical height.
7 Warning sign shall meet all electrical /electronic
specifications and shall conform, in all essential elements,
with the provisions of the U.S. D.Q.T, F.H.A. Manual on
Uniform Traffic Control Devices. Plastics on sign faces
shall be protected by LEXAN or other material providing
equal or greater defense against flying object damage or
vandalism. Signs shall be activated and time controlled
by the Detection unit. Lighting shall be provided by high
output fluorescent bulbs for message and incandescent
bulbs with parabolic reflectors for arrows at the top and
bottom of sign. Flashers on LED signs should be of
300mm diameter.
8 Sign housing shall be as indicated on drawings and
provided with rectangular (shape) reinforced aluminum
capable of withstanding wind loading up 95 km/h and
provided with a sun shield projecting at least 36 cm.
Letters and arrows shall be normally blanked out. When
illuminated, arrows shall be red in color, but can be made
in any color specified (IP 65 rating).
9 Unit mounting poles (shaft) shall be one or two piece,
adjustable height, seamless, round aluminum tube. Poles
shall include a handhole centered 46 cm above the bottom
of the shaft with a cover secured with stainless steel
screws. Base flange for the attachment of the shaft to the
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foundation shall be a one piece cast socket of aluminum
alloy, with 4 anchor bolts for fixing to the concrete base.
10 Single core cables for internal wiring shall be 450/750
volt flexible PVC insulated copper in accordance with BS
6004:1984 or approved equal standard with high
temperature insulation where operating in high ambient
temperature conditions. The conductor size shall be in
accordance with the circuit requirements. Cables shall be
bunched, clipped and properly secured to form a complete
wiring loop.
11 Power and signal cabling shall be provided between
the receiver unit electronics and the junction box adjacent
to the mounting pole foundation. Power for the receiver
and transmitter units will be made available at the junction
box located adjacent to the mounting pole foundation.
12 A solar panel shall be supplied with the OVDS to
make use of solar energy for stand-by power to enable the
system to remain powered even under power failure
conditions for limited periods.
13 A fault reporting function would be incorporated in
the system to detect any malfunctions in the system and
alert the authorities.
14 All non current carrying parts of the equipment and
installation shall be earthed.
15 The armoring and screens of all multi-core cables
installed directly in the ground shall be bonded and
connected to the earth bar together with the earth core of
the electricity supply cable. A separate single core copper
PVC insulated (green/yellow) installed back to the
electricity supply point shall be provided if the incoming
cable does not include the earth.
15.12.5 Construction Requirements
1 Associated civil work for ducts, draw pits and pole
bases shall conform to Clause 15.17.3 – Construction
Requirements.
2 The Contractor shall supply and install the
underground ducts, construct the cable drawpits as
indicated on the Drawings or as required on site for
installation of the cables. The Contractor shall be
responsible for all excavation, draining trenches, forming
of duct assembly, backfilling, and removal of excess earth
and restoring finished grade to its original condition.
3 Ducts shall be as specified under Clause 15.7.2. They
shall be laid in trenches in close cluster formation.
4 Concrete pole bases shall be designed to take into
account the nature of the ground and the dead and
imposed loads of the pole and all attachments. They may
be pre-cast or cast in-situ as detailed on the Drawings or
as instructed by the Engineer.
5 The excavated hole for the pole base shall be well
cleaned and its sides compacted and the base and sides of
the excavation shall be lined with a heavy duty sheet
bitumen or polythene waterproof membrane before work
on the foundation properly commences.
6 Where pre-cast foundations are to be installed they
shall be inserted in the excavation supported at the correct
level and grouted in. In-situ foundations shall be
constructed as shown on the Drawings with the concrete
poured around the reinforcing and holding down bolts
and consolidated in one operation.
7 The position of the anchor bolts and the level of the
top surface shall be exactly determined and adjusted. PVC
ducts of sizes shown on the drawings shall be installed in
the bases for cable access.
15.12.6 Method of Measurement
1 Over-height vehicle detection systems shall be
measured as the number of completed systems. The rate
shall include for supply and installation, testing and
commissioning of transmitter and receiver units, warning
signs, masts with interconnecting cables and earthing as
necessary, cables, including all foundations, ducts,
drawpits and associated civil work.
15.12.7 Basis of Payment
1 The quantity of completed and accepted work
measured as provided for above will be paid for at the unit
rate for a complete operational system stated in the Bill of
Quantities, which rate shall be full compensation for
supplying, installing, testing and putting into service, all
materials, transport, labor, equipment, tools, supplies and
other work items necessary for the proper support and
completion of the work as specified.
15.12.8 Items in the Bill of Quantities
i Overheight vehicle detection and
warning system (system complete)
(location shown on drawings) (nr)
15.13 Emergency Roadside Telephone
System
15.13.1 Description
1 This Sub-section describes requirements for
emergency roadside telephone systems, including
detailed engineering, coordination, manufacture, supply,
transportation, delivery, installation, jointing, connecting
up, testing, commissioning, setting to work, training and
maintenance services during the warranty period. Work
includes:
i. Coordination with Concerned Authority, existing
contractors, and providers of interfaced
systems.
ii. Project management.
iii. Planning management.
iv. Detailed functional analysis until approval by
Concerned Authority.
v. Finalization of system to the approval of
Concerned Authority.
vi. Supply of needed system equipment and
components.
♦ 15- 27♦
copy 249
 vii. Transport, unloading, and storage on the Site of xi. BS EN 60118-4:2006 - Hearing aids - Magnetic
the required equipment and components. field strength in audio-frequency induction
viii. Equipment installation. loops for hearing aid purposes.
ix. System installation and configuration. xii. BS EN 60529:2004 - Degrees of protection
x. System integration with interfaced and existing provided by enclosures (IP Code).
systems. xiii. BS 6305:1992 - Analogue inter working and non-
xi. Complete testing of the system (unit tests, interference requirements for Customer
integration tests, final acceptance tests, users’ Equipment for connection to the Public
tests, etc.). Switched Telephone Network.
xii. Training. 3 Other Standards - International Electro-technical
xiii. System implementation, Commission (IEC):
xiv. System roll-out,
i. IEC60068 Environmental Testing
xv. System maintenance after successful initial
ii. Specification for Concrete works, shall be as per
proving period during Warranty,
subsection: Civil Works for Electrical
xvi. Supply of spare parts for 2 years,
Installations
xvii. System maintenance tools delivery,
xviii. Writing and delivering of documentation (user’s 4 Product Data: For each component including
manual, maintenance manual, test reports, etc.) descriptions, colors, complete technical specifications, and
xix. Testing of emergency roadside telephones in manufacturer catalogues for all equipment and materials.
the field. 5 Factory Tests: All equipment and cables are to be
xx. Commissioning of the installation. tested at manufacturer premises, and test certificates, are
xxi. Connection of emergency roadside telephones to be submitted to Engineer before shipping and delivery
to control center to site.
6 Shop Drawings: Submit drawings for approval
15.13.2 Regulations and Standards including, but not limited to, the following:
1 British Standards and Codes of Practice shall apply to i. Detailed system schematic diagram.
the design and installation of the system ii. Detailed layout, locations, and installation of all
2 The following BS are generally applicable and are equipments.
mandatory: iii. Exact routing of all cabling and wiring.
iv. Equipment assemblies and indicate dimensions,
i. BS3573: 1990 - Polyethylene-insulated copper-
weights, required clearances, method of field
conductor telecommunication distribution
assembly, components, and location of each
cable.
field connection.
ii. BS EN60529: 1992 - Specification for
v. Wiring Diagrams: Detail wiring for power,
classification of degrees of protection provided
signal, and control systems and differentiate
by enclosures.
between manufacturer-installed and field-
iii. BS 1363 - Specification for 13 A plugs, switched
installed wiring. Identify terminals to facilitate
and un-switched socket-outlets and boxes.
installation, operation, and maintenance.
iv. BS EN 60898 - Specification for miniature and
Include a single-line diagram showing cabling
moulded case circuit breakers.
interconnection of components.
v. BS 4293 - Specification for residual current-
operated circuit-breakers.
15.13.3 Definitions and Mode of Operation
vi. BS EN ISO 14713: 1999 - Protection against
corrosion of iron and steel in structures - Zinc 1 Description of emergency telephone operation
and aluminum coatings – Guidelines and ASTM i. The principle of this operation is that when a
123. call is initiated in the field, the emergency
vii. BS EN 10327/2004 - Hot dip zinc coatings on roadside telephone automatically calls the
steel sheet. phone number unique to that particular
viii. BS EN ISO 1461: 1999 - Hot dip galvanized telephone. This unique called number is known
coatings on fabricated iron and steel articles - as the ‘indial’ number.
Specifications and test methods. ii. The indial number is connected to control
ix. EN50082-1 - Electromagnetic compatibility center CC (defined by the Concerned Authority).
(EMC) - Generic standards - Immunity for iii. The PABX (private automatic branch exchange)
residential, commercial and light-industrial is programmed to display on a screen:
environments.
a. The pillar number of the calling emergency
x. BS EN 60068-2-78:2002 - Environmental testing -
roadside telephone
Tests - Test Cab: Damp heat, steady state.
b. Its location
c. Any other information as required.

♦ 15- 28♦
copy 249
 i. From the pillar number and other information i. Button to initiate an emergency call to CC.
programmed into the PABX the CC operator ii. Button to annunciate recorded information.
answering the call is able to identify the location iii. Speaker to broadcast the ring tone and voice
of the phone being used, including which side communications.
of the carriageway, without the caller giving any iv. Two microphones to record and monitor voice
details. communication, respectively.
ii. The CC operators and the caller are able to v. IrDA interface with infra red port for
communicate clearly in a two way (duplex) programming the telephone features in the
manner. vicinity of the unit.
iii. In the event of a failure, the emergency roadside vi. Two (2) locks with different keying to secure the
telephone can detect the listed defects and will emergency roadside telephone module to the
automatically initiate a call to the CC manager enclosure (pillar). Keying must be keyed alike
and log the details of the defect. across the manufacturers’ telephones.
iv. The emergency roadside telephone must have
facilities for it to be called remotely by the CC 15.13.4.2 Pillar Dimensions and Weight
manager and perform the listed self-diagnostics 1 The pillar dimensions shall be:
and report the results accordingly.
i. Height 1400mm ± 100mm
2 Supply of network facilities and equipment ii. Width 200mm ± 50mm
i. Network supplier iii. Depth 130mm ± 50mm
2 The pillar weight, including the phone equipment,
a. Telephone equipment shall be
shall weigh less than 60 Kg.
coordinated with the mobile
telecommunications service provider. 15.13.4.3 Frangibility
b. It is mandatory that the local operator be
1 The pillar and solar cell support combination shall be
used for the services.
so designed as to be frangible in the event that it is hit by
ii. Each Emergency Roadside Telephone is to have an errant vehicle. The frangibility requirements must
a unique series of numbers : comply with the definition and requirements of BS EN 40-
2:2004.
a. Pillar number
b. The indial telephone number 15.13.4.4 Pillar Materials and Color
programmed to call the CC phone
1 The pillar shall be constructed from marine grade
number
aluminum with a minimum thickness 3 mm or extruded
c. CC manager phone number aluminum with a minimum thickness 5mm.
d. Phone service number (SIM Card)
15.13.4.5 IP Rating
e. Serial number
1 The pillar shall be designed to IP55 (IEC 60529)
f. A four-digit Personal Identification
Number (ID) 2 The electronics enclosure shall be designed to IP66
(IEC 60529).
g. The Pillar number shall be allocated
based on local authority guidelines. 15.13.4.6 Vibration and Shock
3 Monitoring of emergency roadside telephones
1 The emergency phone must remain operable under
iii. Calls from the emergency roadside telephones the following conditions of vibration: Three axes to: +/-
are handled and monitored by CC. 1.5mm 5-13Hz and+/-1g 13-150Hz tested.

15.13.4 Products and Materials 15.13.4.7 Wind

1 The emergency phone must remain operable after

15.13.4.1 Pillar Design and Manufacture
withstanding wind speeds of up to 198 km/h.
1 The emergency roadside telephone shall be hands-
free, vandal resistant and weather resistant. 15.13.4.8 Temperature

2 The emergency roadside telephone shall be housed 1 The emergency telephone shall comply with the
in a pillar with only the solar cell being pole mounted. following temperature requirements:
3 The emergency roadside telephone shall be housed i. Storage temperatures range -10ºC to +70ºC.
in a plinth mounted pillar of dimensions described in ii. A minimum start up temperature of -5ºC.
Paragraph 15.13.4.2 iii. An operating temperature range -10ºC to +70ºC
4 The emergency roadside telephone shall have as a continuous.
minimum the following features: iv. Storage temperature shock changes up to 10ºC
± 5ºC per minute.

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15.13.4.9 Lightning Protection
1 Primary protection shall be provided using fitted gas
arrestors.
2 Secondary protection shall be provided using fitted
metal oxide varistors.
3 Earth stake shall be fitted with a conductor no less
than 6 mm bonding the earth stake to the base of the
phone pole and to an earth point within the electronics
enclosure.
15.13.4.10 Vermin Ingress
1 The pillar shall be pest and vermin proof, including
termites, ants, bees, rats and mice.
15.13.4.11 Vandalism
1 The pillar shall be vandal and impact resistant to
prevent unauthorized access to the internal equipment.
Vandal and impact resistance can be defined as being able
to remain functional while withstanding moderate to
severe blows by hand held objects in most circumstances
without suffering more than cosmetic damage.
2 The pillar shall be fitted with an automatic
tilt/vandalism alert feature with configurable sensitivity
settings with provision for the emergency roadside phone
to make maintenance call and log its location and
condition with the CC manager.
3 Access to the fixing bolts attaching the phone to the
concrete pad shall only be obtained from inside the
emergency telephone pillar.
15.13.4.12 Pillar Identification
1 International telephone symbols and pillar numbers
shall be installed on each side of the pillar.
2 The International telephone symbols and emergency
telephone pillar number shall be manufactured using
British Standard.
3 The telephone symbol shall be 150mm in height with
a spacing of 150mm from the top of the pillar to the top of
the telephone symbol.
4 The pillar number shall consist of 80 D N numerals
installed vertically down the pillar with a spacing of
150mm from the bottom of the telephone symbol to the
top of the first pillar numeral.
15.13.4.13 Concrete
1 All concrete and reinforcement for the bases and
anchor bolt assemblies shall be in accordance with Sub-
section 15.17
15.13.4.14 Steelwork
1 All steelwork for the anchor bolt assemblies shall be
hot dipped galvanized in accordance with BS EN ISO
14713: 1999 and BS EN ISO 14761: 1999.
♦ 15- 30♦
15.13.5 Power Supply
15.13.5.1 Power Supply
1 The emergency telephone shall operate from either
of the following, as shown on the Drawings or instructed
by the Engineer:
i. Powered by a 240 V AC mains available from
the nearest light pole, where possible.
ii. A fitted solar panel and battery combination,
supplied by the Contractor.
2 Short circuit protection shall be provided.
15.13.5.2 Battery
1 The battery shall have the following characteristics:
i. Operating temperature range, -10º C - +70º C
ii. Sealed lead acid rechargeable
iii. Sealed and operational in any orientation
iv. Maintenance free
v. Minimum 3 years float service life.
vi. Recyclable
vii. No memory effect
viii. To provide a minimum of 7 days normal
operation under a primary source failure
condition. Normal operation is based on 6 calls
per day at 10 minutes per call for 7 days, the
remaining time being Idle time.
15.13.5.3 Battery Charging
1 The battery shall be charged with a solar cell or from
a 240V AC mains supply.
2 Thermal management of the battery charging to
prevent thermal runaway of the battery shall be
incorporated.
3 The power supply and charging system shall
incorporate battery management to monitor the status of
the battery charge and maintain it at its rated float voltage.
4 Should the battery voltage fall below 90% of its
nominal float voltage an alarm shall be raised.
15.13.5.4 Solar Panel
1 The solar panel shall be of sufficient size and wattage
to ensure that the battery receives sufficient charge under
all weather conditions.
2 A bird guard shall be fitted to the solar cell to
discourage birds from sitting on the cell.
3 The solar cell support shall provide a minimum of 4.0
meters clearance between the ground and the solar cell,
such that the solar cell is not accessible without a ladder.
4 The solar cell shall be vandal resistant and attached
to the mounting such that it cannot be removed without
special tools provided by the supplier.
5 The solar panel shall be installed facing North and be
angled towards the sun, with the angle being dependant
on the latitude of the location.
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15.13.6 Construction Requirements 15.13.6.5 Grouting of Pillar Base

15.13.6.1 Drawings 1 After the installation of the emergency telephone, the

Contractor shall impact mortar grout under the pillar base.
1 The Contractor shall prepare drawings to scale and
diagrams as follows:
15.13.7 Method of Measurement
i. Emergency roadside telephone system
schematic diagrams, detailed design, 1 The emergency roadside telephone system shall be
connection diagrams, etc. measured by number of the complete systems, supplied
ii. Construction drawings, including civil works installed tested and put into operation. The unit rates shall
iii. As-built drawings include for all work, including design, supply and
installation, per road; testing, commissioning,
2 All design development drawings, construction
maintenance provision of all drawings and manuals and
drawings, and as-built drawings shall be submitted in hard
all necessary civil works as specified.
copy format as well as in electronic format in the
quantities specified below.
15.13.8 Basis of Payment
3 Quantity of submittals
1 The emergency roadside telephone system shall be
i. Electronic Files: 1 set.
paid for as a lump sum per completed system including
ii. Reproducible hardcopies: 1 set.
transportation, at the unit rate(s) stated in the Bill of
iii. Prints: 3 sets.
Quantities, which shall be full compensation for the
15.13.6.2 Concrete Pad and Pillar Foundation complete system supplied including the roadside
equipment, the network facilities (mobile telecom service)
1 A concrete pad, complete with anchor bolt assembly implementation and putting into operation after testing in
and steel mesh, shall be constructed as detailed in the accordance with the Specification.
Drawings, at each emergency telephone location.

15.13.6.3 Anchor Bolt Assembly 15.13.9 Items in the Bill of Quantities (Unit)
i Emergency Roadside Telephone System
1 The anchor bolt assembly shall include four (4) nuts
and four (4) washers per assembly (Road Ref. No.) (Lump Sum)
2 Sufficient thread shall be provided on each bolt to
allow for the leveling of the pillar when installed. This 15.14 Public Lighting Management and
shall be not less than twice the sum of the nut, washer and Control System (PLMCS)
pillar base plate thickness.
3 All bolts shall be the same length with respect to the 15.14.1 Description
vertical axis of the assembly. The anchor bolt assembly
1 This Sub-section describes requirements for design,
shall be such that the pillar may be mounted parallel to
supply, installation, testing and commissioning of a
the road center line.
complete PLMCS installed in feeder pillars, with individual
15.13.6.4 Pillar Mounted Telephone phase voltage stabilization, dimming, monitoring, remote
control and remote surveillance suitable for later
1 An emergency telephone shall be installed on a connection to server based software for decentralized
concrete pad at each location indicated on the Drawings. operation.
2 Each pillar shall be installed on the anchor bolt 2 The PLMCS comprises:
assembly and adjusted so as to be vertical. The pillar shall
i. Feeder pillar power controller
comply with the requirements of the applicable British
ii. Switching functions
code for structural design for utility services poles for
iii. Remote control management software and
stability.
hardware
3 The emergency telephone shall be installed such that
the buttons, speaker and microphones are facing away 15.14.2 General Requirements
from the direction of traffic flow such that a person using
the emergency telephone is facing the phone and 1 The PLMCS shall control the function of the ordinary
oncoming traffic. feeder pillars (FP).

The pole for the solar cell shall be installed on the side of
the pillar further away from the curb such that it does not
obstruct the view of the pillar number when viewed by
drivers approaching the pillar.
4 Refer to Series 1500 of the DRMB UK Standards for
highways for all these works.
2 The PLMCS shall be installed at each feeder pillar
position and control all luminaries of that FP.
3 The PLMCS shall be capable of being upgraded later
to have full remote control, including remote servicing,
communication of alarms, down-loading of recorded
information. and reporting malfunctioning to a control
center.

♦ 15- 31♦
copy 249
4 The PLMCS shall work with all luminaires; HPS and
HPMV type, equipped with standard magnetic ballast,
ignitor and PFC capacitor.
5 The PLMCS shall be capable of dimming HPS and
HPMV lamps in a range of 100% - 50% and stabilize the
voltage for MH and FL lamps. It shall be capable of
stabilizing the output voltage for each phase individually
to +/-1% for input voltage fluctuations from 175V to 264V
and shall be able to increase the output voltage by at least
30V to compensate for low input voltage.
6 The PLMCS shall be designed to save between 15%
and 35% of energy on average and shall ensure up to
double the lamp life.
7 The PLMCS shall be completely static, that is with no
moving parts such as ‘variac-type’ transformers and it
shall not contain triac based equipment.
8 The PLMCS shall be a universal system to work with
any brand of HPS, HPMV, MH or FL lamps, mixed in the
same system or circuit of the FP. It shall be independent of
the brand of luminaires used.
9 The PLMCS shall be operated via, and conform to,
the local 3-phase 4 wire, solidly earthed neutral, 415 V A C.
electrical system.
10 The kVa rating installed shall be based on full load
shown on the Drawings at pf of 0.8 and a spare capacity
of 30% for future connection of additional loads. In
addition each unit shall be de-rated by 30%.
11 Each FP shall have an automatic by-pass system. The
by-pass shall be activated automatically in case of any
malfunction of the PLMCS.
12 The local agent for the PLMCS shall have factory
trained and certified personnel to perform commissioning
and all servicing tasks.
13 The PLMCS shall be a field proven system with at
least 1000 similar products installed worldwide. The
chosen supplier shall have similar systems installed in at
least 5 major cities in the Middle East.
14 The PLMCS shall use the latest technology, and
comply with international standards such as CE-mark, CEI
17-13/1, EN 60439-1 and UL916. PLMCS shall be CE
marked and conform to such standards. Under no
circumstance shall the system induce harmonic currents
to the supply grid.
15 The PLMCS enclosure shall be for outdoor
installation, IP 54 minimum to IEC 60529, for both the
power and electronic parts.
16 All system components shall be suitable for
operation within a temperature range from -10deg C to
+60deg C
17 Materials shall be certified to ISO 9002 quality
standard.
18 Load must be started at each switching on under
nominal conditions (230/240V RMS +-1% each phase) even
if the input voltage is at 175V for a programmable time,
(this is very important to conserve the lamp life and
conform to the lamp manufacturer’s warranty).
♦ 15- 32♦
19 The transition from lamp warming to planned stage,
or any intermediate level regulation process, shall be done
without disconnection and shall be applied in maximum
steps of 2.2V. The process of dimming shall be even,
without visible steps in luminance.
20 The PLMCS shall incorporate a high accuracy
astronomical time clock which can be remotely controlled
from the control center.
21 Programming and reading of the parameters shall be
done via PC software, able to read the real time
measurement and to change all the parameters of the
feeder pillar, operable through either a direct cable
connection between the PC and feeder pillar or with GSM.
22 The supplier shall be responsible for installation,
testing and commissioning of the system and shall
organize a local 5-days seminar for training.
23 The PLMCS shall monitor power, voltage, current
and power factor of each lighting circuit and additionally it
shall monitor all other inputs from the FP.
24 Communication to the PLMCS shall be via fiber optic
interface on TCP/IP protocol.
25 Future optional features may include the following:
i. The PLMCS shall have the optional capability in
future to add communication with each
individual lighting point by means of power line
carrier (no additional cables). With this option it
shall monitor the proper functioning of each
lamp, ballast, ignitor and capacitor.
ii. The PLMCS shall have the capability in future to
switch on and off each individual lighting point
or advertising panel by means of power line
carrier (no additional cables).
iii. Communication to the PLMCS shall be possible
via telephone modem, GSM modem, GPRS
modem, radio modem, RS232 interface or
RS485 interface.
15.14.3 Detailed Technical Specification
1 Power controller enclosure shall have the following
features:
i. Housing fabricated of fiber-glass reinforced
polyester or equally approved material
ii. Protection level: IP54 in accordance with IEC
60529 Standard
iii. Color: RAL 7032 - 7035
iv. Base frame made of hot dipped galvanized steel
v. Safety lock.
2 Main technical features of power controller shall
include:
i. Supporting frame made of galvanized steel
ii. Voltage control circuits as provided by
manufacturer.
iii. Serial port RS232 or RS485 for communication
with PC and GSM, and up-to-date software of all
units.
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 iv. Microprocessor unit (PLC) for control of work xiii. Lithium battery for buffering of RAM memory
cycles, made of high-grade components, and of the time clock, with 2 (two) year
suitable to operate within the temperature autonomy under disconnected mains
range -10°C to +70°C - Printed circuits with conditions; control of charging status, with
galvanic insulation of the tracks. analogue measurement of battery voltage;
v. Regulation and stabilization of voltage on load push-button for disconnection during storage
side through static system without wave period; hot replacement.
dimming (wave-form shall remain perfectly 5 Features for future functions (upgradeable) shall
sinusoidal) for each phase independently. include:
vi. Four pole main breaker, thermal and magnetic
i. Alarms programming menu for values above or
protection, with rated current to suit the size of
below the preset thresholds of input voltage,
controller with a short circuit capacity 50 kA.
output voltage, total current, power and PF.
vii. Indicator lights: mains voltage phase colors.
ii. Display of the following information:
3 Connections:
a. Input voltage of each phase
i. Feeder terminals shall be 5 x 35mm2
b. Output voltage of each phase
ii. Each FP shall have at least 4 outgoing circuits,
each terminated with 5 terminals 16mm2. c. Active power of each phase
Configuration, quantity and circuit current rating d. Reactive power of each phase
of each circuit shall be as indicated on the e. Power factor of each phase
Drawings.
f. Frequency of each phase
4 Functional features of power controller shall include:
g. Analogue input value (m A)
i. Static by-pass, no break execution, suitable to
h. Analogue output value (m A)
operate any combination of mixed types of
lamps iii. Recording of the following statistical data:
ii. Power saving of up to 40% depending on the a. Hours of operation on line
type of lamps connected. b. Hours of operation in the by-pass mode
iii. Efficiency 98.5% (at full load, PF=1)
c. Number of switching cycles of control
iv. Stabilization of output voltage with accuracy +/-
relays
1% with input voltage 200 to 245 V independent
for each phase. d. Stability of mains (steps/minute)
v. Stabilization of changes in mains voltage in e. Total energy consumption
extra-rapid time.
f. Number of black-outs
vi. Setting of the following parameters, separate
g. Number of resets
for each phase: starting voltage, full light
voltage, reduced light voltage, warm-up time, h. Possibility to download the historical data
ramp-up speed, ramp-down speed. recorded in the controller, via portable PC
vii. Selection of dimming percentage and of the or modem or from the control center.
corresponding time zones, up to 10 time zones. iv. Provision for connection to a remote control
viii. Availability of one preset yearly program, with network designed for diagnostic and control of
starting and operating cycles configurable in the whole unit (remote servicing).
accordance with seasonal factors and location.
ix. Availability of one customizable yearly cycle 15.14.4 Remote Control Management (RCM)
with different settings for each season and the Software
possibility to set up to ten time zones over night
time. Software shall be designed to operate a remote control
x. Availability of five customized periodical cycles station for supervision and management of lighting
with possibility to set the requested time, the systems, with the features and functions listed in items 1
days of the week and up to ten time zones over to 8, below:
night time. 1 General features:
xi. Availability of one cycle controlled by analogue i. Standard language is English; further local
input (4 - 20 ma) suitable for dimming from languages with text import during program start
signal sent from a luminance sensor or any up later on, should be possible
other equivalent apparatus. ii. Installation on single PC (stand-alone) or in the
xii. Astronomical time clock with precision of ± 4 Concerned Authority’s server configuration in
minutes/year in a temperature range of -10 to future.
+70°C, or, alternatively, high accuracy clock, iii. Facility to share and to display data via internet
with precision ±1 minutes/year in a temperature iv. SQL database
range -10 to +70°C.

♦ 15- 33♦
copy 249
 v. Safety system for control of all accesses,
configurable for the function and the Concerned
Authority’s control.
vi. Customization of program options
vii. Facility to import and export data, already
present in external database, without the need
of manual fill-in
viii. Manual backup utility
ix. Window preference for simple access to the
most-used functions.
x. Creation of log files of the performed
operations.
xi. Wide flexibility in customization
2 Data list management:
i. Loading of data list of plant and components
(FP's, cables, luminaires, lamps, ballasts,
ignitors, capacitors)
ii. Management of data list by means of a tree
structure
iii. Fill-in of plant and component data list from the
tree structure or directly from the maps
iv. Utility functions such as copy, cut, paste, paste
special
v. Management capacity up to 30 towns, 300 FPs
and more than 30,000 objects with possibility to
extend without limit.
vi. Identification (object can belong to more than
one group) and without limitation in numbers
vii. Management of groups by means a tree
structure; data searching and selection via
appropriate filters (with logic addresses)
viii. Data replicate tool to revise and modify the
data list of elements
ix. Facility to personalize the screen and
background
x. Control panel for easy access to the different
program functions
3 Communication:
i. Communication via serial cable or via modem
(standard telephone PSTN, GSM, GPRS, radio
modem, TCP/IP protocol on Ethernet)
ii. Management of 5 modems at the same time or
5 TCP/ IP channels.
iii. Facility to configure the interface modems for
only incoming calls, only outgoing calls, only
manual calls, only automatic calls
iv. Full automatic management of the connections
(automatic disconnection only when required)
v. Emulation in remote mode to enable all the
operations as if in front of the controller
vi. Manual connection to verify the controller state,
to perform a data-download, to synchronize the
clock, to program the operative parameters
vii. Monitoring and recording on log files of the
communications procedure and errors
viii. Diagnostics of communication based on the
errors and faulty answers from the field, with
activation of alarm to signal the most critical
connections
♦ 15- 34♦
ix. Remote reading of operative parameters
(technical data, working cycles, clocks, alarms,
l/0 state, MEM modules settings), active alarms,
records of alarms (in partial or total mode),
record of measures, monthly data, etc.
x. Facility to download the last "n" records
xi. Facility to program in advance the operation to
be performed during the connection with the
controller in field
xii. Remote writing and modification of the
operative parameters
xiii. Real time remote reception of alarms from the
plants
xiv. Alarms notification to the technician via SMS or
e-mail, based on customizable rules
xv. Utility to plan the automatic calls of the
controllers, including the possibility to choose
the operation to be performed, and the
management of errors in the communication
xvi. Remote plant override to switch the lighting
system on and off
xvii. Remote control of input/output relay
4 Plant management by active maps:
i. Map management on three levels in case of a
wide area or on two levels in case of
medium/small area
Up to 324 maps
Maps in whatever graphic format (JPG, BMP,
WMF, TIF, GIF)
Simple insertion of object in the map
Facility to choose the objects to be displayed in
the map, only one object type at a time
ii. Active objects which light-on because of alarms
iii. Color light indication in the quadrants at levels
one and two, indicating the presence of one or
more objects in alarm condition inside the area
iv. Facility to add, delete, remove, new objects
directly from the map
v. Utility functions such as copy, cut, paste, paste
special
vi. Full interactivity of the objects to open data list,
to display a mimic panel or alarms or records of
maintenance activities or set-up , directly from
the map
vii. Zoom function in the detailed map
viii. Tools to navigate into the maps
ix. (As an alternative to normal maps) chart
module, to interface and interact with drawing
Autocad and/or shop files, with facility to import
automatically elements of chart system used
5 Mimic panel application:
i. Remote diagnostic identification by displaying
the operational state of the controller and
relevant components on an interactive on-line
diagram
copy 249
 ii. Display of the state of equipment in real time xiii. Print out of log messages
mode (when on-line) or by records (from 8 Maintenance module
database)
i. Automatic elaboration of programmed
iii. Identification by color code of alarms and
maintenance plan, according to user's needs
operational state of: breakers, limit switches,
and settable parameters
contactors, relays etc…
ii. Facility to customize maintenance operations
iv. Display of all measures done by the local
iii. Print out of plan of activities
control module (voltage, current, power, power
iv. Recording of failures and unplanned activities
factor etc.)
v. Recording of real activity done
v. Manual override commands, in ON-LINE mode,
vi. Management of historical data
controlled directly from the mimic panel
6 Events and data analysis: 15.14.5 RCM Hardware
i. Events shall be able to be programmed in four
1 Personal computers shall be latest models and have
priority levels:
the following features:
Table, to display the events with predefined
i. Processor: Intel 2.0Ghz or over
customizable filters for each PC
ii. RAM memory: 1 GB
Bar graph for the analysis of the types of iii. Multi-serial with 5 ports COM (or in alternative
events and the objects involved USB hub with converters) (if not used by TCP/IP)
Events in cases of: override controls, iv. Parallel port
communication problems, automatic call v. Printer with continuous paper form
results, etc. vi. Double HD with indicative capacity 40GB each
Management of an appropriate printer for one (IDE or SCSI; same type)
recording alarms vii. If the HD is SCSI type, the controller must be
ii. Each alarm/event shall able to be configured to SCSI U/160.
send a message via SMS or e-mail viii. Color video card that grants a definition of
iii. Display of data of the plant (measures, monthly 1024x765 at least.
measures, alarms) through tables, graphs, ix. Minimum video memory card 32 Mb
active mimic panel of the selected unit x. Compatible back-up system
iv. Table to display data with predefined 2 Operative system shall be as stated below or as
customizable filters for each PC selected by the Concerned Authority:
v. Creation of customizable graphs for the analysis i. MS Windows 2000® Professional or Windows
of the most interested values XP® Professional, or latest system (up-to-date)
vi. Availability of different types of graphs (line, complete.
steps, cake, etc.)
3 Modems shall be:
7 Working parameters of controllers
i. Modem standard for wired telephone line
i. Data replicate tool, to revise and modify the (PSTN)
parameters of controllers ii. Modem GSM for SMS alarms
ii. Facility to transfer and read each parameter iii. Modem GSM/GPRS for SMS alarm
iii. Automatic control of errors during the
parameter transfer 15.14.6 Method of Measurement
iv. Facility to program in automatic mode each
controller or groups of them 1 The public lighting management and control system
v. Tool for automatic calculation of switch-on shall be measured by the number of completed feeder
hours of the plant, depending on astronomical pillars controlled by the PLMCS, installed and
clock parameters (for season and for year) commissioned. The rate per feeder pillar shall include for
vi. Print out of data list and the groups of objects the remote control and management software and
vii. Print out of all related tables (streets, supports, hardware, and any transmission/ communication media
lamps) between the feeder pillar and the control center. Rates are
viii. Table and graph print out, with filters, of events deemed to include for all work, including design supply,
ix. Table and graph print out, with filters, of transportation and installation, testing and commissioning
measures and instruction of the Concerned Authority’s personnel in
x. Table and graph print out, with filters, of operation of the system.
monthly data
xi. Report of the energy (theoretical, actual and 15.14.7 Basis of Payment
saving)
1 The amount of completed and accepted work
xii. Detailed print out of the working parameters of
measured as provided for above, will be paid for at the
the controllers
unit rate for PLMCS powered and controlled feeder pillar

♦ 15- 35♦
copy 249
stated in the Bill of Quantities, which rate shall be full
compensation for supplying materials, installation, testing
and putting into operation, for labor, equipment, tools,
supplies, earthing, training, and other items of work
necessary for the completion of the system(s) to the
satisfaction of the Concerned Authority, as specified.
15.14.8 Items in the Bill of Quantities
i PLMCS installation at each feeder pillar
and all related communication and central
control facilities. (nr)
15.15 Earthing
15.15.1 Description
1 This Sub-section describes requirements for
supplying, installing, and testing earthing connections in
electrical installations, including transformer neutral
earthing, main earthing terminals or bars, exposed
conductive parts of electrical equipment, extraneous
conductive parts, and standby generator neutral earthing
where installed.
2 The Contractor shall carry out work in accordance
with the following:
BS 7671 chapter 54 (seventeenth edition)
or IEC 60364-5-54 (2004)
3 Prior to ordering materials, the Contractor shall
submit data for the Engineer’s approval including, but not
limited to, manufacturer’s catalogues for earth rods,
connecting clamps, earthing conductors, protective
conductors, bonding conductors, connectors and other
accessories, exothermic welding kits and tools etc,, and
samples of conductors as requested.
4 The Contractor shall submit drawings for approval by
the Engineer, including, but not limited to the following:
i. exact location of earth pits, rods and details of
installation and connections
ii. exact routing of buried earthing conductors with
indication of cross-section, depth of laying and
covering
iii. cross sectional area of all earthing ,protective
and bonding conductors
iv. layout and details of earthing provisions at
substations, switchgear, distribution
panelboards etc., indicating fittings used,
insulation, plates and markings, passage and
routing of earthing conductors, conduit, sleeves,
grooves, niches etc. giving sizes and
dimensions of component parts.
15.15.2 Materials
1 Fittings, plant, equipment, ducts and cables used for
each earthing installation shall be as specified in other
pertinent Clauses of this Section 15. Unless otherwise
♦ 15- 36♦
specified, all earthing materials and components shall be
of copper.
15.15.3 Construction Requirements
1 Exposed non-current carrying metallic parts of each
electrical installation and the neutral point of the
distribution system shall be earthed. The earthing of the
distribution system shall be made at the neutral point of
the transformers.
2 A separate 50mm x 6mm high conductivity earth bar
shall be mounted on porcelain connectors in each
substation and feeder pillar housing. The bar shall be pre-
drilled with a minimum distance of 75mm between holes
and connected as follows:
i. Insulated cable:
a. Transformer neutral
b. Earth mat
ii. Bare cable:
a. Switchgear frame earth
b. Transformer frame earth
3 The insulated cable shall be green–yellow striped
50mm² single core PVC fixed at regular intervals with non-
magnetic insulating cleats and terminated with suitably
sized lugs. The bare conductors shall be 35mm x 6mm or
50mm² high conductivity copper tape or conductor fixed at
regular intervals with purpose made brass saddles.
4 Each sub-station and feeder pillar earth mat shall
have two 16mm diameter copper covered steel earth rods
of 2.5m length, connected together and to the earth bar.
Each rod shall be housed inside a concrete inspection box
recessed into the ground and fitted with a removable
metal lid with the inscription ’Earthing Rod’. An earth
resistance test shall be carried out on the earth bar at each
sub-station and feeder pillar. Three readings shall be
obtained on each of the two earth paths connected
individually and in parallel. The results shall be tabulated
and submitted to the Engineer for approval.
5 The earth bar shall be labeled and the connections
identified. The insulated earthing cables for high mast and
lighting column circuits shall be earthed at the low voltage
supply position at the earth bar.
6 At the masts and each last column on a circuit,
earthing shall be by connecting the earthing bolt to a
16mm diameter copper covered steel rod of 2.5 m length
minimum, driven into the ground adjacent to the mast or
column to achieve the required resistance (1 ohm
maximum). Bonding is to be by means of a 16mm2
stranded bare copper conductor. Each mast and column
shall be bonded to the earthing cable. Where the supply
cable is looped into the column the earthing cable shall
not be cut. The final column in each distribution circuit
shall be bonded to a separate earth rod.
7 The earthing system at sign lighting installations
shall be as specified for masts and columns.
8 Connections between rods and earthing tape or
cables shall be made by the ’Cadweld’ process to produce
copy 249
a fused joint. Bolted connections may be used for
removable items of equipment only.
9 Protective conductors shall not be formed by conduit,
trunking, ducting or the like. Where armored cable is
specified and armor is steel, it may be used as a protective
conductor, if approved and if not otherwise shown on the
Drawings. In general a protective conductor shall be run
together with the lighting power circuit unless otherwise
waived by the concerned authority.
10 Connection of every earthing conductor to earthing
electrode and every bonding conductor to extraneous
conducting parts shall be labeled in accordance with the
applicable regulations, as follows:
‘SAFETY ELECTRICAL CONNECTION - DO NOT REMOVE’.
15.15.4 Earth Resistance Test
1 Earth resistance tests shall be made by the
Contractor on the earthing system, separating and
reconnecting each earth connection.
2 If it is indicated that soil treatment or other corrective
measures are required to lower the ground resistance
values, the Contractor shall submit proposals for
corrective measures to the Engineer for approval prior to
working on such measures.
3 The electrical resistance of the earthing circuit (ECC)
together with the resistance of the earthing leads,
measured from the connection with earth electrode to any
other position in the complete installation, shall not
exceed one ohm.
5 Earth resistance test shall be performed as the
Engineer’s requirements. The earth resistance of each
electrode shall be measured by means of resistance
bridge instrument and results recorded.
15.15.5 Method of Measurement
1 Earthing shall be measured by the number of
completed sets of earthing rods supplied, installed, and
tested. The interconnecting work within the circuit shall
not be measured separately.
15.15.6 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above will be paid for at the unit
rate stated in the Bill of-Quantities which rate shall be full
compensation for supplying, installing, testing,
transportation, putting into operation and for materials,
labor, equipment, tools, supplies and other items
necessary for the proper completion of the work as
specified.
15.15.7 Items in the Bill of Quantities
i. Twin rod earthing installation (location) (nr)
ii. Single rod earthing installation (location) (nr)
15.16 Labeling, Testing and
Commissioning
15.16.1 Description
1 This Sub-section describes requirements for labeling,
testing and commissioning of electrical and
communication systems installations and equipment. The
work is supplementary to the work specified in the
respective parts of this Section 15.
15.16.2 Materials
1 Labels shall be manufactured from sheet aluminum,
plastics or other approved non-corrosive inert material.
Text shall be die-stamped, engraved, painted or printed
with a legible life expectancy of 20 years. Finished labels
shall be permanently bonded, screwed, riveted, bolted or
wire-locked to the part as appropriate.
15.16.3 Construction Requirements
15.16.3.1 Labeling
1 The Contractor shall submit for approval a
comprehensive labeling and marking plan before work is
started. This shall include all factory labeled items as well
as field labeling.
2 Plant and equipment not labeled to the Engineer's
approval by the manufacturer shall be labeled by the
Contractor on the Site.
3 Equipment labels shall be simply and clearly written
in black on white or white on black in English and Arabic,
in accordance with the schematic diagram on the
installation drawings. Warning labels shall be red on
white or white on red lettering a minimum 15mm in height
4 Each item of plant, including individual parts of a
package sub-station or control panel, shall be labeled on
the exterior of the respective casings.
5 Lighting columns and masts shall be fitted with
identification labels of black lettering 50mm high on a
white background. The labels shall be attached to the
columns by means of galvanized nuts and bolts positioned,
just above the access openings and facing approaching
traffic.
6 Control switchgear labels shall indicate the voltage,
current rating and phase color, together with the
manufacturer's distinguishing mark. A separate label shall
state the service controlled by the switch.
7 Switchgear, distribution boards and apparatus shall
be included in an overall identification scheme and labeled
accordingly.
8 ’Danger High Voltage’ labels in English and Arabic
with red lettering and electrical flash shall be fixed to the
doors of each sub-station and switch station and be clearly
visible from the fence access gates.
9 The interior of each item of electrical equipment shall
indicate the phases by means of colored plastic sleeving
or discs.
♦ 15- 37♦
copy 249
10 Circuit lists shall be mounted on the inside of
distribution board lids or doors. The list shall comprise a
printed sheet heat-sealed into a semi-rigid clear plastic
cover.
11 Power cable cores shall be identified at their
terminations by colored sheaths of the heat or chemically
shrinkable type to indicate the respective phases and
neutral. Where the core insulation is suitably colored
during manufacture the colored sleeve may be omitted.
12 Local switches, switch-fuses, isolators, lighting
fittings, and similar accessories shall carry engraved
identification plates to indicate the circuit number and
phase to which the accessory is connected.
13 Medium voltage cables shall be clearly labeled
'DANGER HIGH VOLTAGE' in English and Arabic every 2m
of exposed length.
14 Prior to final testing the Contractor shall obtain the
Engineer's approval that the labeling is intact over the Site
and that circuit markers have been fitted wherever cables
emerge from the duct system or enter a building.
15.16.3.2 Testing and Commissioning
1 Testing of the installations shall be carried out in
accordance with the relevant regulations and standards
after completion of the work. The tests shall be carried
out to the satisfaction of the Engineer and the concerned
authority. Manufacturer’s test certificates shall be included
in the documented results submitted for approval.
2 Tests shall comprise the following:
- Insulation resistance on MV equipment
including busbars, bushings, through
insulators and feeder terminations, using a
5000 V megger, between phases, and between
phase and earth, with control and protection
circuits, lamps and similar components
disconnected.
- Insulation resistance on every cable and
insulator, power, control and relay circuit of the
LV systems, using appropriate megger range;
500 V for installations rated below 500 V and
1000 V for installations rated up to 1000 V, in
accordance with the IEE Wiring Regulations
(BS 7671) Subsection 612.
- HV test, using power frequency HV test set, to
80% of IEC withstand voltage ( 2.5 rated
voltage) for one-minute, between phases and
phase to earth for each MV switchgear and
transformer, disconnected.
- MV cable tests as Sub-section 15.7, Paragraph
15.7.3.2.
- Any other tests required by the concerned
authority standards, unless waived in writing
by the Concerned Authority,
3 The test and measuring apparatus provided by the
Contractor to carry out the testing shall be sealed as
♦ 15- 38♦
appropriate and have current calibration certificates issued
by an approved laboratory.
4 Advance notice shall be given to the Engineer of the
testing program proposed together with a list of the
equipment to be used.
5 The Contractor shall re-test any item that fails. No
repeat test shall be carried out until the cause of failure
has been identified and removed.
6 After satisfactory completion of the tests the
Contractor shall obtain authorization from the Engineer
and the Concerned Authority to connect the power supply
to the installation.
15.16.4 Method of Measurement and Basis of
Payment
1 No separate measurement shall be made and no
separate payment made for work of labeling, testing and
commissioning of the electrical and telecommunication
installations. The cost of this work is deemed to be
included in the unit rates for the respective items stated in
the Bill of Quantities.
15.17 Civil Works for Electrical and
Telecommunication Installations
15.17.1 Description
1 This Sub-section describes requirements for civil
work, including excavation, concrete, building work, and
duct work, associated with the electrical and telecoms
installations.
15.17.2 Materials
1 Backfill material for excavations shall be as specified
in Section 2, Sub-section 2.7 of these Specifications.
2 Concrete for column and pole bases, equipment
foundations and other structures shall be Class 30 as
specified in Sub-section 5.1. Reinforcement for concrete
shall be mild steel in accordance with Section 5, Sub-
section 5.2 of these Specifications.
3 Anchor bolts shall be as specified and shown on the
Drawings and as instructed by the Engineer.
Minimum standard shall be ASTM F1554, Grade 55,
minimum thread length of 10 inches, galvanized for a
minimum of 12 inches on the threaded end to the
requirements of ASTM A153. Each is to be supplied with
too hexagonal nuts and two flat washers, all to be hooked
end on the embedded side.
4 Buildings to house switchgear for the medium
voltage switching station shall be as shown on the
Drawings. They shall have adequate space for the
concerned Authority’s equipment. If buildings are not
defined on the Drawings, they shall be constructed of
conventional materials with concrete foundations and
floor, blockwork walls, rendered internally and externally,
and suitable waterproof roof. Doors shall be painted steel,
copy 249
lockable, and complete with ventilation louvers and sand
traps. Foundations and floors shall incorporate trenches
and ducts for cables and bases for equipment.
5 Cable ducts shall be uPVC Schedule 40, UL listed, or
equivalent standard as specified or shown on the
Drawings. Minimum requirements shall be non-sparking
type, suitable for direct burial in ground, minimum tensile
strength 500 kg/cm2, impact strength 5 kg/cm2, supplied in
standard 6 m lengths.
6 Unless otherwise indicated on the Drawings,
columns 8m through 16m shall incorporate a cast
aluminium breakaway transformer base and electrical
breakaway quick disconnect. The base shall be designed
and constructed so that when used with the size and
weight of the column, the assembly shall meet the
requirements of AASHTO Standard Specifications for
Structural Supports for Highway Signs, Luminaires and
Traffic Signals.
7 Transformer base and column combination shall be
designed, fabricated and tested to withstand the wind
loads described in Clause 15.1.9, and Paragraph 15.8.2.1.
8 The transformer base shall meet the following
standards:
ASTM B108 alloy 5G70-T6 or alloy 356-T6 for the base
ASTM A-325 for the bolts, ASTM A-563 Grade A for the
nuts, both galvanized to ASTM A-153.
15.17.3 Construction Requirements
15.17.3.1 Bases for Poles and Equipment
1. Excavations for foundations shall be carried out in
accordance with Sub-section 2.7. Foundations located on
old backfill shall have the ground bearing material re-
compacted to the Engineer’s requirements. The sides of
excavations for foundations that will be subject to uplift or
lateral forces shall be compacted and approved before any
concrete is poured.
2. The position of anchor bolts in the concrete bases
shall be set by means of templates. The top of foundation
bases shall be horizontal to a tolerance ±0.25mm across
the width of an individual base.
Where shown on the Drawings duct stubs 300mm long
and to the diameter shown shall be provided in the
structural concrete. uPVC ducts shall be cast into lighting
column, mast and feeder pillar bases to run the incoming
and outgoing power cables.
15.17.3.2 Cable Trenches and Ducts
1 The depth of low voltage cable trench excavation
shall provide a minimum cover to the cable of 500mm in
open ground and sidewalks.
2 Cables shall be ducted where they run under or cross
below roads and shall not be at less than 800mm deep,
with a concrete cover of 100mm all around. Duct ends
shall extend minimum 600mm beyond road structure or
embankment where ducts cross the road
3 When cables cross road, paved area or other services
or are buried in slab, they shall be laid in protective ducts
of adequate size. The duct/ conduit ends after installation
of cable shall be plugged to make them watertight by
means of bituminized hessian or equivalent material.
4 Cables shall be laid without sharp bends or kinks,
and if within 500mm of drainage ware, shall be contained
in a duct.
5 Slack shall be left in cables for which purpose the cut
lengths of cables shall allow about 3% more in the
measured length between terminations (Engineer will
verify the lengths of cables). At junction boxes, ample
slack shall be left to prevent straining of cable joints due to
settlement of cable trench.
6 Cables shall be pulled in uPVC ducts or conduits with
care, preferably without the use of any lubricant. Where
necessary, and after approval of the Engineer, the cable
manufacturer’s recommended lubricant shall be used. Use
of any kind of oil or soap will not be permitted.
7 Sharp bends or tees shall not be allowed. At road
crossings the duct shall have a bedding and surround of
concrete Class 30 and shall be laid at 800 mm below road
surface or as shown on drawings and directed by the
Engineer.
8 Prior to backfilling at duct location, the following
shall be completed:
i. Placement of the approved type of draw cord in
each duct section
ii. Capping ducts at both ends
iii. Recording the coordinates of both ends
9 Where ducts rest over rocky soil, a layer of 200 mm
dune sand shall be spread, compacted and rammed in
order to create proper bedding for the duct. In water-
logged or unstable soil, a concrete base 200mm thick shall
be laid, followed by 100mm layer of dune sand on top of
the concrete as a base for the duct.
10 Spare ducts shall be provided wherever ducts are
used for MV or LV cable routing. 30% spare ducts or at
least one duct per run, whichever is greater, shall be
provided.
11 Cables, whether installed in bare ground or in uPVC
ducts or conduits shall not be bent to a radius less than
that recommended by the cable manufacturers.
i. Install cables as indicated, according to
manufacturer's written instructions.
ii. Use manufacturer-approved pulling compound
or lubricant where approved; compound used
must not deteriorate conductor or insulation.
Do not exceed manufacturer's recommended
maximum pulling tensions and sidewall
pressure values.
iii. Use pulling means, including fish tape, cable,
rope, and basket-weave wire/cable grips, that
will not damage cables or raceways. Do not use
rope hitches for pulling attachment to cable.
iv. Install exposed cables, parallel and
perpendicular to surfaces of exposed structural
♦ 15- 39♦
copy 249
 members, and follow surface contours where
possible.
v. Install direct-buried cables on leveled and
tamped 100-mm bed of clean sand at bottom of
trench. Separate cables crossing other cables
or piping from those items by a minimum of
100 mm of tamped earth.
vi. Install permanent markers at ends of cable runs,
changes in direction, and buried splices.
vii. Install ‘buried cable’ warning tape 305 mm
above cables.
viii. Cable identification/route markers shall be
erected at 25m maximum spacing throughout
the entire length of the cable trench route and at
each bend or intersection. Refer to MEW
Standard OES 2 for all details.
ix. In manholes, hand-holes, pull boxes, drawpits,
junction boxes, and cable vaults, train cables
around walls by the longest route from entry to
exit and support cables at intervals adequate to
prevent sag.
x. Seal around cables passing through fire-rated
elements using approved fire-stopping material.
xi. Identify cables according to Section 15.16-
Labelling, Testing and Commissioning.
15.17.4 Method of Measurement
1 Buildings for the medium voltage switching stations
shall be measured by the number of the constructed block
work buildings, including foundations, concrete roof,
fence, and all necessary related civil works.
2 Bases for package substations shall be measured by
the number of concrete foundations including fence and
other builder’s works, as per the approved related shop
drawings.
3 Buildings for package medium voltage switching
stations shall be measured by the number of the
constructed block work buildings, including foundations,
concrete roof, fence, and all necessary related civil works.
the number and size of duct, including all bends,
couplings and bushings. Concrete encasement shall not
be measured for direct payment but shall be considered as
subsidiary item, the cost of which will be deemed to be
included in rates for the duct.
9 Cable markers, drawpits, handholes and manholes,
shall be measured by detail shown on drawings, and
number completed including all civil work and finishing
work.
15.17.5 Basis of Payment
1 The quantity of completed and accepted work
measured as provided for above will be paid for at the unit
rates for the items stated in the Bill of Quantities, which
rates shall be full compensation for supplying all materials,
formwork, construction, installation, testing and putting
into service, and for labor, equipment, tools, supplies,
transportation, and other work items necessary for the
proper completion of the work as specified.
15.17.6 Items in the Bill of Quantities
i Building for medium voltage intake
switching station (reference drawing
and detail) (nr.)
ii Concrete foundation for package
substation (reference drawing
and detail) (nr.)
iii Building for package
medium voltage switching station
(reference drawing and detail) (nr.)
iv H type concrete foundation for
33kV/low voltage pole mounted
transformer station (reference
drawing and detail) (nr.)
v H type concrete foundation for

4 Bases for the 33kV/11kV pole mounted transformer 11kV/low voltage pole mounted
station shall be measured by the concrete base H type transformer station (reference
construction for 11m poles, to the detail of Concerned drawing and detail) (nr.)
Authority, including all related civil works.
vi Concrete base for feeder pillar
5 Bases for the feeder pillars shall be measured by the
(ref.dwg) (nr.)
number of concrete bases, including incoming and
outgoing ducts for cables and other builders work. vii Trench for low voltage cable for:

6 Trenches for directly buried cables shall be measured - one cable (lin.m)
by linear meter completed, including concrete tile, - two cables (lin.m)
warning tape and excavation and backfilling to levels and - three cables (lin.m)
dimensions as specified in the Drawings.
viii Trench for medium voltage cable for:
7 Bases for lighting columns/high masts shall be
- one cable (lin.m)
measured separately each by the number of concrete base
and other related civil works, including all related civil - two cables (lin.m)
work as the column detail approved. ix Lighting column concrete foundation
8 uPVC ducts shall be measured in linear meters of (Type, ref. dwg) (nr.)
multiple duct run installed in trench or in concrete x High mast concrete foundation
encasement, completed and accepted with reference to
(Type, ref. dwg) (nr.)

♦ 15- 40♦
copy 249
xi uPVC duct (size and nr) (lin.m)
xii uPVC duct, in concrete encasement
(size and nr) (lin.m)
xiii Cable marker as per MEW details (nr.)
xiv Manhole (type, dimension, ref. dwg) (nr.)
xv Handhole or drawpit (type,
dimension, ref. dwg) (nr.)
xvi Cast aluminium breakaway transformer
base for column (height) (details,
ref. dwg) (nr.)

♦ 15- 41♦
copy 249
copy 249
Ref. Title Page No. Ref. Title Page No.
16.1 Landscape 16-1 16.1.3.15 Requirements for Satisfactory Grass 16-8
16.1.3.16 Planting Ground Cover and Plants 16-8
16.1.1 General 16-1
16.1.3.17 Mulching 16-8
16.1.1.1 Summary 16-1
16.1.3.18 Installation of Edgings 16-8
16.1.1.2 Related Documents 16-1
16.1.3.19 Installation of Miscellaneous Materials 16-8
16.1.1.3 Definitions 16-1
16.1.3.20 Cleanup and Protection 16-8
16.1.1.4 Submittals 16-1
16.1.3.21 Disposal of Surplus and Waste
16.1.2 Materials 16-2
Materials 16-8
16.1.2.1 Trees and Shrubs 16-2
16.1.4 Warranty and Maintenance 16-8
16.1.2.2 Ground Cover 16-2
16.1.4.1 Warranty 16-8
16.1.2.3 Palms 16-2
16.1.4.2 Maintenance 16-9
16.1.2.4 Grass Seed 16-2
16.1.5 Method of Measurement 16-9
16.1.2.5 Grass Sod (Turf) 16-2
16.1.5.1 Excavation, Soiling, Cultivating
16.1.2.6 Grass Plugs 16-2
and Grading 16-9
16.1.2.7 Grass Sprigs 16-2
16.1.5.2 Grass Planting and Seeding 16-10
16.1.2.8 Topsoil 16-2
16.1.5.3 Tree, Shrub and Ground Cover
16.1.2.9 Soil Amendments 16-3
Planting 16-10
16.1.2.10 Fertilizer 16-3
16.1.6 Basis of Payment 16-10
16.1.2.11 Mulches 16-3
16.1.7 Items in Bill of Quantities 16-10
16.1.2.12 Stakes and Guys 16-3
16.1.2.13 Landscape Edgings 16-4 16.2 Irrigation System 16-10
16.1.2.14 Erosion-Control Materials 16-4
16.2.1 Description / General 16-10
16.1.2.15 Miscellaneous Materials 16-4
16.2.1.1 Scope 16-10
16.1.3 Construction Requirements 16-4
16.2.1.2 Schedules of Proposed Equipment 16-11
16.1.3.1 General 16-4
16.2.1.3 Approval of Equipment 16-11
16.1.3.2 Preparation 16-4
16.2.1.4 Submittals 16-11
16.1.3.3 Planting Soil Preparation 16-5
16.2.1.5 Delivery, Storage and Handling 16-12
16.1.3.4 Ground Cover and Plant Bed
16.2.1.6 Installation and Checking 16-12
Preparation 16-5
16.2.1.7 Spares 16-12
16.1.3.5 Preparation for Grassed Areas 16-5
16.2.1.8 Equipment Labels and Charts 16-12
16.1.3.6 Excavation for Trees and Shrubs 16-5
16.2.1.9 Operation and Instruction Manuals 16-12
16.1.3.7 Planting, Palms, Trees and Shrubs 16-6
16.2.2 Material 16-13
16.1.3.8 Tree and Shrub Pruning 16-7
16.2.2.1 Pipes, Fittings and Accessories 16-13
16.1.3.9 Tree and Shrub Guying and Staking 16-7
16.2.2.2 Valves and Penstocks 16-15
16.1.3.10 Grass Seeding 16-7
16.2.2.3 Irrigation Equipment 16-17
16.1.3.11 Hydro-Seeding 16-7
16.2.2.4 Valve Operators and Accessories 16-19
16.1.3.12 Sodding 16-7
16.2.2.5 Jointing Material 16-20
16.1.3.13 Plugging 16-7
16.2.2.6 Concrete and Metal Work 16-21
16.1.3.14 Sprigging 16-8
16.2.2.7 Pumping Plant 16-21

♦ 16-1 ♦
copy 249
Ref. Title Page No.
16.2.3 Construction Requirements 16-21
16.2.3.1 Excavation, Bedding and Backfilling 16-21
16.2.3.2 Pipe Laying - Generally 16-21
16.2.3.3 Jointing 16-22
16.2.3.4 Line and Gradient 16-22
16.2.3.5 Floatation 16-22
16.2.3.6 Pipe Built Into Structures 16-22
16.2.3.7 Field Testing: Generally 16-22
16.2.3.8 Hydrostatic Testing of Pressure
Pipelines 16-23
16.2.3.9 Visual Inspection Test 16-23
16.2.3.10 Deflection Tests for GRP Pipes 16-23
16.2.3.11 Flushing 16-23
16.2.3.12 Field Protection and Coating 16-23
16.2.3.13 Irrigation Control 16-24
16.2.3.14 Contract Requirements 16-24
16.2.3.15 Documentation 16-24
16.2.3.16 Maintenance Program 16-24
16.2.4 Method of Measurement 16-24
16.2.5 Basis of Payment 16-25
16.2.6 Items in the Bill of Quantities 16-25

♦ 16-2 ♦
copy 249
16.1 Landscape 2 Sub grade: Surface of subsoil after completing
excavation, or top surface of a fill or backfill immediately
beneath planting soil.
16.1.1 General
3 Manufactured Soil: Soil produced off-site by
16.1.1.1 Summary homogeneously blending mineral soils or sand with
stabilized organic soil amendments to produce topsoil or
1 This Section describes requirements for soft
planting soil.
landscaping and irrigation, including the following:
4 Planting Soil: Native or imported topsoil,
i. Trees and shrubs.
manufactured topsoil, or surface soil modified to become
ii. Ground cover. topsoil; mixed with soil amendments.
iii. Palms.
16.1.1.4 Submittals
iv. Seed.
v. Turf-grass sod. 1 General: Submit the certificates, samples and other
information stated in this paragraph to the Engineer
vi. Plugs.
before ordering materials or starting the relevant work.
vii. Sprigs.
2 Certification of product compliance to specified
viii. Topsoil. requirements signed by manufacturer.
ix. Soil amendments. i. Manufacturer's certified analysis for standard
x. Fertilizers. products.
xi. Mulches. ii. Analysis for other materials by a recognized
xii. Stakes and guys. laboratory made according to approved
international standards.
xiii. Landscape edgings.
iii. Label data substantiating that plants, trees,
xiv. Erosion-control materials.
shrubs, and planting materials comply with
xv. Miscellaneous materials. specified requirements.
xvi. Irrigation iv. Certification of grass seed from seed vendor
2 Requirements for hard landscaping, paving and for each grass-seed or mixture stating the
curbs of sidewalks and areas adjacent to soft landscaping botanical and common name and percentage
are described in Section 12. by weight of each species and variety and
3 Landscape work shall be carried out by an percentage of purity, germination and weed
experienced landscape contractor whose qualifications seed. Include the year of production and date
and resources are approved by the Engineer, including his of packaging.
operatives and supervisors and equipment. v. Certification of each seed mixture for turf grass
4 Where tests and analysis on soil and products are sod, plugs and sprigs, identifying source,
required by this Specification, they shall be carried out by including name and telephone number of
an agency approved by the Engineer. supplier.
vi. Certification of all soil amendments and
16.1.1.2 Related Documents fertilizers signed by product manufacturer.
1 Drawings and other Specification Sections, apply to 3 Samples of each of the following:
this Section. i. 2 kg of mineral mulch for each color and
2 Related Sections: The following Sections contain texture of stone t, in labeled plastic bags.
requirements that relate to this Section: ii. Edging materials and accessories to verify
i. Section 1 for protection of existing trees and color selected.
planting, topsoil stripping and stockpiling, and 4 Qualification data for firms and persons employed in
site clearing. the work to demonstrate their capabilities and experience.
ii. Section 2 for excavation, filling, rough grading Include lists of completed projects with project names and
and subsurface aggregate drainage and addresses, names and address of architects/engineers and
drainage backfill. owners, and other information specified.
iii. Section 8 for subsurface drainage. 5 Material test reports from qualified independent
iv. Section 12 sidewalks, paving areas and curbs”. testing agency indicating and interpreting test results
relative to compliance of the following materials with
16.1.1.3 Definitions requirements indicated:

1 Finish Grade: Elevation of finished surface of planting i. Analysis of existing surface soil.
soil. ii. Analysis of imported topsoil.

♦ 16-1 ♦
copy 249
6 Planting schedule indicating planned dates and
locations for each type of planting.
7 Maintenance instructions recommending procedures
to be established by the Employer for maintenance of
landscaping during an entire year. Submit before
expiration of required maintenance periods.
16.1.2 Materials
16.1.2.1 Trees and Shrubs
1 Provide nursery-grown trees and shrubs conforming
to ANSI Z60.1, with healthy root systems developed by
transplanting or root pruning. Provide well-shaped, fully-
branched, healthy, vigorous stock free of disease, insects,
eggs, larvae, and defects such as knots, sun scald, injuries,
abrasions, and disfigurement.
2 Provide trees and shrubs of sizes and grades l
conforming to ANSI Z60.1 for type of trees and shrubs
specified and shown on the Drawings.
3 Label each tree and shrub with securely attached
waterproof tag bearing legible designation of botanical
and common name.
4 Provide balled and burlapped trees and shrubs.
Container-grown trees will be acceptable in lieu of balled
and burlapped subject to meeting ANSI Z60.1 limitations
for container stock.
5 Shade trees shall be single-stem trees with straight
trunk, well-balanced crown, and conforming to ANSI Z60.1
for type of trees required.
i. Branching Height: 1/3 to 1/2 of tree height.
6 Small trees shall be small upright or spreading type,
branched or pruned naturally according to species and
type and with relationship to caliper, height, and
branching recommended by ANSI Z60.1 and stem form as
follows:
i. Form: Multi-stem, clump, with 2 or more main
stems.
7 Deciduous shrubs shall have no less than the
minimum number of canes required by and measured
according to ANSI Z60.1 for type, shape, and height of
shrub.
8 Broad-leafed evergreens shall be: normal-quality,
well-balanced, broadleaf evergreens of type, height,
spread, and shape conforming to ANSI Z60.1.
16.1.2.2 Ground Cover
1 Ground cover plants shall be established and well
rooted in removable containers or integral peat pots and
with not less than the minimum number and length of
runners required by ANSI Z60.1 for the pot size indicated.
16.1.2.3 Palms
1 Palms shall have a crown of new leaves, proper color
of leaves of adult palms and sufficient hardiness. Palms
shall be supplied earth balled and hessian covered. Height
♦ 16-2 ♦
of palms is measured from nursery ground line to base of
first frond.
2 Heights of palms are to be as indicated in the Plant of
Material Schedules shown on Drawings and shall have
corresponding root-ball diameters as follows:
Palm Height Root-ball Diameter
1.5 m 0.75 - 0.90 m
2.0 m 0.90 - 1.10 m
2.5 m 1.10 - 1.30 m
3.0 m 1.30 - 1.50 m
3.5 m 1.50 - 1.80 m
4.0 m 1.80 - 2.00 m
16.1.2.4 Grass Seed
1 Grass seed shall be fresh, clean, dry, new-crop seed
complying with AOSA's "Journal of Seed Technology;
Rules for Testing Seeds" for purity and germination
tolerances.
2 Seed species shall be as stated in the Special
Specification or shown on the Drawings for the particular
use and location, with not less than 95 percent
germination, not less than 85 percent pure seed, and not
more than 0.5 percent weed seed.
16.1.2.5 Grass Sod (Turf)
1 Grass sod (turf) shall be first quality, complying with
TPI's ‘Specifications for Sod (Turf) Materials’ in its
‘Guideline Specifications to Sodding’, including limitations
on thatch, weeds, diseases, nematodes, and insects,
Provide viable sod of uniform density, color, and texture,
strongly rooted, capable of vigorous growth and
development when planted. Sods shall be nominal size
750mm x 300mm.
2 Grass sod species shall be as stated in the Special
Specification or shown on the Drawings with not less than
95 percent germination, not less than 85 percent pure seed,
and not more than 0.5 percent weed seed:
16.1.2.6 Grass Plugs
1 Grass plugs shall be as specified in paragraph
16.1.2.5 but with a nominal size 100mm x 100mm.
16.1.2.7 Grass Sprigs
1 Grass sprigs shall be healthy living stems, rhizomes,
or solons with a minimum of two nodes and any attached
roots free of soil, of the species stated in the Special
Specification or shown on the Drawings.
16.1.2.8 Topsoil
1 Topsoil shall conform to ASTM D 5268, pH range of
5.5 to 7, 4 percent organic material minimum, free of
stones 25 mm or larger in any dimension, and other
extraneous materials harmful to plant growth, obtained
from any of the sources stated below.
copy 249
 i. Topsoil Source: Reuse surface soil stockpiled
on site. Verify suitability of surface soil to
produce topsoil meeting requirements and
amend when necessary. Supplement with
imported topsoil when quantities
insufficient. Clean topsoil of roots, plants, sods,
stones, clay lumps, and other extraneous
materials harmful to plant growth.
ii. Topsoil Source: Imported topsoil from off-site
sources, obtained from naturally well--drained
sites where topsoil occurs at least 100mm
deep; do not obtain from bogs or marshes.
iii. Topsoil Source: Amend existing surface soil to
produce topsoil. Supplement with imported
topsoil when required. Topsoil shall have a
physical and chemical analysis before any
amendments are added.
16.1.2.9 Soil Amendments
1 Lime shall be dolomite limestone conforming to
ASTM C 602, Class T, agricultural limestone, containing a
minimum 80 percent calcium carbonate equivalent, with a
minimum 99 percent passing a 2.36 mm sieve and a
minimum 75 percent passing a 250 micrometer sieve.
2 Aluminum sulfate shall be commercial grade,
unadulterated.
3 Sand shall be cleaned, washed, natural
manufactured sand, free of toxic materials.
4 Perlite shall be horticultural perlite, soil amendment
grade.
5 Peat Humus shall be finely divided or granular
texture, with a pH range of 6 to 7.5, composed of partially
decomposed moss peat or reed-sedge peat.
6 Peat Humus for acid-tolerant trees and shrubs, shall
be moss peat, with a pH range of 3.2 to 4.5, coarse fibrous
texture, medium-divided sphagnum moss peat or reed-
sedge peat.
7 Sawdust or ground bark humus shall be decomposed,
nitrogen-treated, of uniform texture, free of chips, stones,
sticks, soil, or toxic materials.
i. When site treated, mix with at least 2.4 kg of
ammonium nitrate or 4 kg of ammonium
sulfate per cu. m of loose sawdust or ground
bark.
8 Manure shall be well-rotted, unleached stable or
cattle manure containing not more than 25 percent by
volume of straw, sawdust, or other bedding materials; free
of toxic substances, stones, sticks, soil, weed seed, and
material harmful to plant growth.
9 Herbicides shall be EPA registered and approved, of
type recommended by the manufacturer.
16.1.2.10 Fertilizer
1 Bone-meal shall be commercial, raw, finely ground;
minimum of 4 percent nitrogen and 20 percent phosphoric
acid.
2 Superphosphate shall be commercial, phosphate
mixture, soluble; minimum of 20 percent available
phosphoric acid.
3 Commercial fertilizer shall be commercial-grade
are complete fertilizer of neutral character, consisting of fast-
and slow-release nitrogen, 50 percent derived from natural
organic sources of urea-form, phosphorous, and
potassium in the proportions recommended in reports
from a qualified soil testing agency.
4 Slow-release fertilizer shall be granular fertilizer
consisting of 50 percent water-insoluble nitrogen,
phosphorus, and potassium in the proportions
recommended in reports from a qualified soil testing
agency.
16.1.2.11 Mulches
1 Mineral mulch shall be hard, durable stone, washed
free of loam, sand, clay, and other foreign substances, of
following type, size range, and color:
i. Type: Crushed stone or gravel.
ii. Size Range: 20 mm maximum, 6 mm
minimum.
iii. Color: Uniform tan-beige color range,
acceptable to the Engineer.
2 Straw mulch shall be air-dry, clean, mildew- and
seed-free, salt hay or threshed straw of wheat, rye, oats, or
or
barley.
3 Peat mulch shall be peat humus as specified in
paragraph 16.1.2.9, items 5 or 6 as appropriate.
4 Compost mulch shall be well-composted, stable, and
weed-free organic matter, pH range of 5.5 to 8; moisture
content 35 to 55 percent by weight; 100 percent passing
through 1-inch (25-mm) sieve; soluble salt content of 5 to
10 decisiemens/m; not exceeding 0.5 percent inert
contaminants and free of substances toxic to plantings;
and as follows:
i. Organic Matter Content: 50 to 60 percent of
dry weight.
ii. Feedstock: Agricultural, food, or industrial
residuals; biosolids; yard trimmings; or source-
separated or compostable mixed solid waste.
5 Fiber mulch shall be biodegradable, dyed-wood,
cellulose-fiber mulch; nontoxic; free of plant-growth or
germination inhibitors; with maximum moisture content
of 15 percent and a pH range of 4.5 to 6.5.
6 Non asphaltic tackifier shall be colloidal tackifier
recommended by fiber-mulch manufacturer for slurry
application; nontoxic and free of plant-growth or
germination inhibitors.
7 Asphalt emulsion shall conform to ASTM D 977,
Grade SS-1; nontoxic and free of plant-growth or
germination inhibitors.
16.1.2.12 Stakes and Guys
1 Upright and Guy Stakes: Rough-sawn, sound, new
hardwood, redwood, or pressure-preservative-treated
♦ 16-3 ♦
copy 249
softwood, free of knots, holes, cross grain, and other
defects, 50 by 50 mm by length indicated, pointed at one
end.
2 Guy and Tie Wire: ASTM A 641M, Class 1,
galvanized-steel wire, 2 strands, twisted, 2.7 mm in
diameter.
3 Guys for Palms: 5 mm diameter, 7-strand galvanized
wire in suitable lengths, with chafing guards of 13 mm
diameter PVC pipe, wire adjustments or turn buckles as
approved and 15 mm malleable iron ground anchors.
4 Guy Cable: 5 strand, 4.8 mm diameter, galvanized-
steel cable, with zinc-coated turn buckles, 75 mm long
minimum, with 2 10 mm galvanized eyebolts.
5 Hose Chafing Guard: Reinforced rubber or plastic
hose at least 13 mm in diameter, black, cut to lengths
required to protect tree trunks from damage.
6 Flags: Standard surveyor's plastic flagging tape,
white, 150 mm long.
7 Burlap: Jute of 0.20 kg/m2 or cloth having same
strength and resistance to tearing and capable of rotting in
the ground.
16.1.2.13 Landscape Edgings
1 Polyethylene edging shall be proprietary standard--
black polyethylene edging, 3 mm thick by 125 mm deep,
unless otherwise indicated, extruded in standard lengths,
with 225 mm steel angle stakes.
i. Top Profile: Straight, with top 50 mm, 6 mm
thick.
ii. Top Profile: Rounded.
16.1.2.14 Erosion-Control Materials
1 Erosion-Control Blankets: Biodegradable wood
excelsior, straw, or coconut-fiber mat enclosed in a
photodegradable plastic mesh. Include manufacturer's
recommended steel wire staples, 150 mm long.
2 Erosion-Control Fiber Mesh: Biodegradable twisted
jute or spun-coir mesh, a minimum of 0.5 kg/sq.m. with 50
to 65 percent open area. Include manufacturer's
recommended steel wire staples, 150 mm long.
16.1.2.15 Miscellaneous Materials
1 Anti-desiccant: Water-insoluble emulsion, permeable
moisture retarder, film forming, for trees and shrubs.
Deliver in original, sealed, and fully labeled containers and
mix according to the manufacturer's instructions.
2 Trunk-Wrap Tape: Two layers of crinkled paper
cemented together with bituminous material, 100 mm
wide minimum, with stretch factor of 33 percent
16.1.3 Construction Requirements
16.1.3.1 General
1 Examine areas to receive landscaping for compliance
with requirements and for conditions affecting
♦ 16-4 ♦
performance of work. Do not proceed with installation
until unsatisfactory conditions have been corrected.
2 Topsoil Analysis: Furnish a soil analysis made by a
qualified independent soil-testing agency stating
percentages of organic matter, inorganic matter (silt, clay,
and sand), deleterious material, pH, and mineral and
plant-nutrient content of topsoil. Report suitability of
topsoil for growth of applicable planting material. State
recommended quantities of nitrogen, phosphorus, and
potash nutrients and limestone, aluminum sulfate, or
other soil amendments to be added to produce
satisfactory topsoil.
3 Deliver packaged materials in containers showing
weight, analysis, and name of manufacturer. Protect
materials from deterioration during delivery and while
stored at site.
4 Deliver trees, shrubs, ground covers, and plants after
preparation for planting has been completed and plant
immediately. If planting is delayed more than 6 hours
after delivery, set planting materials in shade, and protect
from weather and mechanical damage, and keep roots
moist.
i. Heel-in bare-root stock. Soak roots in water for
2 hours if dried out.
ii. Set balled stock on ground and cover ball with
soil, peat moss, sawdust, or other acceptable
material.
iii. Do not remove container-grown stock from
containers until time of planting.
iv. Water root systems of trees and shrubs stored
on site with a fine-mist spray. Water as often
as necessary to maintain root systems in a
moist condition.
5 Coordinate installation of planting materials during
normal planting seasons for each type of plant material
required.
6 Coordinate planting periods with maintenance
periods to provide required maintenance from date of
handing over.
7 Proceed with planting only when existing and
forecast weather conditions permit.
16.1.3.2 Preparation
1 Lay out individual tree and shrub locations and areas
for multiple planting. Stake locations, outline areas, and
secure the Engineer's acceptance before the start of
planting work. Make minor adjustments as may be
required.
2 Protect structures, utilities, sidewalks, pavements,
and other facilities, trees, shrubs, and plantings from
damage caused by planting operations.
3 Provide erosion-control measures to prevent erosion
or displacement of soils and discharge of soil-bearing
water runoff or airborne dust to adjacent properties and
walkways.
copy 249
16.1.3.3 Planting Soil Preparation
1 Before mixing, clean topsoil of roots, plants, sods,
stones, clay lumps, and other extraneous materials
harmful to plant growth.
2 Mix soil amendments and fertilizers with topsoil at
rates indicated following soil physical and chemical
analysis. Delay mixing fertilizer if planting does not follow
placing of planting soil within a few days.
3 For palms and tree pit or trench backfill, mix planting
soil before backfilling, and stockpile at site ready for use.
4 For planting beds, mix planting soil either prior to
placing or apply on surface of topsoil and mix thoroughly
before planting.
i. Mix lime with dry soil prior to mixing fertilizer.
Prevent lime from contacting roots of acid-
tolerant plants.
ii. Apply phosphoric acid fertilizer, other than that
constituting a portion of complete fertilizers,
directly to sub-grade before applying planting
soil and tilling.
16.1.3.4 Ground Cover and Plant Bed Preparation
1 Loosen sub-grade of planting bed areas to a
minimum depth of 150 mm. Remove stones larger than 40
mm in any dimension and sticks, roots, rubbish, and other
extraneous materials.
2 Spread planting soil mixture to depth required to
meet thickness, grades, and elevations shown, after light
rolling and natural settlement. Place approximately one
half the thickness of planting soil mixture required. Work
into top of loosened sub-grade to create a transition layer
and then place remainder of planting soil mixture.
3 Till soil in beds to a minimum depth of 200 mm and
mix with specified soil amendments and fertilizers.
4 Remove existing unsuitable soil to a minimum depth
of 200 mm and replace with prepared planting soil mixture.
16.1.3.5 Preparation for Grassed Areas
1 Limit sub-grade preparation to areas to be planted.
2 Newly prepared sub grade: Loosen newly prepared
sub grade to a minimum depth of 150 mm. Remove
stones larger than 25 mm in any dimension and sticks,
roots, rubbish, and other extraneous matter and dispose
off site.
i. Apply superphosphate fertilizer directly to sub-
grade before loosening.
ii. Thoroughly blend planting soil mix off-site
before spreading, or spread topsoil, apply soil
amendments and fertilizer directly to the
surface, and thoroughly blend planting soil
mix.
a. Delay mixing fertilizer with planting soil if
planting will not proceed within a few days.
b. Mix lime with dry soil before mixing
fertilizer.
iii. Spread planting soil mix to a depth of 150 mm
but not less than required to meet finish grades
after light rolling and natural settlement. Do
not spread if planting soil or sub-grade is
muddy or excessively wet.
a. Spread approximately one-half the
thickness of planting soil mix over
loosened sub-grade. Mix thoroughly into
top 100 mm of sub grade and then spread
remainder of planting soil mix.
b. Reduce elevation of planting soil to allow
for soil thickness of sod.
3 If grass is to be sown or planted in areas unaltered or
undisturbed by excavating, grading, or surface soil
stripping operations, prepare surface soil as follows:
i. Remove existing grass, vegetation, and turf.
Do not mix into surface soil. Remove stones
larger than 25 mm in any dimension and sticks,
roots, trash, and other extraneous matter.
ii. Loosen surface soil to a depth of at least of 150
mm. Apply soil amendments and fertilizers
according to planting soil mix proportions and
mix thoroughly into top 150 mm. of soil. Till
soil to a homogeneous mixture of fine texture.
iii. Dispose of waste material, including grass,
vegetation, and turf, off site.
4 Grade planting areas to a smooth, uniform surface
plane with loose, uniformly fine texture. Grade to within
plus or minus 13 mm of finish elevation. Roll and rake,
remove ridges, and fill depressions to meet finish grades.
Limit fine grading to areas that can be planted in the
immediate future.
5 Moisten prepared lawn area before planting if soil is
dry. Water thoroughly and allow surface to dry before
planting. Do not create muddy soil.
6 Restore areas if eroded or otherwise disturbed after
finish grading and before planting.
16.1.3.6 Excavation for Trees and Shrubs
1 Pits and Trenches: Excavate with vertical sides and
with bottom of excavation slightly raised at center to
assist drainage. Loosen hard subsoil in bottom of
excavation.
i. Bare-root trees and shrubs: Excavate at least
300 mm wider than root spread and deep
enough to allow setting of roots on a layer of
planting soil and with collar set at same grade
as in nursery, but 25 mm below finish grade.
a. Shrubs setting layer: Allow 75 mm of
planting soil.
b. Trees setting layer: Allow 225 mm of
planting soil.
ii. Balled and burlapped trees and shrubs:
Excavate approximately 1½ times as wide as
ball diameter and equal to ball depth, plus the
following setting layer depth:
♦ 16-5 ♦
copy 249
 a. Shrubs setting layer: Allow 75 mm of
planting soil.
b. Trees setting layer: Allow 225 mm of
planting soil.
iii. Container-grown trees and shrubs: Excavate to
container width and depth, plus the following
setting-layer depth:
a. Shrubs setting layer: Allow 75 mm of
planting soil.
b. Trees setting layer: Allow 150 mm of
planting soil.
iv. Pits for palms excavate to a depth not less than
1.6m below finished grade and to a diameter of
not less than 1.5 m and at least 1 m greater
than diameter of root ball. Break up bottom of
pits to a depth of 300 mm.
2 Dispose of subsoil removed from excavations. Do not
mix with planting soil or use as backfill.
3 Notify the Engineer if unexpected rock or
obstructions detrimental to trees or shrubs are
encountered in excavations.
i. Hardpan layer: Drill 150 mm diameter holes
into free-draining strata or to a depth of 3 m,
whichever is less, and backfill with free-
draining material.
4 Notify the Engineer if subsoil conditions show
unexpected water seepage or retention in tree or shrub
pits.
5 Fill excavations with water and allow to percolate out,
before placing setting layer and positioning trees and
shrubs.
16.1.3.7 Planting, Palms, Trees and Shrubs
1 Measure trees and shrubs according to ANSI Z60.1
with branches and trunks or canes in their normal position.
Do not prune to obtain required sizes. Take caliper
measurements 150 mm above ground for trees up to 100
mm caliper size, and 300 mm above ground for larger
sizes. Measure main body of tree or shrub for height and
spread;
2 Deliver freshly dug and container grown palms, trees
and shrubs to the site just before planting. Do not prune
before delivery, except as approved by the Engineer.
Protect bark, branches, and root systems from sun scald,
drying, sweating, whipping, and other handling and tying
damage. Do not bend or bind-tie trees or shrubs in such a
manner as to destroy natural shape. Maintain protective
covering during delivery. Do not drop trees and shrubs
during delivery.
i. Immediately after digging bare-root stock, pack
root system in wet straw, hay, or other suitable
material to keep root system moist until
planting.
ii. Handle balled and bur lapped stock by the root
ball
♦ 16-6 ♦
3 Set balled and bur lapped stock plumb and in center
of pit or trench with top of ball raised above adjacent
finish grades as indicated.
i. Place stock on setting layer of compacted
planting soil.
ii. Remove burlap and wire baskets from tops of
balls and partially from sides, but do not
remove from under balls. Remove pallets, if
any, before setting. Do not use planting stock
if ball is cracked or broken before or during
planting operation.
iii. Place backfill around ball in layers, tamping to
settle backfill and eliminate voids and air
pockets. When the pit is approximately half
backfilled, water thoroughly before placing the
remainder of backfill. Repeat watering until no
more is absorbed. Water again after placing
and tamping the final layer of backfill.
4 Set container-grown stock plumb and in center of pit
or trench with top of ball raised above adjacent finish
grades as indicated.
i. Carefully remove containers so as not to
damage root balls.
ii. Place stock on setting layer of compacted
planting soil.
iii. Place backfill around ball in layers, tamping to
settle backfill and eliminate voids and air
pockets. When the pit is approximately half
backfilled, water thoroughly before placing
remainder of backfill. Repeat watering until no
more is absorbed. Water again after placing
and tamping the final layer of backfill.
5 Set bare-root stock on cushion of planting soil.
Spread roots without tangling or turning toward surface,
and carefully work backfill around roots by hand. Puddle
with water until backfill layers are completely saturated.
Plumb before backfilling, and maintain plumb while
working backfill around roots and placing layers above
roots. Remove injured roots by cutting cleanly; do not
break.
i. Set collar 25 mm below adjacent finish grades,
unless otherwise indicated.
6 Dish and tamp top of backfill to form a 75 mm high
mound around the rim of the pit. Do not cover top of root
with backfill.
7 Wrap trees of 50 mm caliper and larger with trunk-
wrap tape. Start at base of trunk and spiral cover trunk to
height of first branches. Overlap wrap, exposing half the
width, and securely attach without causing girdling.
Inspect tree trunks for injury, improper pruning, and insect
infestation and take corrective measures required before
wrapping.
8 Remove suckers, flowering and fruiting parts and
approximately 30% of fronds from palms before planting.
Leave sufficient fronds to enclose and protect growing
bud, trim to 65% of original length, lift to surround
copy 249
growing bud and burlap wrap and securely tie them in
position and leave on palm for around one year after
planting. Special attention is required to protect palm
roots from being bruised during digging and bur lapping.
16.1.3.8 Tree and Shrub Pruning
1 Prune, thin, and shape trees and shrubs according to
standard horticultural practice. Prune trees to retain
required height and spread. Unless otherwise directed by
the Engineer, do not cut tree leader; remove only injured
or dead branches from flowering trees Prune shrubs to
retain natural character. Shrub sizes indicated are size
after pruning.
16.1.3.9 Tree and Shrub Guying and Staking
1 Stake all trees of 50 to 125 mm caliper; stake trees
less than 50 mm caliper only if required to prevent
displacement by wind. Use a minimum of 2 stakes of
length required to penetrate at least 450 mm below
bottom of backfilled excavation and to extend at least 1800
mm above grade. Set stakes vertical and spaced to avoid
penetrating balls or root masses. Support trees with 2
strands of tie wire encased in hose sections at contact
points with tree trunk. Allow enough slack to avoid rigid
restraint of tree.
2 Guy and stake trees exceeding 4.2 m high and more
than 75 mm caliper. Securely attach no fewer than 3 guys
to stakes 750 mm long, driven to grade. Attach flags to
each guy wire, 750 mm above finish grade.
3 Support palms with 4 guy wires secured to ground
anchors and attached to palm at approximately two thirds
height. Adjust tension as necessary with wire adjusters or
turn buckles.
16.1.3.10 Grass Seeding
1 Sow seed with spreader or seeding machine. Do not
broadcast or drop seed when wind velocity exceeds 8
km/h. Evenly distribute seed by sowing equal quantities in
two directions at right angles to each other.
i. Do not use wet seed or seed that is moldy or
otherwise damaged.
2 Sow seed at the rate of 2.3 to 3.6 kg/92.9 sq.m.
3 Rake seed lightly into top 3 mm of topsoil, roll lightly,
and water with fine spray.
4 Protect seeded areas with slopes exceeding 1:6 with
erosion-control fiber mesh and slopes exceeding 1:4 with
erosion-control blankets installed and stapled according to
manufacturer's written instructions.
5 Protect seeded areas with slopes not exceeding 1:6
by spreading straw mulch. Spread uniformly at a
minimum rate of 42 kg/92.9 sq.m. to form a continuous
blanket 38 mm in loose depth over seeded areas. Spread
by hand, blower, or other suitable equipment.
i. Anchor straw mulch by crimping into topsoil
with suitable mechanical equipment.
ii. Bond straw mulch by spraying with asphalt
emulsion at the rate of 38 to 49 L/92.9 sq.m.
Take precautions to prevent damage or
staining of structures or other plantings
adjacent to mulched areas. Immediately clean
damaged or stained areas.
6 Protect seeded areas from hot, dry weather or drying
winds by applying compost mulch, peat mulch or planting
soil within 24 hours after completing seeding operations.
Soak and scatter uniformly to a depth of 4.8 mm and roll
to a smooth surface.
16.1.3.11 Hydro-Seeding
1 Mix specified seed, fertilizer, and fiber mulch in
water, using equipment specifically designed for hydro
seed application. Continue mixing until uniformly blended
into homogeneous slurry suitable for hydraulic application.
i. Mix slurry with no asphaltic tackifier.
ii. Apply slurry uniformly to all areas to be seeded
in a one-step process. Apply mulch at a
minimum rate of 15.3-kg/92.9 sq. m dry weight
but not less than the rate required to obtain
specified seed-sowing rate.
iii. Apply slurry uniformly to all areas to be seeded
in a two-step process. Apply first slurry
application at a minimum rate of 5.1-kg/92.9
sq.m. dry weight but not less than the rate
required to obtain specified seed-sowing rate.
Apply slurry cover coat of fiber mulch at a rate
of 10.2 kg/92.9 sq.m.
16.1.3.12 Sodding
1 Lay sod within 24 hours of harvesting. Do not lay
sod if dormant or if ground is muddy.
2 Lay sod to form a solid mass with tightly fitted joints.
Butt ends and sides of sod; do not stretch or overlap.
Stagger sod strips or pads to offset joints in adjacent
courses. Avoid damage to sub grade or sod during
installation. Tamp and roll lightly to ensure contact with
sub grade, eliminate air pockets, and form a smooth
surface. Work sifted soil or fine sand into minor cracks
between pieces of sod; remove excess to avoid
smothering sod and adjacent grass.
i. Lay sod across angle of slopes exceeding 1:3.
ii. Anchor sod on slopes exceeding 1:6 with wood
pegs or steel staples spaced as recommended
by sod manufacturer but not less than 2
anchors per sod strip to prevent slippage.
3 Saturate sod with fine water spray within two hours
of planting. During first week, water daily or more
frequently as necessary to maintain moist soil to a
minimum depth of 38 mm below sod.
16.1.3.13 Plugging
1 Plant plugs in holes or furrows, spaced 300 mm apart
in both directions. On slopes, contour furrows to neat
levels.
♦ 16-7 ♦
copy 249
16.1.3.14 Sprigging
1 Plant freshly shredded sod sprigs in furrows 63 to 75
mm deep. Place individual sprigs with roots and portions
of stem in moistened soil, 150 mm apart in rows 250 mm
apart, and fill furrows without covering growing tips.
Lightly roll and firm soil around sprigs after planting.
2 Broadcast sprigs uniformly over prepared surface at
a rate of 0.28 cu. m/92.9 sq.m. and mechanically force
sprigs into lightly moistened soil.
i. Spread a 6-mm thick layer of compost mulch,
peat mulch, planting soil or topsoil on sprigs.
ii. Lightly roll and firm soil around sprigs after
planting.
iii. Water sprigs immediately after planting and
keep moist by frequent watering until well
rooted.
16.1.3.15 Requirements for Satisfactory Grass
1 Seeded areas: At end of maintenance period, a
healthy, uniform, close stand of grass has to be
established, free of weeds and surface irregularities, with
coverage exceeding 90 percent over any 0.92 sq.m and
bare spots not exceeding 125 by 125 mm.
2 Sodded areas: At end of maintenance period, a
healthy, well-rooted, even-colored, viable lawn has been
established, free of weeds, open joints, bare areas, and
surface irregularities.
3 Plugged areas: At end of maintenance period, the
required number of plugs has been established as well-
rooted, viable patches of grass; and areas between plugs
are free of weeds and other undesirable vegetation.
4 Sprigged areas: At end of maintenance period, the
required number of sprigs has been established as well-
rooted, viable plants; and areas between sprigs are free of
weeds and other undesirable vegetation.
5 Reestablish grassed areas that do not comply with
requirements and continue maintenance until lawns are
satisfactory.
16.1.3.16 Planting Ground Cover and Plants
1 Space ground cover and plants as indicated.
2 Dig holes large enough to allow spreading of roots,
and backfill with planting soil. Work soil around roots to
eliminate air pockets and leave a slight saucer indentation
around plants to hold water. Water thoroughly after
planting, taking care not to cover plant crowns with wet
soil.
16.1.3.17 Mulching
1 Mulch backfilled surfaces of pits, trenches, planted
areas and other areas with mulch material as indicated on
the Drawings or as directed by the Engineer.
2 Lay the mineral mulch where shown or directed,
average 75mm deep, and finish level with adjacent finish
grades. Do not place mulch against trunks or stems.
♦ 16-8 ♦
16.1.3.18 Installation of Edgings
1 Install plastic edging where indicated, according to
the manufacturer's recommendations. Anchor with steel
stakes spaced approximately 600 mm apart, driven
through upper base grooves of edging.
16.1.3.19 Installation of Miscellaneous Materials
1 Apply antidesiccant using power spray to provide an
adequate film over trunks, branches, stems, twigs, and
foliage. When deciduous trees or shrubs are moved in full-
leaf, spray with anti-desiccant at nursery before moving
and again 2 weeks after planting.
2 Set tree grate segments with adjoining surfaces as
shown on the Drawings. Shim up from supporting
substrate with soil-resistant plastic. Maintain a 75 mm
minimum growth radius around base of tree; break away
units of casting, if necessary, according to the
manufacturer's instructions.
16.1.3.20 Cleanup and Protection
1 During landscaping, keep pavements clean and work
area in an orderly condition.
2 Protect landscaping from damage due to landscape
operations, operations by other contractors and trades,
and trespassers. Maintain protection during installation
and maintenance periods. Treat, repair, or replace
damaged landscape work as directed.
3 Promptly remove soil and debris created by planting
work from paved areas. Clean wheels of vehicles before
leaving site to avoid tracking soil onto roads, walks, or
other paved areas.
4 Erect barricades and warning signs as required to
protect newly planted areas from traffic. Maintain
barricades throughout maintenance period and remove
when instructed. Remove erosion-control measures after
grass or plants are established.
16.1.3.21 Disposal of Surplus and Waste Materials
1 Disposal: remove surplus soil and waste material
including excess subsoil, unsuitable soil, trash, and debris,
and legally dispose of it off site.
16.1.4 Warranty and Maintenance
16.1.4.1 Warranty
1 General Warranty: The special warranty specified in
this Clause shall not deprive the Client Authority of other
rights that it may have under other provisions of the
Contract and shall be in addition to, and run concurrent
with, other warranties given by the Contractor under
requirements of the Contract.
2 Special Warranty: Warrant the following living
planting materials for a period of one year after date of
Completion, against defects including death and
unsatisfactory growth, except for defects resulting from
lack of adequate maintenance, abnormal weather
copy 249
conditions unusual for warranty period, or incidents that Lay out temporary watering system to avoid
are beyond the Contractor's control. walking over muddy or newly planted areas.
i. Trees. ii. Water grass at a minimum rate necessary to
ii. Shrubs. ensure uniform moisture and growth.

iii. Ground cover. 5 Mow grass as soon as top growth is tall enough to
cut. Repeat mowing to maintain grass at a height of 38 to
iv. Palms.
50 mm. Remove no more than 40 percent of grass-leaf
v. Lawns and grasses. growth in initial or subsequent mowing. Do not delay
3 Remove and replace dead planting materials mowing until grass blades bend over and become matted.
immediately unless required to plant in the succeeding Do not mow when grass is wet. Schedule initial and
planting season. subsequent mowing to maintain the following grass
4 A limit of one replacement of each plant material will height:
be required, except for losses or replacements due to 6 Apply fertilizer after initial mowing and when grass
failure to comply with requirements. is dry. Use fertilizer that will provide actual nitrogen of at
least 0.45 kg/92.9 sq.m. to lawn area.
16.1.4.2 Maintenance
7 Maintain ground cover by watering, weeding and
1 Maintain trees, palm and shrubs by pruning, fertilizing to establish healthy viable planting for a period
cultivating, watering, weeding, fertilizing, restoring of 6 months after the date of Completion
planting saucers, tightening and repairing stakes and guy
supports, and resetting to proper grades or vertical 16.1.5 Method of Measurement
position, as required to establish healthy, viable plantings.
Spray as required to keep trees and shrubs free of insects 16.1.5.1 Excavation, Soiling, Cultivating and Grading
and disease. Restore or replace damaged tree wrappings.
1 Excavation and filling to reduce or make up levels
Maintain palms, trees and shrubs for a period of 12
specifically required for landscaping shall be measured in
months following the date of Completion.
cubic meters as the volume shown on the Drawings or
2 Begin maintenance of grassed areas immediately directed on site. Other excavation related to construction
after each area is planted and continue until acceptable is measured under Section 2.
lawn is established, but for not less than the following
2 Excavation for tree and shrub planting and for
periods:
ground cover plants is not measured separately but is
i. Seeded areas: 90 days from date of deemed to be part of the planting items
Completion.
3 Planting soil for grassed and planted areas, whether
When full maintenance period has not elapsed manufactured or imported, shall be measured together in
before end of planting season, or if lawn is not cubic meters as the volume specified or shown on the
fully established, continue maintenance during Drawings or as directed on site.
next planting season.
4 Planting soil for trees and shrubs and ground cover
ii. Sodded areas: 45 days from date of plants is not measured separately but is deemed to be part
Completion. of the planting item.
iii. Plugged areas: 45 days from date of 5 Rates for excavation, filling and soiling shall be
Completion. deemed to include, but not be limited to:
iv. Sprigged areas: 45 days from date of i. marking boundaries of planting areas,
Completion.
ii. excavating by machine or hand, supporting
3 Maintain and establish grass by watering, fertilizing, sides, trimming to slopes and finished levels
weeding, mowing, trimming, replanting, and other and keeping excavated areas free from water,
operations. Roll, re-grade, and replant bare or eroded and disposal of surplus material,
areas and remulch to produce a uniformly smooth lawn.
iii. applying fertilizers and herbicides to surfaces
i. In areas where mulch has been disturbed by to receive filling,
wind or maintenance operations, add new
iv. supplying planting soil from any source, laying
mulch. Anchor as required to prevent
and cultivating and final grading of in situ
displacement.
topsoil and topsoil filling,
4 Watering: Provide and maintain temporary piping,
v. additional cultivation and application of
hoses, and watering equipment to convey water from
herbicides during the fallow period,
sources and to keep grass uniformly moist to a depth of
100 mm. vi. prevention of erosion.

i. Schedule watering to prevent wilting, pudding,

erosion, and displacement of seed or mulch.

♦ 16-9 ♦
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16.1.5.2 Grass Seeding and Planting 16.1.7 Items in Bill of Quantities
1 Each kind of grass shall be measured separately in Excavation, Soiling, Seeding and Cultivating:
square meters as the area shown on the Drawings or i. Excavating to reduce levels (cu.m.)
instructed on site.
ii. Excavating topsoil for preservation (cu.m.)
2 Rates for grass seeding or planting are deemed to
iii. Filling to make up levels (cu.m.)
include, but not limited to, the costs of:
iv. Topsoil filling to make up levels
i. final cultivation and weeding of soil, watering
and for planting (cu.m.)
and application of pre-seeding or planting
fertilizer, Grass Seeding and Planting:
ii. applying fertilizer after planting or seeding, v. Grass seeding (sq.m.)
iii. watering during establishment of grass, vi. Grass sods (turf) (sq.m.)
iv. first and subsequent cuts, including fertilizing vii. Grass plugs (sq.m.)
and watering, viii. Grass sprigs (sq.m.)
v. temporary protection,
Trees, Palms and Shrubs
vi. maintenance and making good defects.
ix. Trees (Type; Size) (nr.)
16.1.5.3 Tree, Palm, Shrub and Ground Cover Planting x. Palms (Type; Size) (nr.)
1 Each type of tree, shrub, palm and plant is measured xi. Shrubs (Type; Size) (nr.)
separately by number, stating the species, height or size Ground Cover and Other Planting:
where appropriate. Botanical names are given in
xii. Ground cover plants (Type) (nr.)
descriptions
xiii. Climbers (Type) (nr.)
2 Rates for trees, shrubs, palms and plants are deemed
to include, but not limited to, the costs of:
16.2 Irrigation System
i. Re-cultivating topsoil in planting areas,
ii. Setting out planting beds, 16.2.1 Description / General
iii. Drainage of planted areas,
16.2.1.1 Scope
iv. Excavating pits and holes including disposal
and breaking up bottoms, 1 This Sub-section describes requirements for
v. Cutting and treating roots, pruning and the like, furnishing, installing, testing and putting into service,
including anti-desiccant and tree wound complete irrigation systems to provide water for the trees,
dressings, shrubs and grassed and planted areas around and
vi. Planting, including backfilling hole with adjacent to the highway system, all as and where shown
on the Drawings.
planting soil and firming,
vii. Watering and fertilizing after planting, 2 The work includes all civil, mechanical and electrical
Works, pipelines, pumping stations, water tanks, filters,
viii. Supports to trees and palms including stakes,
fertilizer injection equipment, control valves, pressure
guys, ties and chafing guards,
regulators and gauges, water meters, automatic or manual
ix. Trunk wrapping, controllers, and all incidentals and spare parts specified
x. Labeling, and as appropriate for the particular irrigation system
specified.
xi. Forking and/or raking soil at completion
3 The irrigation system shall be as specified in the
xii. Applying mulches,
Special Specification for the particular Project and shall be
xiii. Temporary protection, of a type which will supply the quantities of water required,
xiv. Maintenance and making good defects. on a "programmable" basis. The irrigation system shall, in
general, be either drip irrigation utilizing drip emitters
16.1.6 Basis of Payment and/or sprinkler irrigation using either bubblers or
sprayheads.
1 The landscape work, completed, and accepted by the
4 When access to the domestic water supply is
Engineer will be paid for at the unit rates for the relevant
intended, the Contractor shall liaise with the appropriate
items stated in the Bill of Quantities, which unit rates shall
authorities regarding the planning, design, construction of
be deemed to be full compensation for supply of all
the works and the subsequent operation of the irrigation
materials, labor, transport, tools and equipment and
network. Back flow preventers (of the double check valve
provision of all other items and services and maintenance
type) shall be installed at points of connection to the
for the complete work as specified.
domestic water supply network.

♦ 16-10 ♦
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5 The control head for each irrigation branch system 4 The Engineer may verify the performance and quality
shall include all components as shown on the Drawings, of any samples by arranging for such tests as he deems
as required for the complete operation of the system. The appropriate to be carried out, at the Contractor's expense.
final size of all components of each control head for each Approval of samples by the Engineer shall not relieve the
irrigation branch system shall be a minimum of 20% Contractor of his obligations with respect to the suitability
greater than the demand load as submitted by the of equipment or its final performance once installed, and
Contractor, with the working drawings, in tabular form coordination of elements into a fully operational irrigation
drawn up as follows for approval: system. The Contractor shall not be entitled to any
compensation for the rejection of any sample by the
Control Irrigation Capacity Peak Approx.
Head Controller at Water Working Engineer and shall be held responsible for any delay
No. Control Demand Pressure resulting from such rejection.
Head (lit/24 hr) at Control
(lit/hr) Head 16.2.1.4 Submittals
(MN/sq.m)
1 Product Data: Include pressure rating, rated capacity,
settings, and electrical data of selected models for the
following:
16.2.1.2 Schedules of Proposed Equipment
i. Pipes and fittings.
1 Schedules containing full details of all principal items
ii. Pumps/motor and related mechanical and
of the irrigation system shall be submitted by the
electrical works
Contractor together with his Tender. The Contractor shall
ensure conformity of the equipment with the requirements iii. Water hammer arresters.
of the Specification. Any additional information required iv. Valves. Include aboveground and
by the Engineer shall be provided promptly by the underground; general-duty, pressure-reducing,
Contractor. manual and automatic control, and quick-
2 A summary of irrigation equipment manufacture coupler types.
including description, manufacturer, country reference v. Valve boxes.
and catalog origin in a tabular format shall be included in vi. Sprinklers and devices.
the Contractor's submission.
vii. Specialties. Include emitters, drip tubes, and
3 The Contractor shall supply equipment from the other devices.
manufacturer's lists with the characteristics indicated in
viii. Controllers. Include wiring diagrams.
his Tender unless otherwise agreed.
2 Shop Drawings: Show irrigation system, including
4 Approval of a manufacturer does not necessarily
plan layout and locations, types, sizes, capacities, and flow
constitute approval of his product as equal to that
characteristics of piping components. Include water
specified. The Contractor shall ascertain that the approved
meters, backflow preventers, valves, piping, sprinklers and
manufacturers are capable of supplying the required
devices, specialties, accessories, controls, and wiring.
materials and/or equipment and shall ensure conformity
Show areas of sprinkler spray and overspray in
with the Specification in all respects.
accordance with the requirements of the Specification.
16.2.1.3 Approval of Equipment 3 Coordination Drawings: Show piping and major
system components. Indicate interface and spatial
1 Equipment shall not be ordered until approved by the
relationship between piping, system components,
Engineer. All documentation submitted regarding
adjacent utilities, and proximate structures.
equipment shall be in English except if otherwise
indicated in the Contract Documents. 4 Test Reports: Submit reports of tests on materials
and installations as directed by the Engineer.
2 Promptly upon signing the Contract, the Contractor
shall submit to the Engineer 3 copies of the detailed 5 Maintenance Data: Include in maintenance manuals
characteristics of all irrigation equipment proposed, data for the following:
including catalogs (originals not copies) with identification i. Valves / surge control devices.
references. Particulars shall be given of any ii. Automatic, pressure-reducing control valves.
manufacturer's deviations from the Specification. The
iii. Sprinklers.
Contractor shall also confirm that the selected irrigation
system equipment is robust, able to withstand rough iv. Specialties.
handling, and capable of supplying the specified v. Controllers.
quantities of water on a programmable basis.
6 As-Built Drawings: At project close-out, submit
3 The Contractor shall, at his own expense, present record drawings of installed pipework and products, in
samples to the Engineer of the various valves, pipes, accordance with the requirements of the Specification,
fittings and other products proposed for use. Such Section 1, Sub-section 1.12. The drawings shall show the
samples will be required only after approval of their location, with respect to the highway and other pipelines
technical characteristics. and other permanent features, of all pumping stations,

♦ 16-11 ♦
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water tanks, irrigators, valves, pipelines, fittings and other
items incorporated in the Works. They shall also show the
sizes of all pipes, their pressure class or rating, and the
actual pressures as measured on the highest and lowest
spray heads commanded by each control valve.
7 Submit certificates of compliance from manufactures.
16.2.1.5 Delivery, Storage and Handling
1 Preparation for Transport: Prepare valves according
to the following:
i. Ensure that valves are dry and internally
protected against rust and corrosion.
ii. Protect valves against damage to threaded
ends and flange faces.
iii. Set valves in best position for handling. Set
valves closed to prevent rattling.
2 During Storage: Use precautions for valves
according to the following:
i. Do not remove end protectors unless
necessary for inspection; then, reinstall for
storage.
ii. Protect from weather. Store indoors and
maintain temperature higher than ambient
dew-point temperature. Support off ground or
pavement in watertight enclosures when
outdoor storage is necessary.
3. Deliver piping with factory-applied end caps.
Maintain end caps through shipping, storage, and
handling to prevent pipe-end damage and to prevent
entrance of dirt, debris, and moisture.
4. Protect stored piping from moisture and dirt. Elevate
above grade. Do not exceed structural capacity of floor
when storing inside.
5. Protect flanges, fittings, and specialties from
moisture and dirt.
6. Store plastic piping protected from direct sunlight.
Support to prevent sagging and bending.
7. Manufacturer’s recommendations on handling,
repairing, laying, jointing, anchoring, cutting and other
works for pipes and fittings are to be strictly followed.
16.2.1.6 Installation and Checking
1 The irrigation work shall be supervised by qualified
representatives of the Contractor and full facilities and
assistance shall be provided by the Contractor to enable
the Engineer to inspect or check the Works at any time.
Such inspection or checking shall in no way relieve the
Contractor from any of his obligations. He may be
required to open up for inspection any equipment that has
been delivered to the Site partly assembled.
2 The Contractor shall be responsible for making minor
adjustments to the location of sprinklers and specialties as
necessary to avoid plantings and obstructions such as
signs and light standards subject to the approval of the
Engineer.
♦ 16-12 ♦
3 The Contractor shall be responsible for the
correctness and safety of all electrical and mechanical
connections for the irrigation system, before the system is
brought into service, including checking the proximity of
different metals to ensure no chemical reaction or
corrosion will occur.
16.2.1.7 Spares
1 At the commencement of the Contract the Contractor
shall submit a detailed list of minimum essential spares
recommended by the irrigation system manufacturer,
together with current prices and catalog identifications.
2 Lists of any additional spares recommended by the
manufacturers shall also be submitted, referenced to each
major item of equipment and showing the current prices
and catalog identifications.
3 The Engineer will select the types and numbers of
spares he requires and will instruct the Contractor to
proceed with their purchase and delivery to the
Employer's store or depot. The spares shall be supplied
and suitably packed for transportation to the Site and for
long term storage and shall include all fastenings, lugs,
screws, etc. Identification labels shall be attached to the
outside and also enclosed within the package.
16.2.1.8 Equipment Labels and Charts
1 Each piece of equipment shall have a certified
nameplate, permanently attached at the factory and in a
readily accessible location, printed or stamped clearly with
the name and address of the manufacturer, equipment
model number, serial number, date of manufacture,
performance rating or duty, pressure, temperature, or
other limitations and other relevant data.
2 Aluminum tags 50 mm diameter and 1.5 mm thick
with stamped lettering filled with black print and with
heavy aluminum or brass hooks and chains shall be
provided in lieu of labels wherever the latter cannot easily
identify the equipment.
3 Charts indicating the schedules for equipment
lubrication, maintenance and essential operating
instructions shall be prepared, mounted on wooden or 6
mm dense hardboard back boards, covered with heat
bonded clear plastic laminate or framed under glass.
These charts shall be permanently fixed with four brass
screws at approved locations as directed.
4 Prior to preparing labels and tags, and maintenance
charts, a preliminary schedule shall be submitted for
approval, showing the equipment to be labeled or tagged
with suggested nomenclature, and proposed maintenance
schedules.
16.2.1.9 Operation and Instruction Manuals
1 Prior to final acceptance, the Contractor shall submit
to the Engineer 6 sets of operation, maintenance and
instruction manuals relating to the irrigation system. The
manuals shall be A4 size, bound in loose leaf binders or
copy 249
booklets suitably enclosed and shall include the following
information:
i. Setting up, putting into service and operating
instructions.
ii. Fault location and repair procedures.
iii. Maintenance instructions, including schedules
for preventive maintenance, and
recommended lubricants and equivalents.
iv. Complete recommended spares list, including
manufacturers' names and catalog numbers.
v. Names and addresses of manufacturers' local
authorized representatives and service agents.
16.2.2 Material
16.2.2.1 Pipes, Fittings and Accessories
1 Ductile iron pipe
i. Ductile iron pipe for water shall be to BS EN
545 or equivalent. Unless otherwise indicated
in the Bill of Quantities or the Drawings, Class
K9 shall be used for diameters up to 500 mm,
Class K8 for diameters 500 to 800 mm and
Class K7 for diameters greater than 800 mm.
ii. Spigot and socket ended pipes shall be used
for straight runs and adjacent to elbows or
fittings. These joints shall be provided with
rubber gaskets, and an external thrust block is
required at elbows or fittings. Anchored or self
restrained joints shall be used for sections
adjacent to elbows in areas where space is
restricted or indicated on the Drawings or BOQ.
Anchored joints are to be push-in, self
anchored type able to take up the axial forces
thus allowing concrete thrust blocks to be
dispensed with. The Contractor shall submit
calculations verifying the number of restrained
joints required noting that pipe pressure
testing will be made when pipes are partially
backfilled.
iii. Flanged pipes wherever specified shall have
screwed-on or cast-on flanges to sustain
working pressure of NP 16 minimum.
iv. Flanges shall conform to BS EN 1092-2.
v. Factory protection for pipes and fittings:
a. Pipes shall be internally cement lined to
BS EN 545 with ordinary Portland cement
to BS EN 197-1 to specified thicknesses
b. Externally, pipe shall be coated with
metallic zinc to BS EN 545 and followed
by a bitumen coat to BS 3416 of
minimum thickness 6 mils. A hot applied
coal tar based material to BS 4164 may
replace the bitumen coat.
c. Fittings shall be coated internally and
externally by dipping, or other method,
using hot applied coal tar based material
to BS 4164 or hot applied bitumen to BS
3416, Type 1, grade d, minimum
thickness 10 mil.
2 uPVC Pressure Pipes
i. Pipes shall conform to BS EN 1452 or to DIN
8061/8062, Series 4 and 5 or ISO 161 Class 10 &
16. Concrete encasement shall be used if cover
is less than 1 meter or greater than 5 meters.
ii. Fittings shall be to BS EN 1452 part 3 or DIN
8063 part 1 fabricated from pipe.
iii. Joints shall be to DIN 8063 part 1, socket spigot
with rubber sealing rings shall be to BS EN
681-2.
iv. Pipes and fittings shall be protected from the
direct rays of the sun at all times by means of
reflective cover sheets.
3 Polyethylene PE Pressure Pipe
i. Pipes and fittings with 110 mm (4”) diameter
and larger shall be to ISO 4427, DIN 8074/8075
or AWWA C906. Pipe shall be supplied in
straight pieces and not rolled on a drum. The
ends of each pipe shall be plain and suitable
for heat fusion. Pipe and fittings shall be
minimum class 12 kg/cm2, Dimension Ratio 9.3,
according to AWWA C906 Table 9 or ISO 3126.
ii. Irrigation pipes smaller than 110 mm (4”) in
diameter shall be according to ISO 4427, BS EN
12201-2 (PN12) or to DIN 8074/8075 class
12Kg/cm2.
iii. Materials used shall have a standard PE codes
designation 3408 and 3406 with respective
minimum hydrostatic design basis of 1600 and
1250 psi according to AWWA C906 Table 1. PE
Pipes shall contain a minimum 2% carbon
black well dispersed and shall be constructed
with UV stabilizer material according to ASTM
D2239.
iv. Manufacturers shall provide certification that
stress regression testing has been performed
on the pipe products. Materials shall also meet
elevated temperature requirements as given in
Table 2 AWWA C906.
v. Fittings shall be to AWWA C906, extruded or
injection moulded suitable for class of pipe
required:
a. For irrigation pipes with diameters equal
or larger than 50 mm (2”) the following
fittings shall be used:
• for similar size PE pipes joining use
PE butt-weld fittings: to ASTM D3261.
• for dissimilar pipes sizes use PE
socket fittings that uses the electrical
♦ 16-13 ♦
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 heating with the appropriate pipe viii. Pipes and fittings shall show no porosity when
clamps according: to ASTM D2683. tested in accordance with ASTM D 2444 or BS
b. For irrigation pipes with diameters less EN 1796 and BS EN 14364.
than 50 mm (2”) use PVC/PP ix. Samples made from pipe or fitting laminates
compression fittings. The compression shall show no evidence of delaminating or
fittings shall conform to BS 5114 with other impairment when tested in accordance
minimum 12 kg/cm2 nominal pressure. with ASTM D 570.
c. The use of insert and/or solvent welded x. The axial modulus of elasticity of pipes shall be
fittings for PE irrigation pipes shall not be tested in accordance with ASTM D 2925.
allowed thicknesses. xi. The short-time hydraulic failure strength of
vi. Joints for pipes and fittings shall be by heat pipe and fittings, shall be tested in accordance
fusion and in strict accordance with pipe with ASTM D 1599.
manufactures recommendations. Joints shall xii. The axial tensile stress for pipes shall be tested
have a tensile strength equal to that of the pipe. in accordance with ASTM D 2105.
Fusion temperature, interface pressure,
xiii. The hoop tensile strength of pipes shall be
alignment and cooling time, shall be according
tested in accordance with ASTM D 2290.
to manufactures recommendations.
xiv. The indentation hardness of pipes and fittings
vii. Pipes must be marked at intervals of not more
shall be tested in accordance with ASTM D
than 2 m. with legible cast, stamped lettering to
2583.
show the following, as appropriate:
xv. The glass content of the reinforced wall of
a. nominal pipe size,
pipes and fittings, will be determined in
b. type of plastic material in accordance accordance with ASTM D 2584.
with designation code,
xvi. The hydrostatic design stress for pipes and
c. standard dimension ratio SDR, fittings will be obtained from the extrapolated
d. pressure rating, long term hydrostatic tests in accordance with
e. Initials and number of relevant standard, ASTM D 2992.

f. manufacturer name or trademark, xvii. Joints shall be GRP double socket couplings
with rubber rings to ISO 4633 or BS EN 681-2.
g. date of manufacturer:
The allowable angular deflection shall conform
4 GRE Pipes and Fittings to the requirements of BS EN 1796 and BS EN
i. Pipes and Fittings: Conform to AWWA C950-07 14364 Table 3.
or BS EN 1796 and BS EN 14364 or equivalent xviii. Transition couplings for underground piping
suitable for 10 bar working pressure with a shall be to AWWA C219, metal, sleeve-type
minimum stiffness of 10000 N/m2. coupling same size as, with pressure rating at
ii. Resin: Use epoxy resin. The resin-curing agent
mixture will have sufficient chemical and
mechanical resistance to meet the imposed
requirements.
iii. The reinforcement of thermosetting resin shall
consist of two types of glass with a low alkali
content.
iv. C-glass or polyester non-woven shall be used
as reinforcing material for the chemically
resistant inner layer (liner).
v. E-glass shall be used as reinforcing material for
the structural wall. The reinforcing material is
to be provided with a special finish to assure a
good adhesion with the matrix.
vi. GRE pipe and fittings shall have a resin-rich
exterior surface having a minimum thickness of
0.5 mm.
vii. Flexible tensile resistant rubber seal lock joint
shall be used with a O-ring seal and a locking
device on all end connections except those
adjacent to flanged fittings when rigid tensile
resistant flanges are required.

♦ 16-14 ♦
copy 249
 least equal to and ends compatible with, piping
to be joined
16.2.2.2 Valves and Penstocks
1 Gate Valves: Cast Iron.
i. Type: Size 50 mm and smaller to BS 5154
inside screw, solid wedge, rising stem and
screwed bonnet.
ii. Type: Size 65 mm and larger to BS 5163, inside
screw, solid wedge, resilient seated, for valves
350 mm and smaller and metal seated for
valves 400 mm and larger, bolted bonnet, non-
rising stem type, suitable for NP 16 for
irrigation networks.
iii. Material of component parts from basic or
alternative materials listed in BS 5163.
iv. End Connections: Size 50 mm and smaller
screwed end to BS 21.
v. End Connections: Size 65 mm and larger
flanged end connection to BS EN 1092-2.
vi. Operation: Valves larger than 400 mm diameter
are to have spur gear drive operated by
removable key. Valves smaller than 400 mm
are to be operated by hand-wheel.
vii. Factory Protection: Casting surfaces are to be
given an initial coat of protective paint
immediately after shot blasting and a second
coat on assembly. Protective coating is to be
hot applied coal tar or bitumen to BS 4164 or
BS 3416 respectively. Thickness of coat to be
250 microns.
2 Butterfly Valves: Cast Iron.
i. Type: To BS EN 593, double flange with
resilient seating, for horizontal use and suitable
for NP 16.
ii. Size: For 350 mm and larger.
iii. Material of component parts shall be from
basic materials listed in BS EN 593 Table 3.
iv. End Connections: Flanged to BS EN 1092-2.
v. Operation by hand wheel. Maximum shut off
pressure against which valve is operated is to
2 chambers, sealed through piston disc.
be 15 kg/cm .
vi. Factory Protection: Casting surfaces are to be
given an initial coat of protective paint
immediately after shot blasting and a second
coat on assembly. Protective coating is to be
hot applied coal tar or bitumen to BS 4164, or
BS 3416 respectively. Thickness of coat shall
be 250 microns.
3 Globe Valves
i. Type: To ASTM A48/A48M grade 30B with
valve disc to ASTM A276 type 430, valve seat
to ASTM A276 type 420 and stem to ASTM
A276 type 403. Valve is to be suitable for a
working pressure of 16 bars.
ii. Construction: Non-rising stem, straight pattern
with flanged connections.
iii. Material of Component Parts: Cast iron with
stainless steel trim.
iv. Operation: Manual operated valves are to have
hammer type hand-wheel and electric operated
valves are to have motor actuator.
4 Ball Valves
i. Ball valves 50 mm and under shall be full port
of 2-piece construction, lever operated with
bronze body and stem, chrome-plated brass
ball, replaceable PTFE seats and packing,
plastic coated steel handle, threaded end
connection for steel piping, and copper
compression or solder end connections for
copper piping.
ii. Ball valves 150mm to 1200mm shall comply
with the requirements of AWWA C 507.
5 Check Valves
i. Check valves shall be to BS EN 12334, swing,
straight, for horizontal use and suitable for
working pressure of 16 bars.
ii. Material of Component Parts: Ductile iron from
basic materials listed in BS EN 12334 Table 5,
under 'copper alloy faced' column.
iii. Special Requirements: Seating or facing rings
are to be renewable. An arrow showing
direction of flow is to be visible from outside
and cast integral with the valve housing.
iv. End Connections: Either flanged to BS EN
1092-2, or screw ended to BS 21 to suit joints
specified for adjoining pipes.
v. Factory Protection: Casting surfaces are to be
given an initial coat of protective paint
immediately after shot blasting and a second
coat on assembly. Protective coating is to be
hot applied coal tar or bitumen to BS 4164 or
BS 3416 respectively. Minimum thickness of
coating shall be 250 microns.
6 Float Valves
i. Type: Globe pattern, with two operating
ii. Operation: Valves shall operate with a
mechanical compensating float valve
controlling flow to tank by modulating in direct
ratio to minimum fall in water level. Control of
valve is to be through mechanically operated,
three-position, four-way valve. Moving four-
way valve control in one direction is to open
valve and moving lever in other direction is to
close-out valve. When lever is moved to centre,
valve will throttle in an intermediate position.
iii. Valve positioning control consists of float
operated linkage mechanism for remote
mounting which feeds water level changes
back to main valve through low friction,
♦ 16-15 ♦
copy 249
 flexible push-pull cable supplied by same
manufacturer.
iv. Valve operating control consists of secondary
linkage mechanism functioning off common
lever connected to both main valve position
indicator rod and control valve position
indicator rod and control valve operating lever.
Minute changes in water level are transmitted
through push-pull cable to three-position, four-
way control valve.
v. Construction: Cast iron body to ASTM A126,
bronze valve trim and valve operating
mechanism to ASTM B62 and all stainless steel
valve float and pilots.
vi. Factory Protection: Internal coating of epoxy to
a thickness of 250 microns and external coating
of epoxy and nickel plating to a thickness of
250 microns.
7 Air Valves
i. Generally: Valves are to have cast iron body
and bolted cover to BS EN 1561 grade 14
minimum, rubber outlet seat, plastic or ebonite
ball, forged bronze screws and guide for ball
acting under pressure. Valves are to be
dynamic type where there is no possibility of
ball being drawn into orifice due to high air
velocities. Valves are to be factory tested to 1.5
times working pressure and factory coated with
coal tar or bituminous coating to BS 4164 or BS
3416 respectively. Thickness of coat to be 250
microns.
ii. Double Air Valves (or Combination Air Valves):
These are required for relieving air under
pressure and in bulk. Large orifice releases or
admits air during charging or emptying of
mains while small orifice releases air
accumulated at summits of mains under
pressure. Large orifice area is to be equal to or
greater than inlet of valve. Valves are to be
fitted with nitrite rubber lined butterfly valve
with nylon coated disc on stainless steel shaft
operated by lever handle with indicator and
locking thumb screw. Valves are to be flanged
to BS EN 1092-2 and suitable for working
pressures up to NP16.
iii. Single Air Valves: Type 1 (or air vacuum valve)
for releasing or admitting air during filling or
emptying of pipes. Type II (or air release valve)
for automatically releasing, under pressure,
accumulated air at summits of mains. Air
valves larger than 50 mm are to be flanged to
BS EN 1092-2 and are to have nitrite rubber
lined butterfly valve with nylon coated disc on
stainless steel shaft operated by lever handle
with indicator and locking thumb screw. Air
valves 50 mm and smaller are to have B.S.P.
thread with brass or gun metal male screwed
♦ 16-16 ♦
stop valves. Valves are to be suitable for
working pressures up to NP16.
8 Sluice Gates / Penstock
i. Type: To AWWA C560, rising stem, having a
flat back for bolting to wall, suitable for 10
meters seating pressure and 4 meters off-
seating pressure, with standard conventional
closure and rectangular or circular aperture.
ii. Material of Component Parts: Unless otherwise
specified on the Drawings, any materials listed
in Section 2 of AWWA C560 may be used in
manufacture except that materials identified as
being subject to de-zincification or de-
aluminumization are not to be used.
iii. Operation: By floor pillar with gear box.
Maximum operating head from surface of
water to centre line of gate is to be 10 meters.
iv. Factory Testing: Leakage test to meet the
requirements of Section 6.3 of AWWA C560 is
to be carried out on all sluice gates.
v. Factory Protection: Casting surfaces are to be
given an initial coat of protective paint
immediately after shot blasting and a second
coat on assembly. Protective coating is to be
hot applied coal tar or bitumen to BS 4164 or
BS 3416 respectively. Thickness of coat to be
at least 250 microns.
9 Pressure Reducing Valves
i. Types: Installed where shown on the Drawings
to pressure ratings and pressure settings
indicated, to automatically reduce higher inlet
pressure to steady lower downstream pressure
regardless of changing flow rate and/or varying
inlet pressure. Valves are to be high pressure
rating piston type and hydraulic pilot operated
type.
ii. Accessibility: Maintenance is to be possible
without removing valve from pipeline.
iii. End Connections: Flanged to BS EN 1092-2 to
pressure rating of 10, 16 or 25 as appropriate
and provided from factory with necessary bolts,
washers, nuts and gaskets.
iv. Factory Protection: Internal coating of epoxy to
a thickness of 250 microns and external coating
of epoxy and nickel plating to a thickness of
250 microns.
v. Piston Pressure Reducing Valves shall be of the
spring loaded type, balanced out against
upstream pressure by high resistance piston
action. Valve shall control a constant
downstream pressure to a maximum variation
of +/- 10% and close tight with zero flow rate.
Accessories shall include two pressure gauges
with isolation cocks, one fitted upstream and
one downstream.
copy 249
 vi. Diaphragm Pressure Reducing Valves shall be
pilot controlled, single seated, hydraulically
operated, diaphragm type globe valve. Control
system is to be sensitive to slight pressure
changes and is to immediately control main
valve to maintain desired downstream
pressure. Pressure setting adjustment is to be
made with single adjustment screw protected
by a housing that can be sealed. Body and
cover are to be cast iron, ductile iron or cast
steel depending upon operating pressure.
Main valve trim is to be stainless steel and
pilot system all stainless steel. Main valve is to
have single removable seat and resilient disc.
vii. Diaphragm valve assembly shall be fully
guided by a precision machined stem with
bearings at both ends in the valve cover and
seat. Diaphragm is to be nylon bonded with
synthetic rubber. Valve is to have necessary
factory fitted pilot valves, small interconnecting
piping and accessories to perform required
functions. Pilot control is to be direct acting,
adjustable spring loaded, normally open,
diaphragm valve designed to permit flow when
controlled pressure is less than spring setting.
Control system is to include Y-strainer, fixed
orifice and isolation cocks. Pilot control system
is also to include flow control device to
regulate closing speed of valve. Valve is to
close tight at zero flow rate.
10 On-Off Solenoid Operated Valves
i. Type: Pilot controlled, single seated,
hydraulically operated, diaphragm type globe
valve fitted with solenoid control valve to keep
main valve open when energized and to close
tight main valve once de-energized.
ii. Construction: Cast iron valve body and cover,
stainless steel main valve trim and all stainless
steel pilot system.
iii. Controls: These shall comprise auxiliary
controls to permit adjustment of valve opening
and closing speeds of up to 2 minutes for
opening and for closing.
iv. Accessories shall include the following:
a. Adjustable opening speed control.
b. Adjustable closing speed control.
c. No-return check valves.
d. Y-strainers.
e. Interconnecting stainless steel tubing and
unions.
v. Factory Protection: Internal and external
coating of epoxy as described for float valves.
11 Electric Remote Control Valves
i. Type: Normally closed 24 VAC 50/60 cycle
solenoid actuated globe pattern with a
balanced pressure diaphragm design. The
valve operating pressure range shall be
between 1.5 and 14 bars.
ii. Material: The valve body and bonnet shall be
constructed of heavy-duty glass-filled UV-
resistant nylon and have stainless steel studs
and flange nuts; diaphragm shall be of nylon
reinforced rubber.
iii. Operation: The valve shall have manual
open/close control (internal bleed) for manual
opening and closing of valve without
electrically energizing the solenoid.
iv. Operation: The valve shall have a brass flow
control stem for accurate manual regulation
and/or shut off of outlet flow.
v. Construction: The valve construction shall be
such as to provide for all internal parts to be
removable from the top of the valve without
disturbing the valve installation.
12 Electric Remote Control Valves with Pressure
Regulation
i. Type: Electric remote control valve as specified
above shall have a pressure regulating module
capable of regulating outlet pressure between
1 and 7 bars (15 and 100 psi).
ii. Operation: Module shall have an adjusting
screw for setting pressure and Schrader valve
connection for monitoring pressure. The
pressure shall be adjustable from the pressure
regulating module when the valve is manually
bled.
16.2.2.3 Irrigation Equipment
1 Pop-Up Spray Sprinkler
i. Type: Fixed, non-rotating spray or stream
spray adaptable for full circle, part circle, or
strip wetting pattern, suitable for installation
on a pop-up mechanism. Spray head to have
built in check valve and pressure regulated
stem.
ii. Material: The sprinkler body, stem, nozzle, and
screen shall be constructed of heavy duty,
ultra-violet resistant plastic, with a heavy-duty
stainless steel retract spring.
iii. Construction: Spray head to retract flush with
the finished ground level when not in
operation. When spraying, net pop-up height
to be 150 mm from finished ground level.
iv. Performance: This shall meet requirements of
discharge and spray radius as specified on the
Drawings for the given nozzle pressure. The
sprinkler shall have a matched precipitation
rate nozzle with an adjusting screw capable of
regulating the radius of flow.
v. Tests: The Contractor shall provide test results
carried out at factory substantiating required
performance (discharge and radius of throw at
♦ 16-17 ♦
copy 249
 prescribed operating pressure and height
above ground) and giving actual precipitation
rate and its uniformity as obtained for
uniformity test carried out using catch cans.
2 Pop-Up Rotor Sprinkler
i. Type: Full or part circle pop-up rotor sprinkler,
single nozzle. The part circle sprinkler shall
have adjustable arc coverage from 25° to 360°.
The sprinkler shall have a built in check valve
and pressure regulated stem.
ii. Material: The sprinkler body, stem, nozzle, and
screen shall be constructed of heavy duty,
ultra-violet resistant plastic, with a heavy duty
stainless steel retract spring.
iii. Construction: Sprinkler head to retract flush
with the finished ground level when not in
operation. When operating, net pop-up height
to be 100 mm from finished ground level.
iv. Performance: This shall meet the requirements
of discharge, radius and rotation angle as
specified on the Drawings for the given nozzle
pressure. The sprinkler shall have a matched
precipitation rate nozzle, with an adjusting
screw capable of regulating the radius and the
flow.
v. Tests: The Contractor shall provide test results
carried out at factory substantiating required
performance (discharge and radius of throw at
prescribed operating pressure and height
above ground) and giving actual precipitation
rate and its uniformity as obtained for
uniformity test carried out using catch cans.
3 Bubblers
i. Type: Pressure compensating, of the full circle
umbrella or trickle discharge, with inlet screen.
ii. Construction: Bubbler shall be of a
permanently assembled design constructed of
durable ultra-violet resistant plastic.
iii. Performance: Bubbler to operate at constant
flow discharge over a pressure range specified
on the Drawings.
6 Quick Couplings Valve
4 Emitters
i. Type: Pressure compensating, single outlet.
ii. Construction: Emitter shall have self-piercing
inlet barb constructed of durable ultra-violet
resistant plastic.
iii. Performance: The emitter shall have a self-
flushing action to minimize clogging, and shall
operate at a constant flow discharge over a
pressure range specified on the Drawings.
5 Backflow Preventers
i. Backflow preventers shall be installed in the
locations shown on the Drawings. Normally
for each control head in the system a backflow
preventer shall be installed upstream of all
♦ 16-18 ♦
other components in the control head.
Backflow preventers shall only be installed in
locations where they are readily accessible for
maintenance and testing and shall not be
located where any part of the device can
become submerged at any time.
ii. Backflow preventers shall be of the reduced
pressure type.
iii. Backflow preventers shall be evaluated and
tested by an approved authority and certified
by the American Society of Sanitary
Engineering Standards 1013 (latest edition) for
reduced pressure principle backflow preventers.
Such valves shall also meet the performance
requirements of AWWA C 511.
iv. Backflow preventers up to 75 mm in size shall
be of machined cast bronze body construction
and up to 150 mm in size shall be of cast iron
body construction with internal waterways
epoxy coated, stainless steel and/or brass
internal parts and stainless steel flange bolts,
durable, tight-seating rubber check valve
assemblies.
v. Backflow preventers shall be suitable for
supply pressure up to 1.2 MN/sq.m (12
kg/sq.cm) and for water temperature up to 44
degrees C. The operating range for flow and
pressure loss shall be as shown on the
Drawings.
vi. The backflow preventer assembly shall consist
of a pressure differential relief valve located in
a zone between two positive seating check
valves. The relief valve shall contain a
separate means whereby free air will enter the
zone, and contained water will be discharged
to the atmosphere, when the valve is fully open.
vii. The backflow assembly shall include 2 gate
valves for isolating unit, and 3 test cocks for
testing the device to ensure proper operation.
viii. Backflow preventers shall be designed for
inline servicing.
i. Type: The quick coupling valve shall be a two-
piece type.
ii. Construction: The valve body shall be
constructed of heavy cast brass.
iii. Cover: The cover shall be a durable, protective
self-closing, locking rubber cover.
iv. Valve Operating Key: The valve shall be
opened and closed by a brass key supplied by
valve manufacturer having a 25 mm male top
pipe threads and 19 mm female top pipe
threads outlet. The valve throat shall have a
keyway with detent positions for regulating
water flow. Operating keys are to be supplied
copy 249
 at the rate of 1 per five valves installed or
fraction thereof.
16.2.2.4 Valve Operators and Accessories
1 General
i. Gate, butterfly and ball valves are to be
manually or electrically operated depending
upon size, torque applied on valve stem or as
shown on the Drawings.
ii. Valves 350 mm and smaller are to be operated
manually with a maximum applied torque on
handwheel of 100 Nm.
iii. Valves 400 – 500 mm are to be operated
manually with a maximum applied torque of
150 Nm.
iv. Valves of higher torque are to have appropriate
thrust bearings, slides and gearboxes to fulfill
these requirements.
v. Gate valves 600 mm and larger and ball valves
are always electrically operated using thrust
bearings, gearboxes and motor actuators.
vi. Butterfly valves 600 mm and larger are to be
either manually or electrically operated as
shown on the Drawings.
2 Programme Controllers
i. Type: Solid state or hybrid (combining electro-
mechanical and micro-electronic circuiting),
capable of fully automatic or manual operation
of the remote solenoid valves, with dual
programme, independent station timing, 14-
day calendar dial for every day or every other
day or any sequence starts, time-setting
control up to 60 minutes per station in 2
minutes increments 23 starts per day. The
number of stations to be as indicated on the
Drawings or in the Bill of Quantities. Maximum
number of 24 VAC solenoid valves that can be
controlled by a station is 4. Controller is to
allow for valve power output to be interrupted
without affecting the controller timers.
ii. Operation: The controller shall have a remote
pump start circuit to activate a remote pump
start relay to run the pump during the irrigation
cycle.
iii. Operation: The controller shall allow for
opening the first remote control valve before
operating the pump and also for closing the
last remote control valve within 15 seconds
after stopping the pump.
iv. Installation: Controller shall be installed in
pedestal weatherproof, heavy-duty, locking,
steel cabinet adequately protected. Pedestal
mount shall include terminal strips for the
quick connection of cables.
v. Electrical Features: Accept 220 V 50/60 cycle
current; to command 24 VAC solenoid valves;
to include output surge protection to protect
controller from power surges; to include one
arrestor for each valve wire and one for the
common or ground wire; to include a master
on-off switch.
vi. The Controller without exception shall be of
the same manufacturer as the remote control
valve.
3 Cabling for Irrigation Control
i. Low voltage wiring from automatic controllers
to remote control valves shall be direct burial
type, 600 volt solid copper single conductor
wire with heat resistant insulation minimum of
0.4 mm thickness. The Contractor shall submit
proposed low voltage wire routing shop
drawing for the Engineer's approval prior to
installation. The low voltage wire shall be
encased in 5 mm diameter conduit.
ii. Medium voltage cables shall conform to the
requirements of BS 5467, IEC 502, or other
approved comparable international standards
as applicable. Cables shall be 600/1000 volt
grade, multicore, stranded copper conductor,
cross-linked polyethylene (XLPE) insulated,
uPVC oversheather type. The service cable for
irrigation controllers shall be 3 core 10 mm2
minimum.
iii. Conductors shall be annealed stranded copper
in accordance with BS EN60228. Conductor
insulation shall be moisture and heat resistant,
90 degrees C, grade conforming to the relevant
parts of BS EN 50363. The cable cores unless
otherwise approved shall be colored as
follows: Single Phase System: Red (phase),
black (neutral), green or green/ yellow (ground).
4 Valve Chambers, Boxes and Markers
i. Valves shall be installed in chambers or boxes
of suitable size as shown on drawings for easy
access. Chambers and boxes shall be complete
with access covers, ladder rungs and other
incidental works.
ii. Unless shown otherwise on the Drawings all
chambers shall be installed on a suitable base
for proper foundation and easy leveling to
proper grade, and also to provide for sufficient
drainage.
iii. Valve markers showing the reference numbers
of the valves shall be of materials and to the
dimensions, shapes and details as shown on
the Drawings.
5 Valve Accessories
i. Hand-wheels shall be to BS 5163, of cast iron
to BS EN 1561. Hand-wheels are to be marked
'CLOSE' with an arrow to indicate clockwise
direction of closure. Diameters and other
constructional details shall be to
♦ 16-19 ♦
copy 249
 manufacturer's standards. Hand-wheels are to
be supplied at a rate of 1 in 5 valves.
ii. Valve caps shall be to BS 5163, of cast iron or
malleable iron to BS EN 1561 and BS EN 1562
respectively. Set screw of valve cap is to be
mild steel M12.
iii. Operation Keys: Combination prizing bar and
lifting key type, with 1.5 m vertical bar and 0.5
m horizontal bar. Keys are to be supplied at a
rate of 1 in 5 valves.
iv. Extension Spindles for Gate Valves: Steel to BS
2470 - M12, hot dip galvanized to BS EN 10240,
size 18 x 18 mm for valves up to 200 mm
diameter and 24 x 24 mm for valves 250 mm to
400 mm diameter. Length for each valve size is
to suit excavation requirements. Spindles are
to have cast iron or malleable iron cap and
coupling, to BS EN 1561,and BS EN 1562,
respectively, on both sides of extension spindle
(cap for operating spindle and coupling for
connecting to valve). Set screws of caps and
couplings are to be mild steel M12.
v. Protection Tubes: Either uPVC or cast iron.
Shape, sizes and other constructional details
are to be to manufacturer's standards and/or as
shown on the Drawings. Tubes are to have
caps circling extension spindles.
vi. Surface boxes shall be to BS 5834 Part 2.
Frames and lids are to be cast iron to BS EN
1561, studs, bolts, nuts and hinge pins are to
be mild steel M12, chains are to be mild steel
or wrought iron and lid is to have a suitable
identification marking cast on in accordance
with details given on the drawings or as
instructed by the Engineer. Boxes are to be of
the following types:
a. Heavy grade type A for carriageways
(wheel loads up to 11.5 tons).
b. Medium grade type M for use where
heavy commercial vehicles are
exceptional.
c. Light grade type L for use in places
inaccessible to wheeled vehicles
vii. Lifting Key Sets: Malleable iron, supplied at the
rate of 1 per 5 covers installed or fraction
thereof.
viii. Guards for Underground Stop Valves: PVC,
shape and size and other constructional details
to manufacturer's standards and/or as shown
on the Drawings.
6 Plastic Valve Boxes
i. Generally: Valve boxes may be glass reinforced
plastic (GRP) or plastic.
ii. GRP valve boxes are to be designed to suit site
conditions and loadings. GRP is to be
manufactured from E-glass type fibers and
♦ 16-20 ♦
thermosetting resin and is to incorporate a
corrosion resistant liner. Glass fibers are to be
compatible with the resins used. Liner is to
comprise an inner face being a smooth hard
suitably reinforced resin rich layer. Exterior
surface of valve box is to be resin rich.
iii. Inside surface of valve box is to be hard,
durable, free of tackiness and free of bulges,
dents, ridges or other defects that result in a
variation of inside dimensions of more than 3
mm from that obtained in adjacent unaffected
portions of the surface.
iv. No glass fiber reinforcement is to penetrate
interior surface of valve box wall, and any
glass fiber reinforcement on exterior surface
must be thoroughly impregnated with resin.
v. Glass content will be determined by ignition
loss analysis in accordance with ASTM D 2584
or BS EN ISO 1172.
vi. Plastic valve boxes are to be manufactured
from high impact, acid and heat resistant, self-
extinguishing, hard, durable, low coefficient of
expansion PVC compound.
16.2.2.5 Jointing Material
1 Generally
i. Gaskets: Elastomeric full face 3 mm thick joint
rings to ISO 4633 or BS EN 681-2 with
dimensions to BS 3063.
ii. Rings: Elastomeric to ISO 4633 or BS EN 681-2
with dimensions to manufacturer's
recommendations to suit type of joint required.
iii. Bolts and Nuts: ISO metric black hexagon to BS
4190, minimum tensile strength 433 MN/m2,
maximum elongation 17%. After fixing, bolt
projection shall to be maximum 6 mm,
minimum 3 mm.
iv. Washers: Black steel shall be to BS 4320 or ISO
887.
v. Dielectric joints shall have insulating gasket
between flanges and Teflon sleeves and
washers between bolts and nuts and flanges.
Joints are to be suitable for operating pressure
of system.
2 Flexible Couplings
i. Type: Gasketed sleeve type, to allow angular
deflection and axial movement of two joined
pipe ends and to maintain permanent, leak-
tight joint.
ii. Components comprise one centre sleeve, two
end followers or flanges, two rubber-
compounded wedge-section gaskets and
sufficient draw bolts and nuts to properly
compress gaskets. Tightening of bolts to draw
end followers together is to compress gaskets
copy 249
 in recess between centre sleeve and followers
onto pipe ends to effect positive seal.
iii. Size: Couplings are to have diameter
specifically supplied for and to properly fit type
of joined pipe ends. Center sleeve is to be of
adequate thickness and whole coupling
suitable for minimum working pressures
shown on the Drawings.
iv. Centre sleeve and followers shall be true
circular sections, free from irregularities, flat
spots or surface defects and formed from steel
mill sections with space between sleeve and
follower designed to provide confinement of
gasket.
v. Bolts shall be special steel having minimum
2
yield strength of 2800 kg/cm (40,000 psi) and
2 iii.
ultimate strength of 4200 kg/cm (60,000 psi).
Bolts shall be track-head design to prevent
turning when nut is drawn up and threads are
to be rolled with a nominal diameter larger
than diameter of shank. Manufacturer shall
supply information regarding recommended
torque to which bolts are to be tightened.
vi. Gaskets shall be synthetic rubber-base
compound with other products to produce
material which will not deteriorate from age,
heat or exposure to air and which is resilient
and able to resist cold flow of material so that
joint will remain sealed and tight indefinitely
when subjected to shock, vibration, pulsation,
temperature and adjustment of connected
pipes.
vii. Factory Protection: Coupling shall be factory
painted internally with 10 mils coating of epoxy
and externally with red primer to AWWA C203
Type B chlorinated rubber solution compatible
with bitumen, coal tar and general paints.
viii. Installation: Couplings are to be assembled on
site in accordance with manufacturer's
instructions to ensure permanently tight joints
under all conditions of expansion, contraction,
shifting and settlement.].
3 Dismantling Couplings
i. Type: Couplings shall ensure extensible
connection between sections of pipework, to
be mounted next to valves to enable easy
dismantling from pipework or to permit joining
pipework when butterfly valve is removed for
maintenance.
ii. Components: Dismantling piece shall be
flanged type composed of two parts, one
sliding into the other, and a free flange to
compress a trapezoidal section seal to ensure
water tightness. Coupling shall have locking
devices to provide elements of complete
rigidity.
iii. Construction: All steel with flanges class PN 10,
PN 16 or PN 25 depending upon coupling
location on pipework.
iv. Size: Couplings shall have diameter specifically
supplied for and to properly fit type of joined
ends of pipes and valves. Coupling shall
permit tightening of end flanges without risk of
misalignment. Seal shall be locked after end
joints are tightened.
4 Flanged Adaptor: Ferrous
i. Material: Cast iron to BS EN 545.
ii. Length of adaptor shall be 200 mm for
diameters up to 150 mm, 250 mm for
diameters between 200 and 300 mm and as
approved for diameters larger than 300 mm.
Factory Protection: Coated with bitumen or
coal tar to BS 3416 or 4164 respectively.
16.2.2.6 Concrete and Metal Work
1 Concrete shall conform to the requirements of
Section 5, clause 5.1.2, reinforcing steel to Clause 5.2.2
and reinforced concrete to Clause 5.3.2. Structural steel
and other metalwork shall conform to Section 6, Sub-
section 6.2 and as shown on the drawings. Structural steel
and other metalwork shall be painted and protected in
accordance with Section 7.
16.2.2.7 Pumping Plant
1 Refer to Section 17 of the Specification.
16.2.3 Construction Requirements
16.2.3.1 Excavation, Bedding and Backfilling
1 All excavation and backfill shall conform to the
requirements of Sub-Sections 2.3 - ’Road Excavation’ and
2.7 - ’Excavation and Backfilling for Structures’.
2 All piping under pavements shall be installed in pipe
sleeves (ducts) to permit replacement at a later date.
Sleeves for irrigation piping shall be sulfate resistant
reinforced concrete pipe as specified in Section 8, Clause
8.1.2. Locations and sizes of pipe sleeves are as shown on
the Drawings. Pipe and sleeves, or sleeves only, shall be
placed prior to or during construction of the highway. Any
piping installed after completion of the highway
construction shall be placed after jacking a pipe sleeve
under the pavement. The Contractor will not be permitted
to cut into the pavement for pipe installation.
16.2.3.2 Pipe Laying - Generally
1 Lowering: The Contractor shall not lower pipe into
trench until pipe bed is brought to grade and approved. He
shall use ropes, wire slings, band slings, spreader beams
etc. as recommended by manufacturer for each type of
pipe and as approved.
2 Manufactured pipe shall be handled and assembled
in accordance, with the manufacturer's instructions. When
♦ 16-21 ♦
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pipe laying is not in progress, the Contractor shall close manufacturer's of proprietary joints when laying and
open ends of pipes with properly fitted temporary wooden jointing.
plugs or standard caps as directed 4 Differing pipe and fitting material: The Contractor
3 All material shall be carefully examined for damage shall joint with adaptors as recommended by pipe
and tested in accordance with manufacturer's instructions manufacturer.
before laying to the satisfaction of Engineer.
16.2.3.4 Line and Gradient
4 The Contractor shall examine material to ensure
internal coating or lining and outer coating or sheathing 1 In open excavation: The Contractor shall provide and
are undamaged. If damaged, the Contractor shall make maintain sight rails and boning rods properly painted to
good or dispose of as directed. ensure correct alignment of pipe runs. Sight rails shall be
positioned either vertically above the lines of pipes or
5 The Contractor shall remove dirt and other materials
immediately adjacent thereto. At no time shall there be
before lowering the pipe into the trench and verify the
less than three sight rails in position on each length of
pipe inside is clear from construction debris before
pipeline under construction to any one gradient.
making joint.
2 In heading: The Contractor shall provide and
6 Pipe on solid ground: The Contractor shall cut holes
maintain marks to establish line and level of pipeline.
in bottom of trench to allow proper jointing and for barrel
Marks are to be fixed in each working shaft and two
of pipe to bear evenly on solid ground for its full length.
further marks established in each length of heading.
7 Pipe on granular bedding: The Contractor shall scoop
out locally at sockets/couplings to enable pipe to rest 16.2.3.5 Floatation
uniformly on barrel and adjust to exact line and level.
1 Prevention: Whenever water is excluded from interior
After testing, the Contractor shall lay and compact further
of pipe, the Contractor shall place sufficient backfill above
granular material in 150 mm layers or as approved to
pipe to prevent floatation.
levels shown on the Drawings.
2 The Contractor shall remove: any pipe that has
8 The Contractor shall lay pipe on an even formation
floated, correct the bedding and relay.
true to grade and line, with sockets (if any) facing up the
gradient. 16.2.3.6 Pipe Built Into Structures
9 Pipe on concrete bed or surround: The Contractor
1 Treatment of external surface: The Contractor shall
shall provide rectangular blocks of concrete Class 30,
thoroughly clean outside surface of pipes to be built-in
made in approved moulds at least 14 days before use, and
immediately before installation. The Contractor shall
approved hardwood folding wedges. The Contractor shall
remove protective coating to metal pipes, where ordered.
provide two concrete blocks for each pipe, set and bone
The Contractor shall roughen clay and concrete pipes as
into correct level on formation bottom and lay pipe
directed. The Contractor shall paint plastic pipes with
properly centered and socketed.
appropriate solvent cement and sprinkle with dry coarse
10 The Contractor shall insert two hardwood folding sand whilst wet. The Contractor shall cut away sheathing
wedges of width equal to width of concrete block between from sections to be built-in and after installation restore
body of pipe and block and drive together until pipe is protection up to external face of structure with approved
brought to exact level required. The Contractor shall leave bituminous material.
blocks and wedges undisturbed while pipes are being
2 Flexible joints: The Contractor shall provide two
jointed and concrete bed and haunch or surround are
flexible joints or flexible patented joints adjacent to
being placed. The Contractor shall ensure blocks and
structures. The Contractor shall place first joint not more
wedges are of sufficient size and strength to prevent
than one pipe diameter from face of structure and second
settlement of pipes. The Contractor shall leave sufficient
not more than the following distances away from first:
space to enable joints to be made, tested and inspected.
i. Pipelines not exceeding 450 mm: 2 pipe
16.2.3.3 Jointing diameters.

1 Manufacturer's instructions shall be followed ii. Pipelines over 450 mm and not exceeding 1000
regarding placement of bedding and backfilling, mm: 1.2 m.
cleanliness of joint surfaces, lubricant used, correct iii. Pipelines over 1000 mm: 1.8 m.
location of components, provision of correct gaps
between end of spigot and back of socket for flexible joints 16.2.3.7 Field Testing: Generally
etc. 1 Provision of test equipment: All items for tests shall
2 Deflection of joint: The Contractor shall not deflect be provided on site before the test i.e. pressure gauges,
flexible joints beyond maximum permissible angles given instruments, water etc...
by manufacturer and/or relevant Standards. 2 The Contractor shall carry out tests in the presence of
3 Patent detachable and flexible joints: The Contractor the Engineer's Representative.
shall strictly comply with special instructions issued by

♦ 16-22 ♦
copy 249
3 Fittings and joints: The Contractor shall permanently
anchor fittings before testing and leave all joints exposed
for checking.
4 Test sections: The Contractor shall limit test sections
to not more than 500 m.
5 Test sections: The Contractor shall test pressure lines
between valve chambers whenever possible.
6 Test sections: No testing shall be carried out against
or through the pressure reducing valves. The setting of the
pressure reducing valves shall not be changed for testing
purposes.
7 Test plug: The Contractor shall secure end of main
and test plug by struts.
8 Closed valve: The Contractor shall not test against a
closed valve unless there is no acceptable alternative.
9 The Contractor shall apply pressure by manually
operated test pump or, in the case of large diameter mains,
by power driven test pump, if approved.
10 The Contractor shall examine exposed joints and
repair visible leaks.
11 Failure: Should a test fail, the Contractor shall locate
leak and replace or make good defective pipe or replace
and make good faulty joint and retest main.
12 Records: The Contractor shall keep test records in an
approved form and hand original copy to the Engineer
immediately after completion of test.
13 The Contractor shall carry out hydrostatic test while
pipeline is partially backfilled.
16.2.3.8 Hydrostatic Testing of Pressure Pipelines
1 The pipeline shall be filled slowly with water from the
lowest point. After filling with water, absorbent pipes shall
be allowed to stand for at least 24 hours before testing to
allow for complete absorption.
2 Entrapped air shall be bled and pressurizing shall
then proceed until the specified test pressure is reached in
the lowest part of the pipeline section under test. Further
quantities of entrapped air shall be bled while the pressure
is being raised.
3 Unless otherwise specified, the test pressure shall be
equal to 1.5 times the maximum working pressure of the
pipeline as shown on the Drawings or as determined by
the Engineer on Site, but shall in no case exceed 75% of
the factory hydrostatic test pressure.
4 The test pressure shall be maintained for one hour by
pumping using a separate test pump. Pumping shall then
be stopped for 2 hours, at the end of which time the line
shall be re-pressurized to the original test pressure and the
volume of water pumped into the line recorded.
5 The pipeline shall be deemed to have failed the test if
visible leaks are detected (regardless of leakage being
within the allowable specified limit) or if the volume of
water pumped to restore original test pressure after the
period when pumping was stopped exceeds 0.1 liter/day
per km of pipe per mm of pipe diameter for each 3 kg/cm2
of applied pressure for other pipe material.
16.2.3.9 Visual Inspection Test
1 Timing: The Contractor shall carry out test after total
backfilling of length under test.
2 Limit of length to be tested at one time is three full-
length pipes unless otherwise approved.
3 Apparatus: The Contractor shall use rubber tyred
bogies which do not damage lining of pipe and an
adequate supply of electric lamps.
4 The Contractor shall check joints by means of feelers
to ensure rubber rings are correctly located.
5 The Contractor shall check pipe barrel for visible
cracks.
16.2.3.10 Deflection Tests for GRP Pipes
1 The Contractor shall conduct deflection tests for GRP
pipes as required by the Engineer at 3 stages. Deflection
shall be measured at the spigot end at mid point and at
socket end.
2 Stage 1: at completion of primary backfill (deflection
at this stage should be below 0.5%).
3 Stage 2: at final backfill (Maximum allowable
deflection 2.5%).
4 Stage 3: six months after final backfill (maximum
allowable deflection 4.0%).
5 Pipes not passing the deflection tests at Stage 2 or
Stage 3 will be removed and replaced.
16.2.3.11 Flushing
1 Procedure shall be to AWWA C651.
2 The Contractor shall provide equipment, gauges,
temporary connections needed for flushing. The
Contractor shall arrange with the Employer to draw water
from existing sources.
3 The Contractor shall flush mains in sections as
directed by the Engineer.
4 The Contractor shall use washout valves and fire
hydrants to drain flushing water.
5 The Contractor shall flush main until effluent is clean
and then clean as directed. 1 to 2 times volume of pipe is
usually required for such flushing.
16.2.3.12 Field Protection and Coating
1 Iron pipes: Polyethylene encasement shall be to
ANSI/AWWA C105, Section 4.1 minimum thickness 200
microns and/or in accordance with the manufacturer's
instructions.
2 Patented detachable and flexible joints and flanged
connections: The Contractor shall protect metal joints with
mastic compound and protective tape in accordance with
the manufacturer's instructions and provide a minimum
overlap of 55%. The Contractor shall press out firmly all
folds and irregularities.
♦ 16-23 ♦
copy 249
16.2.3.13 Irrigation Control
1 The 24V electrically operated irrigation solenoid
valves shall be controlled by the irrigation program
controller and positioned as shown on the Drawings.
2 The controllers shall be interlocked with the pumping
system to ensure that the pumps operate after the
irrigation valves are open.
3 The irrigation control electric cables, connecting the
irrigation program controller to the solenoid valves shall
be copper PVC insulated and PVC sheathed. The sizes of
cables shall be commensurate with the distances between
the controller and valves, operating pressure and
manufacturer's recommendations. The cables shall be
approved for ground feeders directly buried and rated for
600/1,000V. They shall be clipped to the main water
pipework. Multi-runs of cables shall be bunched and tied
together at one m intervals using PVC tape and clipped to
the underside of the water pipework at 2 m intervals using
plastic straps.
4 To allow full flexibility of the system, each valve shall
have a separate control cable such that any valve
sequence control may be re-adjusted.
5 Where required, cable junction boxes shall be fitted.
These shall be purpose made boxes fitted with fixed
connectors and suitably labeled. The boxes shall be fitted
with glands and gasketed lid to ensure a fully dust tight
and weatherproof enclosure to IP65.
6 Each solenoid valve shall be fitted with fixed
terminals inside an IP65 box and suitable for wiring from
the valve to be connected.
7 All cable cores shall be fitted with marker ferrules at
each end for ease of identification, and all valves shall be
fitted with identification labels.
16.2.3.14 Contract Requirements
1 The Contractor shall prepare working drawings of the
irrigation electrical system including all necessary
calculations and these shall be submitted in triplicate for
approval prior to commencing the Works on Site.
2 The Contractor shall submit, in triplicate, full details
of all equipment to be supplied for approval before firm
orders for the equipment are placed.
3 The Contractor shall submit "As-Built" drawings of
the installation on completion.
4 The Contractor shall maintain the installation
throughout the Period of Maintenance and shall keep a
detailed record of all maintenance and repair action taken.
16.2.3.15 Documentation
1 On completion of the Works, the Contractor shall
supply record, operation and maintenance data. A single
line diagram of the electrical installation shall be framed
and mounted in each pumping station.
2 All equipment and circuits shall be properly labeled
and reference shall be included on the single line diagram,
♦ 16-24 ♦
16.2.3.16 Maintenance Program
1 The Contractor shall submit a detailed Maintenance
Program for approval, at least 2 months prior to putting
the irrigation system into service. This Program shall
include an Operation and Maintenance Organization Chart
and all activities incidental thereto.
2 During the Period of Maintenance, the Contractor
shall maintain in proper operating condition all irrigation
equipment, pipes, valves, pumping stations, and
appurtenances. A record shall be kept of all maintenance
and repair activities throughout the Period of Maintenance,
including the date, location and type of work performed,
all repairs and replacement, activities and equipment
relevant to the Maintenance works. This record shall be
complete and acceptable to the Engineer.
16.2.4 Method of Measurement
1 Trench excavation and backfilling shall be measured
and paid for as indicated in Section 2, Clause 2.8.4.
2 Pipes shall be measured in linear meters of laid pipe
of each type, class and size, measured as a straight line
between the centers of consecutive coupling sections. The
distance between the two centers of the couplings on both
sides of any fitting or valve shall be included as pipe
length. No allowance will be made for cut ends and waste.
3 No separate measurement will be made for setting
out laying and bedding in trenches or fixing to structures,
thrust blocks, sleeves and ducts, jointing material,
couplings of any type, special fittings, connecting to
equipment and chambers, testing, lining and painting and
all other items and work to provide a fully functional
system as specified, all of which is considered to be
subsidiary work , the cost of which is deemed to be
included in the rates stated in the Bill of Quantities for
pipes
4 Valves shall be measured by the number of each type
and size installed completed and accepted. No separate
measurement shall be made for connections to pipes or
equipment, ancillary fittings, bolts nuts and gaskets, lining
and painting, loose keys spindles and hand wheels, valve
boxes or any other items required for a fully functional
unit, all of which is considered to be subsidiary work, the
cost of which is deemed to be included in the rates and
prices for the relevant items.
5 Irrigators, including sprinklers, bubblers and emitters
(excluding drip emitter distribution tubing) shall be
measured by the number of each type and size installed,
completed and accepted. The rates stated in the Bill of
Quantities are deemed to include, as appropriate, the
costs stated in item 4, above.
6 Drip emitter distribution tubing shall be measured by
the linear meter of each size installed, completed and
accepted. The rates stated in the Bill of Quantities shall be
deemed to include, as appropriate, the costs stated in item
3 above.
copy 249
7 Irrigation program controllers shall be measured by
the number of each type or specification reference
installed. The rates stated in the Bill of Quantities shall be
deemed to include for all items and work required for a
fully operational system, including transport, electrical
installations and civil work.
8 Where spares are ordered by the Engineer, they will
be measured by number and paid for at the rates stated in
the Bill of Quantities for each type, size and class of spare
part authorized by the Engineer, purchased by the
Contractor, handed over, and accepted.

16.2.5 Basis of Payment

1 The amount of completed and accepted work
measured as provided for above, will be paid for at the
unit rates for the various items listed in the Bill of
Quantities, which unit rates shall be full compensation for
supplying, fabricating, connecting and testing, and for
labor, transport, materials, equipment, tools, and other
items necessary for the completion of the Work as
specified in Sub-section 16.2.

16.2.6 Items in the Bill of Quantities

i Pipe (type, class and diameter) lin.m.
ii Valves (type and diameter) nr.
iii Irrigation Program Controller (type) nr.
iv Irrigators (type and size) nr.
v Drip Emitter Distribution Tubing
(type and diameter) lin.m.
vi Spares for Irrigation System (type,
class and size) nr.

♦ 16-25 ♦
copy 249
copy 249
Ref. Title Page No. Ref. Title Page No.
17.1 Scope 17-1 17.3.5 Fertilization Equipment 17-11
17.3.5.1 Fertilizer Injection Equipment 17-11
17.1.1 Description 17-1
17.3.6 Instrumentation and Controls 17-11
17.2 Materials 17-1 17.3.6.1 General 17-11
17.3.6.2 Level Controller Type LC-1 17-11
17.2.1 Metalwork Generally 17-1
17.3.6.3 Pressure Gauges 17-11
17.2.2 Bolts, Inserts and Cushions 17-1
17.3.7 Method of Measurement 17-11
17.2.3 Covers and Frames 17-1
17.3.8 Basis of Payment 17-12
17.2.4 Painting Metalwork 17-1
17.3.9 Items in the Bill of Quantities 17-12
17.2.5 Piping and Appurtenances 17-1
17.2.5.1 General Requirements 17-1 17.4 Construction Requirements 17-12
17.2.5.2 Pipes and Fittings 17-1
17.4.1 Pipe Laying and Jointing 17-12
17.2.5.3 Pipe Accessories 17-2
17.4.2 Valve Installation 17-12
17.2.5.4 Jointing Material 17-2
17.4.3 Pump Installation 17-13
17.2.6 Valves and Accessories 17-3
17.4.4 Method of Measurement and Basis of
17.2.6.1 Gate Valves 17-3
Payment 17-13 
17.2.6.2 Butterfly Valves 17-3
17.2.6.3 Check Valves 17-3
17.2.6.4 Control Valves 17-4
17.2.6.5 Sundries 17-5
17.2.7 Method of Measurement 17-5
17.2.8 Basis of Payment 17-5
17.2.9 Items in the Bill of Quantities 17-5

17.3 Equipment 17-5

17.3.1 General Requirements 17-5
17.3.2 Pumps 17-6
17.3.2.1 Submersible Drainage Pump 17-6
17.3.2.2 Horizontal Pumps 17-7
17.3.2.3 High Pressure Booster Pumping Set
Employing Membrane Tank 17-7
17.3.2.4 High Pressure Booster Pumping Set
Employing Variable Speed Pumps 17-8
17.3.2.5 Duplex Sump Pumps 17-9
17.3.3 Surge Tanks 17-10
17.3.4 Overhead Material Handling
Equipment 17-10
17.3.4.1 Monorail System 17-10

copy 249
copy 249
17.1 Scope
17.1.1 Description
1 This Section describes requirements for the supply
and installation of the pumping stations, including pipe
works, pumps and other equipment, motor, control
centers, automatic controls, structural steel and other
supports, connections, valves, appurtenances and
ancillary materials, as shown on the Drawings or as
ordered by the Engineer.
2 The descriptions of materials, equipment and
construction requirements given in this Section are
generic. Particular requirements for each pumping station
shall be as stated in the Special Specification and on the
Drawings.
17.2 Materials
17.2.1 Metalwork Generally
1 Metalwork includes all purpose-made items shown
on the Drawings, including stairs, ladders, equipment
supports and the like.
2 Staircases, ladders and safety cages, shall be
fabricated from galvanized mild steel or aluminum alloy
as shown or stated in the Special Specification..
Submersed steel structures shall be fabricated from
stainless steel.
17.2.2 Bolts, Inserts and Cushions
1 Masonry expansion bolts approved types and shall
be installed in accordance with manufacturer's
instructions.
2 U-bolts shall be welded to pipes at points of contact
and bolted to structural angle frame securely fixed to
structure.
3 Embedded inserts shall be installed during
concreting.
4 Spring cushions shall be used where a horizontal
pipe is subject to considerable vertical movement or
vibration.
17.2.3 Covers and Frames
1 Cast iron covers and frames shall be to BS EN 124
Grade B, heavy duty rectangular cover and frame, coated,
locking, solid top.
2 Steel covers and frames shall be fabricated steel
checkered plate, single seal lift out type, zinc protected,
and capable of supporting a load of 5 tonnes.
17.2.4 Painting Metalwork
1 All ferrous metal surfaces shall be given one shop
coat of rust preventative paint primer and two coats of an
approved oil base or alkyd paint applied on Site, as
directed by the Engineer.
17.2.5 Piping and Appurtenances
17.2.5.1 General Requirements
1 Materials shall be supplied with the manufacturer's
certificate for each delivery, stating that products comply
with and have been factory tested in accordance with
specified Standards.
2 Unless otherwise specified in the relevant Standard,
products must have legibly cast, stamped or indelibly
painted on, the following marks, as appropriate:
- Manufacturer's name, initials and identification
mark.
- Nominal diameter.
- Class designation.
- Initials and number of relevant Standard.
- Length of pipe if shorter than standard length.
- Angle of bends in degrees.
- Date of manufacture.
3 Whenever required by the Engineer, the Contractor
shall arrange to collect samples of the materials selected
by the Engineer, and transport them to, and have them
tested by an independent Laboratory.
17.2.5.2 Pipes and Fittings
1 Ductile iron pressure pipe: flanged pipe shall
conform to BS EN 545, Class K 9.
i. Fittings shall conform to BS EN 545, pressure
rating suitable to sustain the system working
pressure.
ii. Flanged pipes shall have screwed-on or cast-on
flanges to sustain the system working pressure.
iii. Flanges shall conform to BS EN 1092 with
pressure rating suitable for the system working
pressure.
2 Factory protection for water supply pipe and fittings:
i. Coated internally and externally by dipping, or
other method, using hot applied coal tar based
material to BS 4164 or hot applied bitumen
based material to BS EN 13000.
3 Factory protection for sewerage pipe and fittings:
i. Internally: epoxy lined to ASTM C541. Lining
shall be held by centrifugal action.
ii. Externally: coated using hot applied coal tar
based material to BS 4164 or cold applied
bitumen coating to BS 3416.
4 uPVC pressure pipe: pipe shall conform to BS 3506
Class C with outside diameters to BS ISO 11922-1.
i. Fittings shall conform to BS EN 1452, injection
molded type joints shall be solvent welded to BS
EN 1452 Part 1.
♦ 17-1 ♦
copy 249
17.2.5.3 Pipe Accessories
1 Ferrous flexible pipe couplings: types shall be
straight couplings to bridge two plain ended pipes of
same outside diameter and stepped couplings for pipes of
large diametrical differences. Couplings shall be with
center register.
i. Material shall be malleable iron conforming to
BS EN 1562 grade 20/10 or rolled steel to BS 970-
060A12 with bolts to BS 970-EN3A and rubber
rings to BS EN 681.
ii. Couplings shall be able to take 6 deg. angular
deflections for sizes up to 600 mm diameter
reducing to 2 deg. for sizes up to 1800 mm
diameter.
iii. Couplings shall be factory coated with cold
applied bitumen or hot applied coal tar
conforming to BS 3416 or BS 4164 respectively,
thickness 1 mil.
2 Ferrous flanged adaptors: material shall be cast iron
body conforming to BS EN 1561 grade 14 or mild steel
plate to BS 10025 and malleable cast iron flange to BS EN
1562 grade 20/10 or rolled steel to BS 970-EN3A and
rubber rings to BS EN 681.
i. Length of adaptor shall be 200 mm for diameters
up to 150 mm, 250 mm for diameters between
200 and 300 mm and as approved by Engineer
for diameters larger than 300 mm.
ii. Adaptors shall be factory coated with cold
applied bitumen or hot applied coal tar
conforming to BS 3416 or BS 4164 respectively.
3 Flexible pipe connections: flexible connections shall
be seamless bronze tubing with annular corrugations
covered with high tensile bronze braid suitable for the
system working pressure.
i. Connections shall have screwed ends for pipes
50 mm diameter and under and flanged ends for
pipes over 50 mm diameter.
4 Flexible couplings: gasket sleeve type, shall allow
angular deflection and axial movement of two joined pipe
ends and to maintain permanent, leak-tight joint.
i. Components shall comprise one center sleeve,
two end followers or flanges, two rubber-
compounded wedge-section gaskets and
sufficient draw bolts and nuts to properly
compress gaskets. Tightening of bolts to draw
end followers together must compress gaskets in
recess between center sleeve and followers onto
pipe ends to affect positive seal.
ii. Couplings shall have diameter specifically
supplied for and to properly fit type of joined
pipe ends. Center sleeve shall be of adequate
thickness and whole coupling suitable for
minimum working pressures shown on the
Drawings.
♦ 17-2 ♦
iii. Center sleeve and followers shall be true circular
sections, free from irregularities, flat spots or
surface defects and formed from steel mill
sections with space between sleeve and follower
designed to provide confinement of gasket.
iv. Bolts shall be special steel having minimum yield
strength of 2800 kg/cm2 and ultimate strength of
2
4200 kg/cm . Bolts shall be track-head design to
prevent turning when nut is drawn up and
threads shall be rolled with a nominal diameter
larger than diameter of shank. Manufacturer
must supply information regarding
recommended torque to which bolts must be
tightened.
v. Gaskets shall be synthetic rubber-base
compound with other products to produce
material which will not deteriorate from age,
heat or exposure to air and which is resilient and
able to resist cold flows so that the joint will
remain sealed and tight indefinitely when
subjected to shock, vibration, pulsation,
temperature and adjustment of connected pipes.
vi. Coupling shall be factory painted internally with
200 microns coating of epoxy and externally with
red primer conforming to AWWA 203 Type B
chlorinated rubber solution compatible with
bitumen, coat tar and general paints.
vii. Couplings shall be assembled on site in
accordance with manufacturer's instructions to
ensure permanently tight joints under all
conditions of expansion, contraction, shifting
and settlement.
5 Dismantling couplings shall have an extensible
connection between pipe sections, and be mounted next
to valves to enable easy dismantling from pipe work or to
permit pipe joining when butterfly valve is removed for
maintenance.
i. Dismantling piece shall be flanged type
composed of two parts, one sliding into the
other, and a free flange to compress a
trapezoidal section seal to ensure water
tightness. Coupling shall have locking devices to
provide elements of complete rigidity.
ii. Construction shall be all steel with flanges
having rating matching adjoining pipes.
iii. Couplings shall have diameter specifically
supplied for and to properly fit type of joined
ends of pipes and valves. Coupling shall permit
tightening of end flanges without risk of
misalignment. Seal shall be locked after end
joints are tightened.
17.2.5.4 Jointing Material
1 Gaskets shall be elastomeric full face 3 mm thick
joint rings conforming to BS EN 681 with dimensions
conforming to BS 3063.
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2 Rings shall be elastomeric conforming to BS EN 681.
Dimensions to manufacturer's recommendations to suit
type of joint required.
3 Bolts and nuts shall be ISO metric black hexagon
conforming to BS 4190, minimum tensile strength 433
MN/m2, maximum elongation 17%. After fixing, bolt
projection shall be maximum 6 mm, minimum 3 mm.
4 Washers shall be black steel conforming to BS 4320.
5 Dielectric Joints shall have insulating neoprene or
phenol gasket between flanges and phenol or
polyethylene sleeves and washers between bolts, nuts
and flanges. Joints shall be suitable for the operating
pressure of the system.
17.2.6 Valves and Accessories
17.2.6.1 Gate Valves
1 Cast iron gate valves: type shall conform to BS 5163,
inside screw, solid wedge, resilient seated, bolted bonnet,
non-rising stem type, suitable for the system working
pressure.
2 Material of component parts shall be from basic or
alternative materials listed in BS 5163.
3 End connections shall be as shown on the Drawings.
Flanged end connections shall conform to BS EN 1092.
Plain end connections shall be machined to suit joints
specified for adjoining pipes.
4 Casting surfaces shall be given an initial coat of
protective paint immediately after shot blasting and a
second coat on assembly. Protective coating shall be hot
applied coal tar or cold applied bitumen conforming to BS
4164 or BS 3416 respectively. Thickness of coat shall be 1
mil.
17.2.6.2 Butterfly Valves
1 Cast iron butterfly valves: type shall conform to BS
EN 593 with resilient seating suitable for system working
pressure. Component parts shall be from basic materials
listed in BS EN 593 Table 3.
2 For valves 100 mm and smaller, operation shall be by
lever arm. For sizes above 100 mm and up to 250 mm,
operation shall be by hand wheel. For valves 300 mm and
larger shall be gear operated.
3 Casting surfaces shall be given an initial coat of
protective paint immediately after shot blasting and a
second coat on assembly. Protective coating shall be hot
applied coal tar or cold applied bitumen conforming to BS
4164 or BS 3416 respectively. Thickness of coat shall be 25
microns.
17.2.6.3 Check Valves
1 Cushioned check valves: type shall be cushioned
type, counter-weighted metal seated check with attached
cushion chamber to permit valve to close without slam or
bang. Valve shall have a pressure rating suitable for the
system working pressure.
i. Cast iron body shall conform to ASTM 126 Class
B or cast steel body to ASTM 216 Class WCB
depending upon working pressure and with
stainless steel seat ring to ASTM A157 C9 non-
corrosion shaft for attachment of weight and
lever and complete non-corrosion shock less
chamber to ASTM B 62. Valve shall be tight
seating and seat ring shall be removable.
Cushion chamber shall be attached to side of
valve body and constructed with a piston
operating in a chamber to permit valve to
operate without hammering action. Shock
absorption shall be by dry air and cushion
chamber shall be arranged for closing speed to
be adjustable to meet service requirements.
Valve disc shall be of same material as valve
body and shall be suspended from a stainless
steel type 303 shaft connected to the cushion
chamber through a stuffing box.
ii. End connections shall be as shown on the
Drawings. Flanged end connections shall
conform to BS EN 1092.
iii. Valves shall be factory protected with an internal
coating of epoxy to a thickness of 120 microns
and external coating of epoxy and nickel plating
to a thickness of 120 microns.
2 Cast iron check valves: type shall conform to BS EN
12334, swing straight pattern, for vertical use and with
pressure rating suitable for the system working pressure.
i. Material of component parts shall be from basic
materials listed in BS EN 12334 Table 5, under
'copper alloy faced'.
ii. Seating or facing rings shall be renewable. An
arrow showing direction of flow shall be visible
from outside and cast integral with the valve
housing.
iii. End connections shall be as shown on the
Drawings. Flanged end connections shall be to
BS EN 1092.
iv. Casting surfaces shall be given at factory an
initial coat of protective paint immediately after
that blasting and a second coat on assembly.
Protective coating shall be hot applied coal tar or
cold applied bitumen to BS 4164 or BS 3416
respectively. Thickness of coat shall be 1 mm.
3 Silent check valves: type shall be non-slam, spring
loaded and suitable for installation in any position.
i. Valves 50 mm diameter and under shall be
screwed, with bronze body, seat and disc, 18-8
stainless steel spring, with pressure rating
suitable for the system working pressure.
ii. Valves over 50 mm diameter shall be flanged,
with cast iron body, bronze seat and disc, 18-8
stainless steel spring, with pressure rating
suitable for the system working pressure.
iii. Valves shall have straight guided disc with two-
point bearing. Wearing parts including discs,
♦ 17-3 ♦
copy 249
 seats and other guide bushings shall be
replaceable.
iv. Valves shall have flow area in excess of pipe area
for minimum pressure drop.
17.2.6.4 Control Valves
1 General: pump control valves, and surge control
valves, shall be automatic, hydraulically operated, pilot
controlled, piston actuated, single seated, globe or angle
pattern as shown on the Drawings, consisting of valve
body, piston assembly and cover with the piston assembly
as the only moving part. Valves shall be sized for pressure
rating shown on the Drawings and shall be the product of
a reputable, approved manufacturer.
i. Valve body shall be cast steel to ASTM A216
WCB standard, flanged, with flange rating as
shown on the Drawings and containing a
removable seat insert. Main valve trim shall be
bronze to ASTM B 61.
ii. Piston assembly shall be fully guided on its
outside diameter by long stroke stationary V-
ports downstream of seating surface to minimize
consequence of throttling. Piston shall be
bronze to ASTM B 62 with seal of stainless steel
to AISI 140.
iii. Repairs shall be possible without removing valve
from line. Valve shall have no external packing
glands or stuffing boxes.
iv. Valve shall be supplied complete with factory
fitted pilot valves, small interconnecting piping
and accessories to perform required functions.
Pilot control system shall be stainless steel to
AISI type 303.
v. Factory protection shall be internal coating of
epoxy to a thickness of 120 microns and external
coating of epoxy and nickel plating to a thickness
of 120 microns.
vi. Provide manufacturer with necessary and
pertinent data for setting control valves, at
factory, to required settings to suit individual
conditions of different pumping stations.
vii. Prior to shipping valves from factory, submit
shop drawings for approval giving factory
settings, range of adjustments, control diagram,
wiring diagram, size, arrangement and other
pertinent data necessary for approval by the
Engineer of every control valve in the system.
Submit with the shop drawings detailed
instructions for field adjustment and setting,
installation, start-up and proper operation.
viii. Each control valve shall be tested individually at
factory and certified test results submitted.
ix. Provide the services of a specialized factory
technician or engineer to set, test, adjust and
commission the control valves as specified.
x. Control valve pressure rating shall be suitable to
system working pressure.
♦ 17-4 ♦
2 Surge control valves: type shall be straight pattern,
specifically designed to prevent excessive surge pressures
in event of power failure. Valve shall have pilots to cause
valve to open on either low pressure or high pressure
wave. Under normal operation, valve acts as relief valve
which can be set to open at any pressure above normal
operating pressure. At the same time, valve shall open at
any set pressure below its normal operating pressure.
i. Function shall be such that on power failure,
valve opens on initial down-surge in pressure (if
this surge is not already controlled by surge
chamber) and remains open until high pressure
wave returns and passes through valve without
generating a large up-surge in pressure. After
high pressure wave has passed, valve closes
slowly in 2 minutes to prevent further pressure
surges. Valve also opens on high pressure
unless surge has been attenuated by surge
chambers.
ii. Operation shall be on differential piston principle
such that area on underside of piston is no less
than pipe area, and area on upper surface of
piston is of greater area. Valve shall operate in
any position without assistance of springs.
iii. Valve size shall be as shown on the drawings and
pressure rating shall be suitable for system
operating and anticipated maximum surge
pressure. Valve shall be of extra heavy
construction throughout with body of cast steel
to ASTM A216 WCB and flanges conforming to
ANSI standards. Internal trim shall be bronze to
ASTM B 62. Piston shall be guided on its outside
diameter by long-stroke stationary V-ports
downstream of seating surface to minimize
consequence of throttling. Piston shall be
bronze and pilots stainless steel. Valve shall
contain rubber removable seat insert.
iv. Repairs shall be possible without removing valve
from line. Valve shall have no external packing
glands or stuffing boxes.
v. Pilots and accessories shall include the following:
- Low pressure pilot.
- Pressure relief pilot.
- Flow limiting device.
- Needle valves.
- Strainer.
- Check valve.
- Valve position indicator.
- Pipe plug for pressure gauge.
- Shut-off cocks.
- Interconnecting copper tubing and unions.
- Pilot mounting bracket.
- Other accessories recommended by
manufacturer.
copy 249
 vi Factory protection shall be complete epoxy (iii) uPVC pressure pipe
coating for protection against corrosion. (state size) (lin.m.)

17.2.6.5 Sundries (iv) Gate Valves (state

size) (nr.)
1 Hose Bibb: shall be a chrome plated metal bibcock,
15 mm male back inlet connection and 15 mm male, hose (v) Butterfly Valves (state
thread outlet, with 15 mm chrome plated metal hose size) (nr.)
coupling female threaded. (vi) Check Valves (state
size) (nr.)
17.2.7 Method of Measurement
(vii) Silent Type Check
1 Metalwork including but not limited to staircases, Valves (state size) (nr.)
ladders, and safety cages; bolts, inserts and cushions;
covers and frames; shall each be measured by number of (viii) Control Valves (state
each item installed. Rates shall include for factory and on- size) (nr.)
site tests, fixings, preparing, priming and painting.
(ix) Surge Control Valves
2 Pipes shall be measured by linear meter of each type (state size) (nr.)
and size of pipe. Measurement shall be of the center line
of pipes (overall), couplings, fittings and branches. Rates (x) Cushioned Type Check
for pipes shall be deemed to include all related pipe work, Valves (state size) (nr.)
including but not necessarily limited to:
- Flexible pipe couplings adaptors and
connections. 17.3 Equipment
- Header pipes and dismantling couplings,
- Purpose made pipes and purpose made fittings.
17.3.1 General Requirements
- Everything necessary for jointing.
- Bends, tees, joints, unions, flanges, and pipe 1 Materials and products: materials for pumps shall be
fittings including cutting and jointing pipe to suitable for pump operating conditions and adequate for
fittings, valves and equipment. total heads to which pumps are subjected. Corrosion
- Pipe supports and support assemblies, hangers, resistant materials shall be used. Assembly arrangements
clips, anchors and guides. shall include isolation of dissimilar metals to avoid
- Wrapping and waterproofing of underground galvanic interaction.
and or exposed pipes. 2 Pumps shall have factory plugged connections for
- Pipe sleeves and packing. casing vent, drain and suction and discharge pressure
- Pipe cleaning priming and painting. gauges.
- All other pipe and pipe work ancillaries’
3 Impellers and rotating assemblies shall be statically
necessary required or reasonably inferred.
and dynamically balanced at factory.
3 Valves shall be measured by the number of each 4 Packing rings shall be installed in alternate layers
type installed. Rates shall be deemed to include for factory staggered 90 degrees. Packing shall be tightened for seal
and on-site test, tests at independent laboratories, all while permitting prescribed amount of leakage for
fixing and jointing accessories. lubrication.
5 Pumps shall have shaft packing or mechanical seals
17.2.8 Basis of Payment compatible with pump design and nature of liquid
1 The amount of completed and accepted work as pumped in accordance with manufacturer's
provided above shall be paid for at the unit rates for the recommendations or as specified.
items describes in the Bill of Quantities and shall include 6 Pump operating point of specified flow and head
for furnishing all materials, installation, civil, mechanical, shall fall near the point of maximum efficiency as obtained
electrical, piping and miscellaneous works, testing, from manufacturer's published data.
commissioning, and putting into operation, maintenance
7 Horsepower rating of pump drive motor shall ensure
and all labor, transport, equipment, tools, supplies and
non-overloading of motor throughout capacity range of
other items necessary for the proper completion of the
pump for impeller diameter selected.
work as specified.
8 Electric motors shall be suitable for available electric
17.2.9 Items in the Bill of Quantities current voltage and frequency. Motor speeds shall not
exceed 1450 rpm for 50 Hz. Motors shall be designed to
(i) Metal works (Type) Lump Sum operate in 50oC ambient temperature.

(ii) Ductile Iron pressure pipe

(state size) (lin.m.)

♦ 17-5 ♦
copy 249
9 Shop drawings: The Contractor submit shop
drawings for each pump for approval, prior to shipment
from factory, as follows:
- Certified performance curves showing job
number, customer and customer order number,
pump designation number shown on the
drawings, date of manufacture, model number,
pump size, impeller diameter, impeller type,
maximum impeller diameter pump can
accommodate, rpm, noise data, flow-head
characteristic curve, consumed horsepower
curve and pump efficiency curve.
- Pump cross-sectional drawings showing major
components with parts numbers and parts list.
- Pump outline dimensional drawing showing
overall dimensions, location of foundation bolt
holes and sizes, location and rating of suction
and discharge nozzles.
- Recommended list of spare parts, where not
specified elsewhere.
- Installation, operation and maintenance
instruction manual.
- Details and wiring diagrams of factory supplied
pump controllers, starters, controls or other
electrical device or accessory.
- Special instructions for field installation and
connection of factory or field supplied electrical
device, control or accessory.
10 Shop tests: The Contractor shall submit for each
pump, certified results of shop tests made by
manufacturer, prior to shipment from factory, as follows:
- Performance test throughout capacity range of
pump with specified design operating point
clearly indicated on pump flow-head
characteristic curve.
- Hydrostatic pressure test to 1-1/2 times shut-off
pressure of pump.
11 Pump test report shall include the following
information:
- Pump data: pump designation number shown on
the Drawings, model number, serial number,
customer order number, flow, suction and
discharge pressures, shut-off pressure, rpm and
brake horsepower.
- Motor data: make, model number, serial number,
horsepower rating, rpm, voltage, phase,
frequency, class of insulation, allowable
temperature rise, full load amperes, locked rotor
amperes and actual voltage and amperes at all
test points.
- Starter data: make, model number, size, heater
sizes, ampere rating, line voltage, control voltage
and frequency.
♦ 17-6 ♦
17.3.2 Pumps
17.3.2.1 Submersible Drainage Pump
1 Non-clog, centrifugal, submersible, with guide-rails,
quick-disconnect type, suitable for drainage water
application and designed to permit quick and easy ground
level removal of pump from pit for service or inspection
without disconnecting or disturbing discharge piping and
electrical connection. Pump design shall permit pump to
be automatically connected to discharge elbow in a tight
and leak-proof manner without axial or lateral movement
and without further adjustment. Pump shall be designed
to withstand dry running.
2 Each pump shall be supplied complete with the
following:
- Close-coupled submersible vertical electric
motor.
- Required length of durable multi-conductor
waterproof electric cable.
- Special quick disconnect flange elbow with
integral bracket for floor mounting and lower
guide rail holder.
- Required length of stainless steel guide rails.
- Upper guide rail bracket.
- Rail guided lifting assembly.
- Lifting yoke and stainless steel chain for raising
and lowering pump.
3 Casing shall be cast iron volute, to ASTM A48 Class
35B or BS EN 1561 Grade 260, horizontally split.
Passageways shall permit smooth flow of liquid served
and shall be free from sharp turns and projections. Pump
volute bottom and impeller shall have easily replaceable
stainless steel wear rings.
4 Impeller shall be cast iron to ASTM A48 Class 35B or
BS EN 1561 Grade 260, single channel type running in
volute, capable of passing solids with 75mm diam.,
suitable for service required, non-clog and dynamically
balanced for smooth operation. Impeller parts and
internal parts including studs, nuts and screws shall be
stainless steel.
5 Mechanical seal system shall consist of two
independent seal assemblies and of materials suitable for
the application.
6 Motor shall have Class F insulation, designed for use
in hazardous locations, suitable for continuous duty, with
horsepower to ensure non-overloading of motor
throughout capacity range of pump. Motor shall have cast
iron frame, stainless steel shaft, double mechanical shaft
face seals of carbon/tungsten carbide, built-in thermal
overload protection and moisture sensing probes. Motors
shall be dimensioned to be sufficiently cooled by
surrounding environment or pumped media.
7 Pump and motor bearings shall be heavy-duty,
permanently lubricated and sealed ball bearing type, not
requiring re-lubrication on site.
copy 249
8 Pump shall be supplied from factory with required
number of level regulators of the pear-shaped type, with
internal coated type switch and weighted to be vertical in
air and horizontal in water without floating. Regulator
shall have three contacts to make it suitable for either
starting or stopping motors. Regulators shall have
necessary lengths of three-core electric cable and both
regulator case and cable insulation shall be non-corrosive
material resistant to and for application in liquid served.
Level regulators shall be supplied from factory with
special cable holder bracket designed to guide and
support power and level regulator cable. Level regulators
shall start and stop pumps at pre-set levels through the
control panel. Levels shall be shown on the Drawings. In
the event of a fault in one pump, control panel shall switch
off defective pump give an alarm signal and start stand by
pump. Starting sequence of pumps shall be automatically
alternated through the control panel.
9 Pump motor control panel shall be weatherproof and
suitable for outdoor installation, minimum IP 55 enclosure
protection, with lockable cover and completely assembled,
wired and tested at factory ready for installation with
simple external electrical connections. Panel shall contain,
but is not necessary limited to, the following:
- Motor starters.
- Over-riding starter buttons.
- Indicating lamps for pump in operation.
- Reset buttons for overload relays.
- Electric alternator for required number of pumps.
- 24 V control circuit transformer.
- Running hour meters to record time each pump
is in operation.
- Accessories required for automatic operation of
pumps.
- Auxiliary volt free contacts for remote
monitoring and alarms.
- Water level meter for water level in well.
10 Impeller and pump outer casing shall be factory
protected by shot blasting and priming with epoxy
suitable for duty. Casing shall then be given two coats of
epoxy resin, to 125 microns thickness each coat.
17.3.2.2 Horizontal Pumps
1 Description: Horizontal, base-mounted, centrifugal,
flexible-coupled, rated for minimum 1.5 times the working
pressure.
2 Pumps shall be end suction, horizontal multi-stage,
or split case pumps, type as required by the Drawings.
3 End suction pumps: shall be back-pull-out, radial split
case design.
4 Split case pumps: shall be of axially split casing
design.
5 Construction Features
i. Casing: Cast iron, with integral feet or other
means on volute to support weight of casing and
attached piping.
ii. Impeller: ASTM A48 Class No 25 A or higher cast
iron, statically and dynamically balanced, closed,
single suction, keyed to shaft, and secured by
locking cap screw.
iii. Wear Rings: Replaceable type with material
suitable for the application.
iv. Shaft and Sleeve: High grade stainless steel shaft
and rated for minimum 1.5 times the working
pressure, and high-grade stainless steel sleeve.
v. Seals: Mechanical, with carbon-steel rotating
ring, stainless-steel spring, ceramic seat, and
flexible bellows and gasket.
vi. Coupling: Flexible-spacer type, capable of
absorbing torsion vibration and shaft
misalignment; with flange and sleeve section
that can be disassembled and removed without
removing pump or motor.
vii. Coupling Guard: Galvanized steel, removable,
and attached to mounting frame.
viii. Mounting Frame: Factory coated welded-steel
frame and cross members, factory fabricated
from ASTM A36/A36M channels and angles.
Fabricate for mounting pump casing, coupling
guard, and motor. Field-drill motor-mounting
holes for field-installed motors.
6 Motor: Secured to mounting frame, with adjustable
alignment. Motors: IP 55, squirrel cage induction type, and
fan cooled. Cooling fans shall be bi-directional so that
cooling is independent of direction of rotation and shall be
fabricated from non-rusting and non-sparking material.
7 Motors shall have high efficiency and high power
factor at full load. All motors shall meet or exceed the
minimum efficiencies stated in the highest level in the EU
agreement of the LV motors (EFF1/EFF2). All motors shall
bear the IEC reference and CE marking on the motor
nameplate.
8 All motors shall be suitable for continuous heavy-
duty application with a minimum service factor of 1.25;
alternatively, the next larger IEC motor size shall be
selected.
9 Motors shall be full voltage direct-on-line start.
10 Motor Insulation shall be class F, non-hygroscopic,
Class H varnish.
11 Motor temperature rise shall be limited to 70°C
above the maximum ambient temperature of 50°C, as
measured by resistance
17.3.2.3 High Pressure Booster Pumping Set Employing
Membrane Tank
1 Packaged type, comprising multiple close-coupled
pumps, membrane tank, interconnecting pipe work, valves,
pressure switches and electrical control panel all
completely assembled on steel frame, piped, wired and
delivered as a complete packaged unit ready for
♦ 17-7 ♦
copy 249
installation and operation with simple piping and electrical
connections. One of the pumps shall be stand-by pump
2 Pumps shall be close-coupled, centrifugal, single or
multiple stage type, horizontally or vertically mounted and
driven by electric motor at specified rpm. Pumps shall
have self-adjusting mechanical seals with carbon rotating
face running against stationary ceramic seat. Pumps shall
have close-grain cast iron or stainless steel casing and
mechanical seal housing, gunmetal, cast bronze, or
stainless steel impeller and stainless steel shaft.
3 When the duty pumps are running together, they
shall supply the maximum demand specified, with the
remaining pump acting as stand-by. Under low demand
conditions one pump shall supply sufficient water, with
remaining duty pumps acting as back up. Controls shall
automatically start second duty pump when one pump is
unable to supply demand and shall cut in stand-by pump
on failure of any of the duty pumps.
4 Motor shall be totally enclosed, fan cooled, drip proof,
squirrel cage type, weatherproofed construction for
operation in specified ambient temperatures. Motor
horsepower shall ensure non-overloading of motor
throughout capacity range of pump.
5 Membrane tank shall be welded mild steel plate,
suitable for system operating pressure constructed in
accordance with BS EN 286-1, Part 1, with cylindrical shell
and convex dished ends. Membrane tank shall contain
removable rubber bag and shall be pressurized with air at
factory to correct system operating pressure to provide
sealed air cushion eliminating use of air compressor.
Tank shall have air valve of type permitting recharging on
site by small hand compressor or simple car type pump.
Rubber bag shall be guaranteed suitable for intended use
without deterioration and without bursting.
6 Membrane tank shall be complete with factory
fabricated steel legs welded to tank before testing, air-
charges connection, pressure relief valve and pressure
gauges.
7 Pumping set shall be automatically controlled by
pressure switches to start pumps on fall of pressure in
tank and stop pumps on rise of pressure.
8 Interconnecting pipe work shall be galvanized steel
pipe and fittings to ASTM A53 schedule 40. Valves shall be
threaded, with bronze body and trim and have a pressure
rating suitable for system working pressure. Each pump
shall have swing type, non-return valve at discharge,
adjustable pilot-operated pressure regulating value at
discharge, adjustable individual suction and discharge
shut off valves, Discharge manifold shall have pressure
switches, pressure gauge and vent cock.
9 Control panel shall be heavy gauge mild steel sheet
finished with stove hammer paint internally and externally,
with minimum IP 55 enclosure rating. Control panel shall
be automatic, with load control and protection function
and shall contain, but shall not be necessarily limited to,
the following:
♦ 17-8 ♦
- Mounting and Wiring: Factory installed and
connected as an integral part of unit.
- Enclosure: IP 55.
- Motor Controller: Full-voltage, combination-
magnetic type with under-voltage release feature,
motor-circuit-protector-type, and short-circuit
protective device.
- Motor Overload Protection: Overload relay in
each phase.
- Starting Devices: Hand-off-automatic selector
switch in cover of control panel, plus pilot device
for automatic control.
- Multi-pump, Sequence (Lead-Lag-Lag) Starter:
Switches lead pump to one lag main pump and
to multi-pump operation.
- Instrumentation: Unit suction and discharge
pressure gauges.
- Alarm Signal Device: Sounds alarm when
backup pumps are operation.
- Pump Duty Alternation Device: Switches the lead
pump.
10 Mounting frame shall be mild steel hollow section
members reinforced against deflection and with bolt holes.
Steel surfaces shall be factory protected by shot blasting,
zinc sprayed to 75 microns thickness and given one coat of
priming paint. External steelwork shall have one
undercoat and one top coat chlorinated rubber paint of
approved color to 75 microns thickness each coat. Internal
steelwork shall have two coats black bitumastic paint, 125
microns thickness each coat and suitable for service.
17.3.2.4 High Pressure Booster Pumping Set Employing
Variable Speed Pumps
1 Packaged type, comprising multiple close-coupled
pumps, membrane tank, interconnecting pipe work, valves,
pressure switches and electrical control panel all
completely assembled on steel frame, piped, wired and
delivered as a complete packaged unit ready for
installation and operation with simple piping and electrical
connections. One of the pumps shall be stand-by pump
2 Pumps shall be close-coupled, centrifugal, single or
multiple stage type, horizontally or vertically mounted and
driven by electric motor at specified rpm. Pumps shall
have self-adjusting mechanical seals with carbon rotating
face running against stationary ceramic seat. Pumps shall
have close-grain cast iron or stainless steel casing and
mechanical seal housing, gunmetal, cast bronze, or
stainless steel impeller and stainless steel shaft.
3 When the duty pumps are running together, they
shall supply the maximum demand specified, with the
remaining pump acting as stand-by. Under low demand
conditions one pump shall supply sufficient water, with
remaining duty pumps acting as back up. Controls shall
automatically start second duty pump when one pump is
copy 249
unable to supply demand and shall cut in stand-by pump plus pilot device for automatic control. Retain
on failure of any of the duty pumps. one of first two subparagraphs below.
4 Motors: Variable speed, with pre-greased, a. For duplex boosters, Automatic, Alternating
permanently shielded, ball-type bearings. Select motors Starter: Switches lead pump to lag main
that will not overload through full range of pump pump and to two-pump operation.
performance curve.
b. For triplex or multiplex boosters, Sequence
5 Membrane tank shall be welded mild steel plate,
(Lead-Lag-Lag) Starter: Switches lead pump
suitable for system operating pressure constructed in
to one lag main pump and to three-pump
accordance with BS EN 286-1, Part 1, with cylindrical shell
operation.
and convex dished ends. Membrane tank shall contain
removable rubber bag and shall be pressurized with air at vi. Pump Operation and Sequencing: Pressure-
factory to correct system operating pressure to provide sensing method.
sealed air cushion eliminating use of air compressor.
Tank shall have air valve of type permitting recharging on a. Time Delay: Controls pump on-off
site by small hand compressor or simple car type pump. operation; adjustable from 1 to 300 seconds.
Rubber bag shall be guaranteed suitable for intended use vii. VFC: Voltage-source, pulse-width, modulating-
without deterioration and without bursting. frequency converter for each pump.
6 Membrane tank shall be complete with factory
viii. Manual Bypass: Magnetic contactor arranged to
fabricated steel legs welded to tank before testing, air-
transfer to constant-speed operation upon VFC
charges connection, pressure relief valve and pressure
failure.
gauges.
7 Pumping set shall be automatically controlled by ix. Instrumentation: Suction and discharge pressure
pressure switches to start pumps on fall of pressure in gages.
tank and stop pumps on rise of pressure. x. Lights: Running light for each pump.
8 Interconnecting pipe work shall be galvanized steel
xi. Alarm Signal Device: Sounds alarm when
pipe and fittings to ASTM A53 schedule 40. Valves shall be
backup pumps are operating.
threaded, with bronze body and trim and having a
pressure rating suitable for system working pressure. a. Time Delay: Controls alarm operation;
Each pump shall have swing type, non-return valve at adjustable from 1 to 300 seconds, with
discharge, adjustable pilot-operated pressure regulating manual reset.
value at discharge, adjustable, individual suction and
discharge shut off valves, Discharge manifold shall have xii. Thermal-bleed cutoff.
pressure switches, pressure gauge and vent cock. xiii. Low-suction-pressure, Water-storage-tank, low-
9 Control Panel: Factory installed and connected as an level cutout.
integral part of booster pump; automatic for multiple-
10 Where shown on the Drawings or Schedules, motor
pump, variable-speed operation, with load control and
control panels shall any or all of the following:
protection functions.
i. High-suction-pressure cutout.
i. Control Logic: Solid-state system with
transducers, programmable microprocessor, ii. Low-discharge-pressure cutout.
VFC, and other devices in controller. Install VFC
iii. High-discharge-pressure cutout.
for pump motors larger than 25 Hp in separate
panel; same type as motor control panel 17.3.2.5 Duplex Sump Pumps
enclosure.
1 Components shall comprise two pumps, float switch
ii. Motor Controller: NEMA ICS 2, variable- assembly with mechanical alternator, high water alarm
frequency, solid-state type. Some manufacturers and electric control panel.
may offer low-voltage controls. Revise "Control
2 Pump shall be vertical, centrifugal, wet pit type, self
Voltage" Subparagraph below if required.
lubricating, to rest directly on sump floor, with vertical
motor connected to pump with steel tubular shaft housing.
a. Control Voltage: 220 V AC, with integral
control-power transformer. 3 Pump shall be supplied complete with the following,
factory assembled to form a self-contained, compact unit
iii. Enclosure: NEMA 250. ready for operation with simple discharge piping and
iv. Motor Overload Protection: Overload relay in electrical connections:
each phase. - Cast iron combination base and suction strainer.

v. Starting Devices: Hand-off automatic selector - Cast iron motor head box.
switch for each pump in cover of control panel,

♦ 17-9 ♦
copy 249
 - Cast iron motor adaptor flange designed to carry
motor and float switch.
- Steel tubular shaft housing.
- Electric motor.
- Unsinkable plastic float and stainless steel rod.
- Adjustable stops and counter-weight.
4 Casing and cover shall be close grained cast iron
volute of uniform quality, free from blow-holes, porosity
shrinkage defects, cracks and other defects.
5 Impeller shall be cast iron volute to ASTM A 48 Class
35B or BS EN 1561 grade 260, heavy open non-clog type
design, statically and dynamically balanced, over hung,
single suction, keyed and securely locked to stainless steel
shaft of size to transmit required power without distortion
or vibration. Pump shaft shall be directly connected to
motor shaft through a flexible coupling. Motor adaptor
flange shall be machined to close tolerances to ensure
permanent alignment between pump and motor.
6 Pump shall be fitted at drive end of shaft with grease
packed, deep groove, self-aligning, radial thrust ball
bearing, mounted in dust-proof housing machined in
motor support base and having moisture proof seal
protection from sump vapors. Pump shall also have
bottom column bearing of renewable water-lubricated
type.
7 Motor shall be vertical, totally enclosed, squirrel cage,
induction type, permanently lubricated with sealed ball
bearings. Motor horsepower shall ensure non-overloading
of motor throughout capacity range of pump. Motor shall
be suitable for continuous operation in ambient
temperature specified.
8 Operation shall be automatic, float switch operated,
alternating start-up sequence. One pump shall be
intended for normal operation, while the other for backup.
Standby pump shall start if abnormal flow exceeds one
pump capacity and in the event of a fault in other pump.
Fault condition in a pump or if flow exceeds pumping
capacity shall actuate an alarm.
9 Float switches shall be base mounted, contact type,
enclosed in drip-proof and splash-proof enclosure.
10 Starters shall be totally enclosed, wall mounted,
direct on-line type with no-volt and overload protection
and suitable for automatic operation.
11 Control panel shall be wall mounted, watertight,
completely assembled, wired and tested at the factory and
ready for installation with simple connections.
12 Control panel shall have minimum IP 55 enclosure.
13 Control panel shall contain all necessary accessories
for duplex pump operation, including, but not necessarily
limited to the following:
- Main incoming isolating switch.
- Magnetic trip circuit-breakers.
- Magnetic starters.
- Overload relays with thermal unit
- Hand- off automatic selector switches.
♦ 17-10 ♦
- Electric alternator between duty and stand-by.
- High and low level alarms.
- 24 V control circuit transformer.
- Manual reset fail-safe alarm circuits.
- Pilot lights.
- Moisture sensing relay.
- Loss of power alarm unit.
- Auxiliary, volt free, contracts for remote
monitoring and alarms.
14 Cables, wiring and conduits shall be provided as
necessary for connecting control panel to pumps, float
switch assembly and alarm unit. Make connection as per
manufacturer's wiring diagram.
15 Impeller and pump outer casing shall be factory
protected by shot blasting and priming with suitable
epoxy. Casing shall then be given two coats of epoxy resin,
to 125 microns thickness each coat.
17.3.3 Surge Tanks
1 The membrane tank shall contain an interchangeable
bladder and be pre-charged with air at the factory to
correct pressure to provide a sealed air cushion
eliminating use of an air compressor. Tank shall have air
valve to permit recharging on site by small compressor.
Bladder shall be guaranteed by manufacturer for use on
pumped fluid without deterioration with time, and without
bursting. Tank shall be welded mild steel plate for
operating pressure of 16, 25, and 40 bars (as shown on
drawings), with cylindrical shell and convex dished ends,
shot blasted and painted internally with bitumastic paint
and externally with zinc primer and hammer enamel paint.
2 The tank shall be horizontally installed and shall be
supplied from factory complete with the following
accessories:
i. Access manholes.
ii. Hoisting hooks.
iii. Inflator valve.
iv. Flange and counter flange for fixing of the
bladder.
v. Flanged water connection.
vi. Pressure gauge.
vii. Level gauge system.
17.3.4 Overhead Material Handling
Equipment
17.3.4.1 Monorail System
1 System shall comprise a carrier with electric hoist
attached, for picking up the load at one point and
transporting it to destination on overhead tracking system
without re-handling.
copy 249
2 Suspension system shall comprise hanger rod
assemblies with ball-and-socket or T-type joints, flexibly
constructed so that carrier wheels always contact rail on
each side. Rail shall be sufficiently thick to carry load and
provide for wear with safety factor of 5.
3 Hoist and trolley shall be of low head- room
construction to permit maximum lifting and shall
comprise standard assemblies with interchangeable parts.
Hoist ropes shall be retained in position in drum grooves
by encircling spring-loaded steel rope bands and high
grade gunmetal rope guards. Rotating shafts shall be
splined to receive gears and mounted on ball journals.
Gears shall be protected by readily removable sheet steel
covers.
4 System shall be medium duty with 5 tonnes lifting
capacity, 10 meters standard lift and lifting speed 8 meters
per minute with 10% creep speed.
5 Trolley hoist shall be electrically operated, self-
aligning, low head-room type comprising hoist and trolley
in compact unit designed to run on lower flange of I-beam
with travelling speed of trolley 20 meters per minute.
6 Lifting mechanism shall comprise shock resistant
steel frame, with suspension members and covers, gear
drive system, positive action load brake, lifetime
lubricated and sealed bearings and drop forged alloy
swivelling and rocking load safety hook.
7 Trolley shall be electrically driven, with size to fit I-
beam girder and with alloy cast iron wheels, heat treated
and machined to uniform diameter, mounted on sealed
heavy duty precision-machined anti-friction roller or ball
bearings lubricated for life. Trolley brakes shall have 50%
torque.
8 Hoist motion brakes shall stop motion under all
service and weather conditions, with lining material
producing constant coefficient of friction, not wearing
rapidly and not scoring. Brakes shall have 150% torque of
nameplate rating of hoist motor.
9 Controls shall be selective push-button control for
floor operation with emergency stop button, and designed
to NEMA Standards.
10 Electric motors shall be totally enclosed, fan cooled,
squirrel cage type, weatherproof and tropicalized (IP56
Class F insulation) for operation in ambient temperatures
up to 50 deg. C.
11 Steel surfaces shall be factory painted with one coat
etch primer and one coat gloss finish paint.
12 Safe working load shall be clearly marked in large
print on unit in English and Arabic.
17.3.5 Fertilization Equipment
17.3.5.1 Fertilizer Injection Equipment
1 Injector shall be of the Venturi type bypassed on the
main pipeline. The system shall consist of a fertilizer tank
with a minimum capacity of 1000 kg of dry chemical
fertilizer, having a hinged pressure-tight cover. The
connections from the tank to the pipeline shall be sized so
as to allow the required quantity of fertilizer to be
dissolved and dispersed in 45 minutes with normal group
operation.
2 All parts in contact with fertilizer shall be in corrosion
resistant material.
3 The Contractor shall provide spares suitable for a
period of 5 years pumping operations in accordance with
the manufacturer’s recommendations.
17.3.6 Instrumentation and Controls
17.3.6.1 General
1 The Contractor shall submit complete control and
wiring diagrams for control systems for approval showing
control instruments, auxiliaries and accessories.
2 The Contractor shall provide accessories and
appurtenances as necessary and appropriate to
accomplish intended control functions, irrespective of
whether or not shown or specified, including switches,
relays, transformers etc.
3 The Contractor shall provide control wiring and
conduits as necessary and appropriate for complete
control systems, to the requirements of this Section as
directed by the Engineer.
4 Indicating instruments including pressure gauges
and level indicators shall each have a range such that
normal readings are indicated in middle of instrument
range.
5 Pressure gauges shall have a brass cock on inlet.
17.3.6.2 Level Controller Type LC-1
1 Controller shall be electrode type, using semi-
conductor technology, designed to be installed in wet
sump, to start and stop pump or to give high or low level
alarm signal.
2 Components shall include rigid electrode and control
head with power supply/relay circuit board and heavy
duty housing.
17.3.6.3 Pressure Gauges
1 Pressure gauges shall be Bourdon tube type,
minimum 100mm dial diameter, with flangeless back and
12 mm male threaded bottom connection, and graduated
in bars with 0.1 bar divisions.
2 Components shall include black finished cast
aluminium case; threaded black epoxy cast aluminium
ring with gasketed flash face, type 316 stainless steel
spring tube, stainless steel precision movement and
micrometer adjustment on needle.
17.3.7 Method of Measurement
1 Equipment and ancillaries are given separately and
measured by the number of each type installed. Rates for
equipment and ancillaries are deemed to include, but not
limited to :
- Factory assembled components and controls.
♦ 17-11 ♦
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 - Loose equipment supplied by the manufacturer.
- Electrical connection and wiring.
- Supports and fixation including supporting steel
work or concrete work.
- Valves, strainers, flexible connections, controls,
instruments and fittings as shown on the
Drawings.
- Loose keys, tools and spare parts as specified.
- Factory and on-site tests and test reports
- Shop drawings, diagrams, instruction
maintenance manuals
2 Monorail system shall be measured as a Lump Sum,
complete, installed, tested, and accepted.
3 Fertilizer injection system shall be measured as a
Lump Sum, complete, installed, tested, and accepted.
4 Electrical work in connection with pumping stations
is given separately and measured as a Lump Sum,
furnished, installed, tested and accepted and is deemed to
include all electrical work shown or the Drawings,
described in the Specification or reasonably to be implied
as necessary for the proper execution of the work.
17.3.8 Basis of Payment
1 The amount of completed and accepted work as
provided above shall be paid for at the unit prices for the
items describes in the Bill of Quantities and shall include
for furnishing all materials, installation, civil, mechanical,
electrical, piping and miscellaneous works, testing,
commissioning, and putting into operation, maintenance
and all labor, equipment, tools, supplies and other items
necessary for the proper completion of the work as
specified.
17.3.9 Items in the Bill of Quantities
(i) Submersible Drainage Pumps (nr.)
(ii) Horizontal Pumps (nr.)
(iii) High Pressure Booster Pumping
Set Employing Membrane Tank (nr.)
17.4 Construction Requirements
17.4.1 Pipe Laying and Jointing
1 General: examine materials carefully for damage.
Test for soundness in accordance with manufacturer's
instructions before laying the pipe.
2 The Contractor shall examine materials to ensure
coating or lining and outer coating or sheathing is
undamaged. If damaged, make good or dispose of and
replace, as directed.
and
3 The Contractor shall remove dirt and foreign matter
from pipe before lowering.
4 The Contractor shall clear construction debris from
inside of pipe before making joint.
5 When pipe lying is not in progress, the Contractor
shall close open ends of pipes with properly fitted
temporary wooden plugs or standard caps as directed
6 Jointing: manufacturer’s instructions shall be
followed regarding cleanliness of joint surfaces, lubricant
used, correct location of components, provision of correct
gaps for flexible joints etc.
7 Flexible joints shall not be deflected beyond
maximum permissible angles given by manufacturer
and/or relevant standard.
8 For patent detachable and flexible joints strictly the
Contractor shall comply with special instructions issued by
manufacturers of proprietary joints when laying and
jointing.
9 The Contractor shall joint differing pipe and fitting
material with adaptors as recommended by pipe
manufacturer.
17.4.2 Valve Installation
1 General: prior to installation, inspection for
cleanliness of bores, seating surfaces etc. and for handling
damage, cracks, missing parts and tightness of pressure-
containing bolting shall be performed.
2 The Contractor shall ensure that valves are in the
closed position before installation.

(iv) High Pressure Booster Pumping 3 Valves must be operated through one complete
Set Employing Variable Speed opening and closing cycle in the position in which they
Pumps (nr.) shall be installed to ensure proper functioning.
4 Joint between valve and pipe must be set in the
(v) Duplex Sump Pumps (nr.)
manner specified for laying and jointing pipe and to
(vi) Monorail System Lump Sum manufacturer's instructions.
5 Valves shall be provided with concrete pads as
(vii) Fertilizer Injection System Lump Sum
shown on the Drawings so that pipes do not support
(viii) Electrical Works Lump Sum weight of valve.

(ix) Instrumentation and Controls Lump Sum 6 Valves without concrete pads shall be placed on firm
footings to prevent settling and excessive strain on
connection to pipe.
7 Valves shall not be used to bring misaligned pipe
into alignment during installation.

♦ 17-12 ♦
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8 All pressure-containing bolting (bonnet, seal plate
and end connections) must be inspected for adequate
tightness after installation but prior to field testing.

17.4.3 Pump Installation

1 Installation: realign pump and motor in the field after
grouting in base and connecting piping.
2 Support piping independently of pump nozzles.
3 Drains for packing glands and base shall be piped to
nearest floor drain or sump.
4 Before operation, the Contractor shall ensure pump
is properly lubricated, rotating element rotates freely by
hand, casing is vented and full of water, direction of
rotation is correct, strainer is clean and suction and
discharge valves are open.

17.4.4 Method of Measurement and Basis of

Payment
1 No separate items are measured for the work
described in this Sub-section and no separate payment
will be made.
2 All work related to installation of pumping stations
and all general requirements and builder's work in
connection with the installation, including all work shown
on the Drawings, described in the Specification or
reasonably to be implied as necessary for the proper
execution of the work shall be considered as subsidiary
Work, which shall not to be measured for direct payment,
the cost of which will be deemed to be included in rates
for the items in the Bill of Quantities.

♦ 17-13 ♦
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Ref. Title Page No.
18.1 Locating and Protecting
Existing Utilities 18-1 
18.1.1  Description / General 18-1 
18.1.1.1  Submittals 18-1 
18.1.2  Materials 18-1 
18.1.3  Construction Requirements 18-1 
18.1.4  Method of Measurement 18-1 
18.1.5  Basis of Payment 18-1 
18.1.6  Items in the Bill of Quantities 18-2 

18.2  Removing and Disposing of or

Relocating Existing Utilities 18-2 
18.2.1  General 18-2 
18.2.1.1  Submittals 18-2 
18.2.2  Materials 18-2 
18.2.3  Construction Requirements 18-2 
18.2.4  Method of Measurement 18-3 
18.2.5  Basis of Payment 18-3 
18.2.6  Items in the Bill of Quantities 18-3 

18.3 Future Utility Crossing 18-3 

18.3.1  Description / General 18-3 
18.3.2  Materials 18-3 
18.3.3  Construction Requirements 18-3 
18.3.4  Method of Measurement 18-3 
18.3.5  Basis of Payment 18-3 
18.3.6  Items in the Bill of Quantities 18-4

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18.1 Locating and Protecting Existing
Utilities
18.1.1 Description / General
1 This Sub-section describes requirements for locating
and protecting existing underground services and plant
that are affected by execution of the Works but to remain
in their position, such as utility lines and underground
water streams (Falajs) etc. The full scope of the protection
work required will be determined after investigation by the
Contractor, and he shall prepare working drawings for
such work as directed by the Engineer.
2 Existing utility services and plant, and Falajs will not
be considered as obstructions as defined in Section 1. The
Contractor shall liaise with the utility owners and other
concerned authorities regarding such utility services, plant
and Falajs in all aspects of the work. The cost of locating
and recording their positions and of working around or in
proximity to them is deemed to be included in the
Contractor’s allowance for his obligations under Section 1.
18.1.1.1 Submittals
1 Submit coordination drawings showing pipes and
major system components. Indicate interface and spatial
relationship between pipes, system components, adjacent
utilities, and proximate structures.
2 Submit shop drawings of existing underground
services and plant to be protected including plan layout
and locations, types and sizes.
3 At project close-out, submit record drawings
showing the protected pipes and related components with
sufficient details to allow for locating the pipes for future
maintenance.
18.1.2 Materials
1 Concrete shall conform to the requirements of Sub-
section 5.1 and shall be of the class instructed by the
Engineer. Reinforcing steel shall comply with Sub-section
5.2. Reinforced concrete shall comply with the appropriate
requirements of Sub-section 5.3. Metalwork should
comply with Section 6.
18.1.3 Construction Requirements
1 All excavation and backfill shall conform to the
requirements of Sub-Sections 2.3 – ‘Roadway Excavation’
and 2.8 – ‘Earthwork for pipe trenches’.
2 The protection of existing underground plant and
Falajs shall be carried out in strict compliance with the
requirements of the Concerned Authorities and utility
owners. The protection shall normally be in the form of
encasing the services or plant with a split 100 or 300 mm
diameter uPVC pipe wrapped with polyethylene sheets
and surrounded by concrete Class 15/20 or enclosing such
plant of large diameter such as oil or water pipes or Falajs
with an inverted concrete box culvert or slab or in any
other forms as instructed by the Engineer or the
concerned authorities.
3 Before commencing any work on site, the Contractor
shall send a ‘Notice of Intent’ including two sets of
drawings, plan work, construction method and safety
measured to all Concerned Authorities and shall obtain
information in the form of a formal notice and/or signed
drawing showing the location of all underground utility
plant and Falajs. The Contractor shall search for and
ascertain the exact location of the plant on site by making
trial pits and shall repair, at his own expense, any damage
caused to the plant by his works, to the satisfaction of the
Engineer and the Concerned Authorities.
4 Whenever, in the course of the work, water pipes,
irrigation pipes, drainage pipes, sewers, oil, gas pipes,
electrical or telephone cables, or other unforeseen items
are encountered, the Contractor shall inform the Engineer,
who shall issue the appropriate instruction for each
individual case.
5 The precise location of existing utilities and Falajs
shall be investigated and established by the Contractor in
consultation with the relevant Utility Operator. Service
supply lines damaged in the course of the search shall be
replaced with equivalent approved materials at the
Contractor’s expense.
18.1.4 Method of Measurement
1 Excavation and backfilling, whether by hand or
machinery, for searching and protection of existing utility
plant and Falajs including making trial pits shall be
measured as described in Sub-section 2.8, Clause 2.8.4.
and 1.8.3.
2 Split pipes shall be measured in linear meters of laid
pipe of the various sizes, measured as a straight line. No
allowance will be made for cut ends and waste.
3 Concrete surround to pipes and ducts and concrete
for inverted box culverts and for blinding shall be
measured as described in Sub-section 5.1, Clause 5.1.5.
The volume occupied by the pipe including pipe wall shall
be deducted from the gross volume of the concrete
surround and only the net volume of the concrete
surround so calculated shall be paid for.
4 Reinforcing steel shall be measured as described in
Sub-section 5.2, Clause 5.2.4.
18.1.5 Basis of Payment
1 The quantity of completed and accepted work for
split pipes measured as provided for above will be paid for
at the unit rate in the Bill of Quantities. The unit rate per
linear meter shall include labor, materials, markers and
warning tape, equipment, transportation to and hauling
about the Site, loading, unloading and cutting, machining,
etc. of standard length pipes.
2 Excavation and backfilling shall be paid for as
indicated in Clause 2.8.5.
3 Concrete shall be paid for as indicated in Clause 5.1.6.
♦ 18-1 ♦
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4 Reinforcing steel shall be paid for as indicated in
Clause 5.2.5.
18.1.6 Items in the Bill of Quantities
(i) Split pipe (diameter) lin.m
18.2 Removing and Disposing of or
Relocating Existing Utilities
18.2.1 General
1 This Sub-section describes requirements for removal,
disposal or relocation/diversion of existing utilities. Full
scope of the relocation work required will be determined
after investigation by the Contractor and he shall prepare,
shop/working drawings for the work, as directed by the
Engineer. The Contractor shall liaise with the utility
owners and other Concerned Authorities in all aspects of
the work.
2 Permanent removal and, relocation or diversion of
any existing utilities will be ordered by the Engineer where
they obstruct the permanent work and where such utilities
need to be maintained in operation as required by the
utility owner. The Engineer may also order permanent or
temporary diversion of utilities when in his opinion it is
reasonable that this should be done for carrying out the
proposed work, but such orders will not normally be given
where the services concerned cross the work area and are
either redundant or can be dealt with by the Contractor in
the normal course of work. The diversions ordered by the
Engineer shall be paid for in the Contract, but any other
temporary diversion or removal required shall be at the
Contractor's own expense.
3 No service diversion shall be made without the
approval of the Engineer and the Concerned Authority.
18.2.1.1 Submittals
1 Submit coordination drawings showing pipes and
major utility components. Indicate interface and spatial
relationship between pipes, system components, adjacent
utilities, and proximate structures.
2 Submit shop drawings of existing underground
utilities and plant affected by the work including plan
layout and locations, types and sizes.
3 At project close-out, submit record drawings
showing the relocated services and related components
with sufficient details to allow for locating the utility for
future maintenance.
18.2.2 Materials
1 All material for relocation/diversion of utilities shall
comply with the specifications of the Concerned Authority
and shall conform to the following listed requirements.
2 Concrete shall conform to the requirements of Sub-
section 5.1 and shall be of the class instructed by the
Engineer. Reinforcing steel shall comply with Sub-section
♦ 18-2 ♦
5.2. Reinforced concrete shall comply with the appropriate
requirements of Sub-section 5.3.
3 Gravity pipes and pressure pipes shall conform to the
requirements of Sub-section 8.2, Clause 8.2.2.
4 Electricity poles, ducts, handholes/manholes and
overhead and underground electricity cables, shall
conform to the requirements of Section 15 and of the
Concerned Authority.
5 Telecommunication ducts, handholes/manholes and
cables related to telephone works, shall conform to the
telecommunication authority specifications and details.
6 Sand and sieved backfill material free from stones or
other debris shall be provided for reinstating the trenches
after the laying of ducts.
18.2.3 Construction Requirements
1 Prior to commencing the work, the Contractor shall
prepare layout drawings, proposed working method and
the time schedule for disconnecting and reconnecting of
the affected services and shall obtain approval of these
from the Engineer and Concerned Authorities. During the
work, the Contractor shall exercise great care not to cause
any damage to the exiting utilities.
2 Electricity, gas, oil, water, sewage, drainage,
irrigation and telephone service lines which are identified
to be relocated shall be shown on the drawings, along
with the required re-routing. The full scope of the services
to be relocated cannot be determined at tender stage and
the Contractor shall allow in his rate for verifying or
revising the services that should be re-routed and
adjusting the proposed re-routing alignment and for any
variation in quantities, preparation of revised working
drawings, design, etc.
3 The precise locations of existing utilities shall be
investigated and established by the Contractor in
consultation with the relevant utility owner. The
Contractor shall notify and obtain permission from the
Concerned Authority before interrupting any service.
Service supply lines damaged in the course of the search
shall be replaced with equivalent approved materials at
the Contractor’s expense.
4 All excavation and backfill shall conform to the
requirements of Sub-Sections 2.3 – ‘Road Excavation’, 2.7
– ‘Excavation and Backfilling for Structures’ and 2.8 –
‘Earthwork for Pipe Trenches’.
5 Removal of existing utilities shall conform to the
requirements of Sub-section 2, Clause 2.2.2. Designated
salvageable material shall be removed without
unnecessary damage, in sections or pieces, transported or
stored by the Contractor as instructed by the Engineer.
Other material shall be disposed of off-site.
6 Utility lines which should remain, but with added
protection, shall be shown on the drawings. Cavities left
by utilities removal shall be backfilled to the level of the
surrounding ground and compacted.
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7 During excavation, warning tiles or tape shall be
retrieved carefully and may be reused. The damaged
warning tiles or tape shall be replaced by the Contractor at
his own cost. Concreting and backfilling operations shall
be carefully executed to ensure that there shall be no
damage to the utilities.
18.2.4 Method of Measurement
1 Removal and disposal of existing redundant utilities
ordered by the Engineer under Clause 18.2.1, Item (2),
shall be measured in linear meters of the length removed.
The rates shall include for all work except excavation as
stated in Item (4), below.
2 Removal and relocation of existing utilities shall be
measured in linear meters of the length of the relocated
work. Rates shall include for all work except excavation as
stated in Item (4) below.
3 Provision and installation of new utility services shall
be measured in linear meters of the length of new service
installed. Rates shall include for all work except excavation
as stated in Item (4) below.
4 Excavation and backfilling whether by hand or
machinery for removal, relocation/diversion of existing
utilities shall be measured as indicated in Sub-section 2.8,
Clause 2.8.4.
5. No work will be measured and no payment made for
work carried out by the Concerned Authorities nor for any
work in connection therewith by the Contractor unless
prior approval for payment is given by the Engineer
18.2.5 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above shall be paid for at the
unit rate for each service stated in the Bill of Quantities,
which rate shall be considered full compensation for
locating, removing, relocating, installing and jointing of
utilities and for materials, labor, transport, equipment,
tools supplies and all other items necessary for the proper
completion of the work, except excavation which is
measured as stated in Clause 18.2.4, Item (4).
18.2.6 Items in the Bill of Quantities
(i) Remove and dispose of (utility)
(size/description) lin.m.
(ii) Remove and relocate (utility) (size/
description) lin.m.
(iii) Provide and install new (utility)
(size/description) lin.m.
18.3 Future Utility Crossings
18.3.1 Description / General
1 This Sub-section describes requirements for
provision of pipe sleeves/ducts under pavements for
future utility crossings. Full scope of the work will be
determined according to conditions on Site.
2 The Contractor shall be responsible for preparation
of shop/working drawings, procurement of material and
for following-up/co-ordination with the concerned
authorities in all matters relating to this work.
18.3.2 Materials
1 Concrete shall conform to the requirements of Sub-
section 5.1 and shall be of the class instructed by the
Engineer. Reinforcing steel shall comply with Sub-section
5.2. Reinforced concrete shall comply with the appropriate
requirements of Sub-section 5.3.
2 Sleeves/ducts shall be uPVC for small pipes less than
400 mm in diameter and concrete for larger pipes. Pipes
shall conform to the requirements of Sub-section 8.2,
Clause 8.2.2.
3 Locations and sizes of pipe sleeves are as shown on
the Drawings.
18.3.3 Construction Requirements
1 Before commencing any work on site, the Contractor
shall send a ‘Notice of Intent’ including two sets of
drawings, plan of work, construction method and safety
measures to all Concerned Authorities and shall obtain
information in the form of a formal notice and/or signed
drawing showing the required location of sleeves for
future connection.
2 Sleeves/ducts shall be placed prior to or during
construction of the highway. Any piping installed after
completion of the highway construction shall be placed
after jacking (thrust boring) a pipe sleeve under the
pavement. The Contractor will not be permitted to cut into
the pavement for pipe installation.
3 Markers should be placed on both ends of the
sleeves/ducts. In addition a rope should be installed inside
the pipe and tied at both ends to the markers underground
concrete support block or to an adjacent landmark.
4 All excavation and backfill shall conform to the
requirements of Sub-sections 2.3 – ‘Roadway Excavation’
and 2.7 – ‘Excavation and Backfilling for Structures’.
18.3.4 Method of Measurement
1 Sleeves/ducts shall be measured in linear meters of
pipe of the various types, classes and sizes laid, measured
as a straight line. No allowance will be made for cut ends
and waste. The rates shall be deemed to include for all
work including the laying of markers and concrete
surrounds, but does not include excavation as stated in
Item (2) below.
2 Trench excavation and backfilling shall be measured
and paid for as indicated in Clause 2.8.4 Item (4).
18.3.5 Basis of Payment
1 The quantity of completed and accepted work for
sleeves/ducts pipes measured as provided for above will
be paid for at the unit rate in the Bill of Quantities, which is
♦ 18-3 ♦
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deemed to cover all costs except excavation as stated in
Clause 18.3.4, item (2).

18.3.6 Items in the Bill of Quantities

(i) Sleeves/ducts (type) (diameter) lin.m.

♦ 18-4 ♦
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Ref. Title Page No. Ref. Title Page No.
19.1 General 19-1 19.10 Heating Equipment 19-6
19.1.1 Description 19-1 19.11 Mixers for Concrete Pavements 19-6
19.2 Compaction Plant 19-1 19.12 Portable Concrete Mixers 19-7
19.2.1 General 19-1 19.13 Truck Mixers and Agitators 19-7
19.2.2 Pneumatic-Tired Rollers 19-1
19.14 Concrete Batch Plants 19-7
19.2.3 Heavy Pneumatic-Tired Rollers 19-1
19.2.4 Self-Propelled Pneumatic-Tired Rollers 19-1 19.14.1 General 19-7
19.2.5 Tamping Rollers 19-1 19.14.2 Automatic Concrete Batching Plants 19-8
19.2.6 Tandem Two and Three-Wheeled
19.15 Equipment for Concrete
Rollers 19-1
Pavement 19-9
19.2.7 Vibrating Rollers 19-2
19.2.8 Trench Rollers 19-2 19.15.1 General 19-9
19.15.2 Subgrade Preparation Equipment 19-10
19.3 Miscellaneous Equipment 19-2 19.15.3 Mechanical Concrete Spreaders
19.3.1 Disc Harrows 19-2 and Finishers 19-10
19.3.2 Mechanical Sweepers 19-2 19.15.4 Miscellaneous Minor Equipment
19.3.3 Mechanical Rammers 19-2 for Concrete Pavements 19-11
19.3.4 Motor Graders 19-2
19.16 Method of Measurement
19.3.5 Rotary Speed Mixers 19-2
and Basis of Payment 19-11
19.3.6 Travelling Mixing Plant 19-2

19.4 Hauling Equipment 19-2

19.5 Weigh Bridges 19-2
19.6 Water Distribution Equipment 19-3
19.7 Hot Mix Asphalt Equipment 19-3
19.7.1 General 19-3
19.7.2 Additional Requirements
for Batch-Type Plants 19-4
19.7.3 Additional Requirements
for Continuous Mixing Plants 19-5

19.8 Spreading and Finishing

Machines 19-5
19.8.1 Asphalt Pavers 19-5
19.8.2 Aggregate Spreaders 19-5

19.9 Pressure Distributors 19-6

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19.1 General
19.1.1 Description
1 The plant and equipment used for the Works shall be
as proposed and itemized in the Contractor’s approved
detailed program and equipment list, unless otherwise
permitted by the Engineer.
2 The plant and equipment shall be of sufficient power
and size and in sound and well maintained mechanical
condition to meet the requirements and produce a
satisfactory quality of work. All items shall be ready for
use when required by the Engineer, The Engineer may
order removal of unsatisfactory plant and equipment and
require replacements meeting his approval. Assessment
of capacity and efficiency shall be based on the actual
performance on Site.
3 Whenever either the Specification or the Engineer
requires use of plant and equipment of a particular size or
type the Contractor may request in writing, permission to
use alterative equipment. The proposal shall contain
evidence satisfactory to the Engineer that the output of the
alterative proposed is at least equal to that of the specified
item.
4 The purpose of this provision is to encourage the
development of new or improved plant and equipment.
The Engineer may require trials in advance of the use of
the item in works construction.
5 If permission is granted, it shall be on the
understanding that it may be withdrawn at any time the
Engineer determines that results are not satisfactory.
Upon withdrawal of permission the Contractor shall use
plant and equipment originally specified and shall remove
and dispose of or otherwise remedy at his own expense
defective or unsatisfactory work produced with the
alternative. No compensation will be allowed for any
delay or additional costs incurred by the Contractor as a
result of implementation of this provision.
19.2 Compaction Plant
19.2.1 General
1 No item of plant shall be used that has in any way
been thrown out of its original balance by the application
of attachments not approved by the Engineer.
2 The Contractor shall provide the means of readily
determining the effective mass of each roller or wheel of
plant being operated. Any ballasting shall be included in
the weighing.
3 The mass and compactive effort, or load, applied by
the roller shall be as specified, or as appropriate to the
work being undertaken.
19.2.2 Pneumatic-Tired Rollers
1 These rollers shall have not less than 9 pneumatic
tires revolving on 2 axles. Tires on the front and rear
wheels shall be staggered so that they cover the entire
area over which the roller travels. Under working
conditions rollers shall develop a compactive effort of not
less than 10kN per wheel.
19.2.3 Heavy Pneumatic-Tired Rollers
1 These rollers shall have a mass of not less than 25
tonne and shall consist of not less than 4 pneumatic-tired
wheels revolving in one transverse line. The width of the
roller shall be not less than 2.4m and it shall be
constructed in 2 or more sections in such a manner that
each section is free to oscillate or move independently.
Under working condition the roller shall develop a
compactive effort of not less than 25kN per wheel.
19.2.4 Self-Propelled Pneumatic-Tired
Rollers
1 These rollers shall be of the oscillating wheel type
having not less than 7 pneumatic-tired wheels revolving
on two axles, and capable of being ballasted to the mass
required.
2 Tires on front and rear wheels shall be staggered so
that tire sidewalls have a minimum overlap of 12mm.
Rollers shall operate smoothly and without jerking when
starting, stopping or reserving direction. Tires under
working conditions shall be inflated to pressures between
2
0.4 and 0.8 N/mm . The roller shall be fitted with a water
system to keep all tires uniformly wet it necessary.
19.2.5 Tamping Rollers
1 These rollers under working conditions shall have a
minimum mass of 4000 kg per meter width of drum, and
each individual tamping foot shall develop a compactive
effort of not less than 0.7N/mm2 of tamping face area. The
width of the roller shall be not less than 2.4m and shall be
constructed in 2 or more sections so that each section is
free to move independently. It shall be fitted with cleaning
teeth at the rear.
19.2.6 Tandem Two and Three-Wheeled
Rollers
1 These rollers shall be self-propelled or towed and
capable of being operated smoothly and without jerking
when starting, stopping, or reversing directions. The
steering shall permit the roller to be accurately directed on
the alignment desired. Roller drum wheels shall be
smooth steel and free from openings or projections which
will mar the surface on which the roller is operated.
Rollers shall be equipped with drip pans designed to
prevent oil, grease or petrol from dripping onto the work
surface. They shall be provided with adjustable scrapers
to keep the surface of the wheels clean.
2 When used on a bituminous surface, rollers shall be
fitted with water tanks and sprinkling devices which shall
♦ 19-1 ♦
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be used when necessary to wet the wheels and prevent
the bituminous mixture from sticking to them.
3 Rear wheels may be crowned at a rate of not more
than 1 in 288 for two wheeled, and 1 in 320 for three
wheeled rollers,
4 Rear wheels of three-wheel rollers, shall be propelled
with a differential gear. The front wheel shall show no
noticeable crown and shall overlap the compacted area of
each rear wheel by not less than 60mm.
19.2.7 Vibrating Rollers
1 These shall be self-propelled or towed and have a
means of applying mechanical vibration to one or more
smooth steel-drum wheels. They shall be fitted with a
device, or provided with the means for, indicating the
frequency at which the roller is operating, which will be as
recommended by the manufacturer.
19.2.8 Trench Rollers
1 These shall be self-propelled, steel wheel rollers,
capable of being operated smoothly and without jerking
when starting, stopping or reversing direction. The width
of the wheel shall be not more than 500mm and diameter
of the compaction rolls shall be not more than 1.5m.
2 Wheels shall be smooth and free from openings or
projections which will mar the surface on which the roller
is operated. Rollers shall be equipped with drip pans
designed to prevent oil, grease, or gasoline from dripping
onto the work surface, and shall be provided with
adjustable scrapers to keep the outface of the wheels
clean. The balance wheel of the roller shall be adjustable
in height to provide the slope of surface required.
19.3 Miscellaneous Equipment
19.3.1 Disc Harrows
1 Disc harrows shall be of the tandem type and shall be
of sufficient size, mass and number of discs to perform the
manipulation required
19.3.2 Mechanical Sweepers
1 Sweepers shall be constructed in a manner which
will permit the revolution of the broom to be adjusted in
relation to its progression and permit adjustment of the
broom height in relation to the surface being cleaned.
Broom bristles shall be stiff enough to sweep clean
without cutting into the surface. Brooms with steel bristles
shall not be used.
19.3.3 Mechanical Rammers
1 Mechanical or power rammers shall have a mass
between 100 kg and 750 kg.
♦ 19-2 ♦
19.3.4 Motor Graders
1 Motor graders shall be self-powered and equipped
with an adjustable mold board. The cutting blade shall be
straight.
19.3.5 Rotary Speed Mixers
1 Rotary speed mixers shall be either of the power
take-off or self-powered type, equipped with a hydraulic
lift.
19.3.6 Travelling Mixing Plant
1 Travelling or stationary mixing plant shall be either
of the type which will pulverize the material to be treated
and mix it with the binder and the proper amount of water
without picking up material from the roadway, or the type
which elevates roadway material into a pugmill for mixing.
Plant shall be fitted with a device which will accurately
control and measure the quantity of water used.
19.4 Hauling Equipment
1 Hauling equipment for construction materials shall
be vehicles having hydraulically operated dump bodies
suitable for depositing loose materials in a windrow or
into spreader boxes. Bodies shall be so constructed that
volume measurement can be accurately carried out. They
shall be constructed and maintained to prevent loss of
materials during hauling operations. Dump controls that
can be operated from the driver's seat shall be fitted.
19.5 Weigh Bridges
1 Weighing equipment tor truck-hauled material shall
consist of platform scale accurate to 0.5% throughout the
range of use. Scales shall have a platform of adequate
length to weigh, in one operation, the longest truck or
truck-trailer combination which is in use on the works.
2 Scales shall be inspected and certified by an
approved company as often as the Engineer deems
necessary. Each certification shall show the date of the
inspection and the name of the Company making the
inspection.
3 If no suitable company exists, or if instructed by the
Engineer, the Contractor shall check and adjust the scale
in the presence of the Engineer, using the method
recommended by the manufacturer and approved by the
Engineer. The Contractor shall provide a minimum of ten
25kg standard test weights for each scale on Site for
checking purposes.
4 The Contractor shall, when instructed by the
Engineer, make mass comparisons with other
permanently located scales that meet the approval of the
Engineer. The comparisons shall be for the purpose of
providing information on the performance of the
Contractor’s scale and will not be used as a basis for
adjusting the scale.
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5 Access to the scale platform shall be maintained by
the Contractor to the satisfaction of the Engineer and a
suitable weathertight building shall be provided to enclose
the indicating mechanism. Adequate lighting for the scale
operator's use shall be installed.
19.6 Water Distribution Equipment
1 Equipment for the distribution of water shall consist
of self propelled or towed tanks equipped with spray bars
and, when required, pumps to operate under pressure.
Pumps shall be of sufficient capacity to provide uniform
and adequate distribution. The tanks shall be mounted on
pneumatic-tired trucks or on pneumatic-tired trailers
pulled by pneumatic-tired equipment. The minimum
capacity of a tank shall be 4000 liters.
2 Distribution equipment shall be constructed so as to
permit accurate and uniform distribution of the desired
quantities of water, Control valves shall fully close with no
leakage and shall be constructed to operate from the
driver's seat, or provision made for an additional operator
to work control valves while the equipment is travelling.
19.7 Hot Mix Asphalt Equipment
19.7.1 General
1 Hot-mix plant shall be either of the batch-type or
continuous-type. Plant shall not be used to produce
mixtures concurrently for more than one contract unless
permission is granted by the Engineer. Plant units shall
be designed and operated so that they will function
properly and produce bituminous mixture of uniform
temperature and composition within the tolerances
specified.
2 The plant shall be approved by the Engineer before
production begins. It shall be fitted with adequate and safe
stairways to the mixer platform and sampling points plus
a room of
3 The plant shall be complete with a control room of
2 into the drier so that uniform production shall be
approximately 18m floor area for performing tests for
control of the mixture. The room shall be provided with
sufficient heat, natural and artificial light and air
conditioning, and be equipped with a desk, chair, drafting
stool, work bench 1m by 3m by 1m high with drawers and
cabinets below, service sink, water supply and electric
power outlets. First aid equipment, telephone, fire
extinguisher (having a minimum Underwriters Laboratory
rating of 2A10BC), and sanitary facilities shall be provided.
When approved by the Engineer a room conforming to the
above requirements, in a separate building, may be
substituted.
4 Guarded ladders shall be placed at all points where
access to plant operation is required. Access to the top of
truck bodies shall be provided by a platform or other
suitable device to enable the Engineer to obtain samples
and mixture temperature data. A hoist or pulley system
shall be provided to raise scale calibration equipment,
sampling equipment and other similar equipment from
the ground to the mixer platform and return. Gears,
pulleys, chains, sprockets and other dangerous moving
parts shall be properly guarded. Ample and unobstructed
space shall be provided on the mixing platform. Clear and
unobstructed passage shall be maintained in and around
the truck loading area which shall be kept free from
droppings from the mixing platform.
5 The plant shall be equipped with a dust collecting
system. Collected dust shall be stored in a hopper and
shall be fed to the boot of the hot elevator at a uniform
rate by a variable speed vane feeder or mechanical feeder
during the period when a full stream of aggregate is being
fed from the drier to the hot elevator. The accuracy of the
feeder shall not be affected by the head of material in the
collected dust storage hopper. A 'low bin' indicator shall
be required ahead of the feeder.
6 The plant shall be located where it can be supplied
with adequate storage and vehicle movement space.
Separate stockpiles of each size of aggregate shall be
arranged, with rigid partitions to prevent intermixing of
different materials between adjacent stock piles. In
general, fine aggregates to be used in bituminous
mixtures shall be placed in separate stock piles before
they are placed in the cold bins. Aggregates shall be kept
separated until they are fed in proper proportions onto a
belt conveyor or into the boot of the cold aggregate
elevator. Aggregates shall be handled as to prevent
contamination and degradation.
7 When compartment aggregate feeders are used, the
width of the crane bucket shall not be more than half the
minimum width of the top of bin compartments and the
maximum length of the bucket when fully open shall be at
least 300mm less than the length of the top of the bin
compartment, When an end loader is used to charge cold
bins the maximum discharge width of the bucket shall be
600mm less than the width of the top of the bin
compartment.
8 The plant shall be provided with accurate mechanical
means for feeding each aggregate in proper proportion
maintained. Control of the total quantity of combined
aggregates fed to the drier shall be by a variable speed
system. Other methods may be proposed for approval by
the Engineer. Gates shall be capable of being locked or
bolted securely in the required position. A minimum of 4
bins and feeders will be required.
9 The plant shall be equipped with revolving cylindrical
drier or driers for heating aggregates to the temperatures
required when the plant is operating at its full rated
capacity.
10 Screens used in separating aggregates shall be the
vibrating type. The system shall be equipped with a
scalping screen having openings not more than 12.5mm
greater than the largest size of aggregate used in
preparing the bituminous mixture. The screening system
shall have a tailing pipe for removal of oversized
♦ 19-3 ♦
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aggregate. The discharge point of the tailing pipe shall be
located so that it will not create a hazard.
11 Hot aggregate storage bins at sufficient capacity to
supply the mixer when it is operating at full capacity shall
be provided. Bins shall be arranged to give separate
storage of the appropriate proportions of mineral
aggregates. Separate dry storage shall be provided for
mineral filler and the plant shall be equipped to feed
material into the mixer. Each bin shall be provided with
overflow pipes to prevent backing up of material into
other compartments or bins. Each compartment shall be
provided with an individual outlet gate constructed so that
when closed there shall be no leakage. Gates shall cut off
quickly and completely. Bins shall be so constructed that
samples can be readily obtained.
12 Temperature recording shall be done either by
recording pyrometer or recording thermometer having at
least 2 terminals when a single drier is used and at least 3
terminals when a dual drier is used. The type and accuracy
of the recording instrument shall be approved by the
Engineer. Unless otherwise approved, one terminal shall
be installed at a suitable location at the discharge of each
drier and the others near the discharge gate in each bin
compartment used for fine aggregate. The temperature
recording instrument shall be capable of producing
accurate temperature charts for submission to the
Engineer after each day's operation.
13 The recording instrument shall be installed in a
position free from dust and vibration. If the instrument is
not located to indicate clearly to the drum fireman the
temperature of the mineral aggregates at the discharge of
each drier, a non-recording pyrometer shall also be
installed in view of the fireman.
14 Storage tanks for bitumen shall be equipped to heat
and hold material at the required temperatures. Heating
shall be accomplished by steam coils, hot oil coils,
electricity or other approved means so that no flame shall
be in contact with the tank. Lines and fittings shall be
steam, electric or hot oil jacketed. Provision shall be made
for sampling from the line leading to the weigh bucket if
more than one grade of bitumen is required for concurrent
operations, adequate storage and separate piping to the
weigh bucket for each grade shall be provided to prevent
intermingling. An armored thermometer or pyrometer
which will accurately show temperatures between
100°Cand 200°C shall be located in the line or within the
tank.
19.7.2 Additional Requirements for Batch-
Type Plants
1 Equipment for weighing and measuring aggregate
shall include means for accurately weighing each size in a
weigh box or hopper suspended on scales and of ample
size to hold a full batch without hand raking or
overflowing. The gate shall close lightly so that no
material is allowed to leak into the mixer while a batch is
being weighed.
♦ 19-4 ♦
2 If aggregates are measured by volume in calibrated
compartments these shall form the weigh hopper and
shall be arranged so that the volume measurement of
each compartment and each batch may be checked by
mass. Means of checking the volume measurement shall
meet the approval of the Engineer.
3 The weigh scale shall be a springless dial type with a
capacity of not more than twice the mass of the capacity
of the mixer.
4 The mineral filler shall be weighed in the aggregate
hopper or measured by volume in a calibrated
compartment and shall be conveyed by means of a dust
elevator and screw conveyor system. The system shall be
so arranged that the accuracy of the feed will not be
affected by the head of material in the mineral filler bin.
The screw conveyor shall operate at such a speed that
small fractions of material to be weighed may be added
accurately. The chute used to introduce mineral filler into
the weigh hopper shall be so constructed that no material
is retained in it after the required amount has been
deposited in the weigh hopper.
5 Equipment for weighing and measuring bitumen
shall consist either of a weigh bucket or a metering device.
If a weigh bucket is used it shall be a non-tilting type and
shall be completely suspended from a springless dial scale
accurate to ±0.4%. The weigh bucket, discharge valve or
valves and spray bar shall be heated and shall have a
capacity of at least 15% in excess of the mass of material
required in the batch. Heated, quick-acting, non-drip
valves shall be used in charging the bucket.
6 Metering devices shall have a capacity at least 15% in
excess of the quantity of bitumen used in a batch. Controls
shall be constructed so that they may be locked at any dial
setting and will automatically reset to that reading after
the addition of bituminous material. The amount of
material which the Contractor will be permitted to mix per
batch shall be determined by the Engineer. The mixer
shall be a twin-shaft type. Drip pans shall be used under
the mixer where necessary to prevent moisture from
dripping onto truck loads of freshly prepared asphalt. Pipe
fittings shall be tight. The mixer platform shall be
sufficiently rigid and of ample size to provide safe and
convenient access to the mixer and other equipment.
7 The mixer shall be equipped with an accurate time
lock to control the operations of a complete mixing cycle.
It shall lock the weigh box gate after the charging of the
mixer until the closing of the mixer gate on completion of
the cycle. It shall lock the bitumen bucket throughout the
dry mixing period and shall lock the mixer gate
throughout both dry and wet mixing periods. The dry
mixing period is defined as the interval of time between
the opening of the weigh box gate and the start of the
introduction of bitumen. The wet mixing period is the
interval of time between the start of the introduction of
bitumen and the opening of the mixer gate. Control of the
timing shall be flexible and capable of being set at
intervals of 5 seconds or less throughout a total cycle.
Setting of time intervals shall be performed in the
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presence of the Engineer who shall then lock the case
covering the timing device until such time as a change is
to be made in the timing periods. A mechanical batch
counter shall be installed as part of the time lock device. It
shall register only upon actuation of the asphalt weigh
bucket or valve release. It shall not register any dry
batches or any material released during the operation of
filling the bins.
19.7.3 Additional Requirements for
Continuous Mixing Plants
1 A gradation control unit shall be included for
accurately proportioning each size of aggregate and
mineral filler.
2 Feeders shall be mounted under each compartment
bin. Each compartment bin shall have an accurately
controlled individual gate to form an orifice for
volumetrically measuring the material drawn. The feeding
orifice shall be rectangular with one dimension adjustable
by positive mechanical means provided with a lock.
Indicators marked in millimeters shall be provided on each
gate to show the gate opening. Bins shall be equipped
with tell-tale devices to indicate the position of aggregates
in bins at the lower quarter points. The condition of the
conveyor belt shall be continuously checked and adjusted
to avoid segregation of the aggregates.
3 A cutoff system shall be provided which shall
automatically stop mixing operations when any bin
becomes empty or when the bitumen reaches a level in
the tank where the specified quantity is not delivered to
the pugmill.
4 The plant shall include means for calibration of the
gate openings by weighing test samples. Provision shall
be made so that materials fed out of individual orifices
may be bypassed to individual test boxes. The plant shall
be equipped to conveniently handle individual test
samples weighing not less than 100kg. Accurate scales
shall be provided by the Contractor to weigh lest samples.
5 Interlocking mechanical controls or other positive
methods approved by the Engineer shall be provided to
synchronize the flow of aggregates from the bins and the
flow of bitumen from the meter or other proportioning
device. A revolution counter graduated in 0.01 revolutions
shall be visibly located on the plant. Means shall be
provided for checking by mass the flow of bitumen.
6 The heated mixer shall be capable of producing a
uniform mixture within job-mix tolerances. It shall be
equipped with a discharge hopper with dump gates which
will permit rapid and complete discharge of the mixture.
Paddles shall be adjustable for angular position on shafts
and reversible to retard the flow of mix. The spray bar of
the mixer shall be equipped with a pressure gauge. An
adjustable baffle or dam which can be locked or bolted in
position shall be placed at the discharge end of the
pugmill. The mixer shall have a nominal capacity of not
less than 50t/h and shall have a manufacturer's plate
giving the net volumetric contents of the mixer at the
several heights inscribed on a permanent gauge. Charts
shall be provided showing the rate of feed of aggregate
per minute.
7 Unless otherwise agreed by the Engineer the mixing
time shall be determined using the following formula. The
mass shall be determined for the job by tests made in the
presence of the Engineer.
Mixing time in seconds = Pugmill dead capacity (kg)
Pugmill output (kg/s)
8 The pugmill shall be equipped with a discharge
hopper having a minimum capacity of 900kg.
19.8 Spreading and Finishing
Machines
19.8.1 Asphalt Pavers
1 Asphalt pavers shall be self-contained, power-
propelled units provided with an activated screed or
strike- off assembly, heated if necessary and capable or
spreading and finishing courses of bituminous plant-mix
material in widths appropriate to the typical sections and
thicknesses shown on the Drawings.
2 Automatic controls of the paver shall be by a linkage
arrangement so that through the process of automatically
adjusting the screed thickness control, the asphalt can be
placed and finished to a predetermined grade and uniform
slope and cross-section. Manually controlled pavers may
be used if approved by the Engineer. Such pavers shall be
capable of spreading the mix in such a manner that no
supplemental shaping will be required.
3 Pavers shall be equipped with a receiving hopper of
sufficient capacity for the spreading operation. The hopper
shall be equipped with a distribution system to place
mixture uniformly in front of the screed. The screed or
strike-off assembly shall produce a finished surface of the
required evenness and texture without tearing, pushing or
gouging the mixture. When laying the mixture, the paver
shall be capable of being operated at forward speeds
consistent with satisfactory placement.
19.8.2 Aggregate Spreaders
1 Spreaders used in placing aggregates in layers shall
contain a strike-off plate capable of being adjusted so as
to place material in uniform layers from 10 to 300mm in
thickness. They shall be fitted with two end gates or cut-
¬off plates so that aggregates may be spread in widths
varying up to the full lane width.
2 Spreaders used for surface treatment, shall be of a
mechanical type approved by the Engineer. They shall
distribute aggregate uniformly and shall be capable of
being adjusted so that spreading rate will not vary by
more than ±1kg/m2.
♦ 19-5 ♦
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19.9 Pressure Distributors
1 Pressure distributors used for applying bitumen or
bituminous emulsions shall be mounted on self-propelled
trucks which shall be capable of operating smoothly at
speeds down to 1.0km/h when used on construction and
at road speeds from 50 to 70km/h when used for
transporting bitumen.
2 The bitumen tank shall have a capacity between 2000
liters and 9500 liters. Approval shall be obtained from the
Engineer prior to use of a larger tank. The tank shall be
covered by a minimum of 25mm Insulation. It shall be
equipped with a removable access cover, an overflow pipe
and a suitable strainer located at the pump intake or the
outlet to prevent the passage of any material which might
clog the nozzles. A dial gauge visible to the spray bar
operator shall indicate the contents of the tank at various
levels, and a pressure gauge shall show the pressure at
which bitumen is applied. The tank shall be fitted with an
accurate measuring stick.
3 The bitumen distributor shall be equipped with a
heating system. The system shall consist of heat flues
having sufficient radiation to give rapid circulation of hot
gases of combustion from one or more efficient smokeless
burners of the torch type, a circulating device to give
uniform heating of material, and a suitable fuel supply
tank.
4 The distributor pump shall be of a rotary positive
pressure type of sufficient size and discharge capacity to
apply uniformly the specified amount of bitumen in widths
up to 7.5m. It shall be driven by a petrol motor, other than
the vehicle propelling motor. The pump motor shall have
sufficient power to operate the distributor pump at the
required volume and pressure. If the pump motor is
equipped with a transmission it shall have a governor.
Suitable housing or heating jackets shall be provided to
enclose the distributor pump and piping.
5 Spray bars of various lengths shall be used to spray
bitumen over widths varying from 1.2m to 7.5m. Spray
bars shall be arranged so that they may be traversed
laterally over a distance of not less than 230mm to match
joints and to clear obstructions. They shall be fitted with
spray nozzles to give uniform distribution of the material
in the specified quantities. Means shall be provided to
stop the flow quickly and to prevent it from dripping when
the flow is shut off. Means shall be provided for obtaining
samples of material from the tank or from piping leading
from the tank to the spray bars.
6 A hand spray bar and nozzle having a suitable length
of flexible hose with packed couplings shall be provided
for applying material at intersections, shoulders and
similar locations.
7 A mercury thermometer with a stem extending into
the material or into a well, shall be placed in a suitable
position in the tank to give the temperature of the contents.
8 A substantial platform for the operator shall be
provided at the rear of the distributor. It shall be so located
♦ 19-6 ♦
that it will provide a clear view of the operation of the
spray bars.
9 A tachometer shall be attached to the truck so as to
be visible to the truck operator and to enable him to
maintain the constant speed necessary for application of
the specified quantity of bitumen. Suitable charts shall be
prepared showing the truck speeds necessary to obtain
the required results. Alternatively, a synchronizer can be
used. The synchronizer shall deliver the specified quantity
of bitumen onto the road surface regardless of the speed
at the truck.
10 The distributor shall be calibrated in the presence of
the Engineer before work is started and the Contractor
shall supply equipment, tools, and materials for the
calibration.
19.10 Heating Equipment
1 The heating equipment shall have sufficient capacity
to heat the bituminous material by circulating steam or
hot oil through coils in the tank or by any other method
approved by the Engineer. Tanks which have defective
coils or which are without coils will be rejected unless
some satisfactory auxiliary means can be provided by the
Contractor to heat the material without introduction of
moisture. Use of any equipment to agitate bituminous
material while it is being heated will be prohibited if, in the
opinion of the Engineer, it changes the characteristics of
the material. Free steam or hot oil shall not be introduced
directly into the material.
19.11 Mixers for Concrete Pavements
1 Paving mixers shall be the batch type and shall have
3
a rated capacity of not less than 0.75m of mixed concrete.
Mixers having multiple mixing drums may be used. The
mixer shall be equipped with boom and bucket delivery
and the bucket shall be so constructed that it will
distribute concrete in a uniform and satisfactory manner.
The mixer skip shall be equipped with a bulkhead suitably
placed and capable of retaining a full batch of aggregates
and cement without spillage.
2 The mixer shall be equipped with a batch meter for
counting batches and a timing device which automatically
locks the discharge lever until the end of the mixing period.
The timing device shall be equipped with a bell adjusted
to ring each time the lock is released. If the timing device
becomes out of order the Contractor will be permitted to
continue while it is being repaired, provided each batch is
mixed and manually timed for at least 1.5 minutes. If the
timing device is not in good working order within 72 hours,
further use of the mixer shall be prohibited until repairs
are completed.
3 The mixer shall be equipped with a water measuring
device which shall be capable of measuring and
discharging the specified amount of water to ± 1%. The
accuracy of measurement shall not be affected by
variations in pressure in the water supply. Water
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measuring equipment shall include an auxiliary tank from
which the water measuring tank shall be filled. The
volume of the auxiliary tank shall be not less than the
volume of measuring tank. Equipment shall be so
arranged that water pressure in the measuring tank cannot
exceed that due to the difference in elevation between the
two tanks. The measuring tank shall be equipped with an
outside tap to provide for checking the graduation on the
indicator unless other means are provided for readily and
accurately determining the amount of water discharged.
Means shall be provided to automatically stop the flow of
water from the measuring tank when the desired quantity
has been delivered.
4 The type of equipment shall be such that the quantity
of water delivered shall not be affected by tilting the mixer.
There shall be no leakage and if the water measuring
equipment fails to deliver the proper quantity of water due
to the mechanical condition of the equipment, the
operation of the mixer shall be suspended until repairs
have been made.
5 Pick-up and throw-over blades in the drum of the
mixer which are worn down 20mm or more in depth shall
be replaced with new blades.
19.12 Portable Concrete Mixers
1 Portable concrete mixers for incidental construction
3 minutes, measured between loading discharge and
shall be of the batch type. Mixers involving placing 25m
or more in a single pour shall have a rated capacity of not
3 required for charging a truck, the time of haul shall be
less than 0.25m per batch. Other portable mixers shall
3 reckoned from the start of mixing of the first batch.
have a rated capacity of not less than 0.17m per batch.
The mixer shall be equipped with a batch meter, timing
device and water measuring device as specified in Clause
19.11.
2 Pick-up and threw-over blades in the drum of the
mixer which are worn down more than 20mm shall be
replaced with new blades.
19.13 Truck Mixers and Agitators
1 Truck mixers shall be of the type having a watertight
revolving drum, suitably mounted and fitted with blades
inside the drum. They shall be capable of combining
aggregates, cement and water into a uniform mixture and
of discharging the mixture without segregation. A truck
mixer shall have attached to it a metal plate on which is
stated its capacity in terms of volume of mixed concrete
for the various uses for which the equipment is suitable.
2 Except when used exclusively for agitating premixed
concrete, trucks shall be provided with a batch meter and
locking device capable of preventing discharge of concrete
before the required number of revolutions has been
obtained or with a revolution counter suitably mounted to
provide means of verifying the amount of mixing
performed. Water shall not be added to concrete in transit
from a pre-mix plant.
3 The water measuring device shall be capable of
discharging the specified amount of water with an
accuracy of 1%. If water is added during transit, the
measuring device may be mounted on the truck mixer and
an outside tap or valve shall be provided for checking the
graduations on the indicator, unless other means are
provided for readily and accurately determining the
amount of mixing water discharged. Provision shall be
made to automatically stop the flow of water when the
desired amount has been delivered. If not mounted on the
truck, the water measuring device shall be located at the
site selected for adding water and shall conform to the
requirements of Sub-section 19.11.
4 Equipment for weighing and batching materials
intended for truck mixing shall comply with the relevant
clauses of these specifications
5 Truck agitators shall be of the type having a
watertight revolving drum suitably mounted and fitted
with internal blades attached to the drum. Truck agitators
when fully loaded shall be capable of maintaining the
concrete in a thoroughly mixed and uniform mass and of
discharging concrete without segregation. Agitators shall
transport and discharge concrete without leakage of
ingredients. A truck agitator shall have attached to it a
metal plate on which is stated its capacity in terms of
volume of the pre-mixed concrete for the various uses of
which the equipment is suitable.
6 Concrete from central or pre-mix plants shall not be
in transit in truck mixers or agitators longer than 30
commencement of pouring. If more than one batch is
19.14 Concrete Batch Plants
19.14.1 General
1 The plant shall be approved by the Engineer before
production begins. Bins, weighing hoppers and scales
shall be arranged to the satisfaction of the Engineer so
that the weigh beam, dial or dial scale is in full view of the
operator controlling the gates, valves or belts that feed
material into the weighing hopper. The plant shall be
equipped with a room as specified in Sub-section 19.7
2 Storage bins shall have sufficient capacity for
adequate supply of material to weighing hoppers. They
shall be supported by a rigid framework on a solid
foundation. Bins shall have adequate separate
compartments for each size of aggregate and for bulk
cement when used. The top of the fine aggregate
compartment shall be equipped with a tilted screen
having a maximum mesh size of 2.5mm through which all
fine aggregate must pass. Each compartment shall be
designed to discharge material efficiently and freely into
the weighing hopper. Means of control shall be provided
so that when the quantity to be obtained is being
approached the flow of material can be gradually retarded
and completely shut off, without leakage, at the moment
the desired amount has been discharged.
♦ 19-7 ♦
copy 249
3 Weighing hoppers shall be completely suspended
from scale and shall hang free and except as further
provided, shall have sufficient capacity to contain
materials to be weighed for one batch of concrete without
shoveling and without jiggling the hopper to keep bin
gates and chute openings free of material. Cement shall
be weighed in a hopper and independent of the hoppers
used for weighing aggregate.
4 Batching equipment insufficient in capacity to weigh
materials required for a full batch will be permitted
provided the capacity of the hoppers is sufficient to weigh
3
all materials for at least 1m of concrete for any mixer of
3
rated capacity of 1m or larger. Disproportion between
batching equipment and the mixer shall not be so great
that more than 3 weighings of each material will be
required for charging the mixer.
5 Aggregate hoppers shall have a port or other
opening for removal of overload unless sufficient
clearance exists between the bottom of the bin gate and
the top of the hopper. The top of the cement hopper shall
be closed to prevent escape of cement while it is being
weighed. Hoppers shall be designed to eliminate
accumulation of unused material and leakage through
discharge gates during weighing. They shall be capable of
discharging material efficiently and completely into batch
trucks or the mixer without the necessity of beating or
jiggling. If a hopper in the opinion of the Engineer does
not discharge material satisfactorily, it shall be provided
with a vibrator of sufficient frequency and power to
provide complete discharge. Weighing hoppers shall be
enclosed or otherwise protected against wind. When bins
are not available, materials shall be weighed in containers.
End loaders shall not be used for loading the weighing
hopper.
6 Scales may be of either the horizontal beam or
springless dial type designed as an integral unit of the
batching plant and shall be of rugged construction. Beam
type scales used for weighing one size or kind of
aggregate shall have one full capacity weigh beam.
Multiple beam scales used in weighing more than one size
or kind of aggregate shall have as many beams as the
number of sizes or kinds of aggregate to be weighed.
Individual beams shall have such capacities as will permit
the required mass of each size or kind of material to be set
off on a single beam. The scale shall be provided with
suitable lockouts so that weigh beams may be engaged to
weigh in the desired order.
7 Each weigh beam shall have some means placed in a
position from which it can be viewed without parallax by
the operator while charging the hopper, to indicate when
the beam is in the proper balance position. Poises shall be
constructed so that they will be held firmly in position.
Beam scales shall have a provision such as a tell-tale dial
for indicating to the operator that the required load in the
hopper is being approached. Such a device shall indicate
at least the last 100kg of load in the case of scales used for
weighing aggregate and at least the last 50kg of load in
the case of scales used for weighing cement.
♦ 19-8 ♦
8 Springless dial scales shall be provided with suitable
markers inside the glass cover and in front of the dial
which may be set to show the position of the dial indicator
for the required load or various cumulative loads when
more than one size or kind of aggregate is weighed in the
same hopper. Markers shall be in distinctive colors for the
various materials to be weighed.
9 The value of the minimum graduation interval of any
scale shall be not more than 0.2% of the batch mass and
not more than 0.1% of the capacity of the scale. The value
of the minimum graduation interval of any scale used for
weighing water shall be not less than 1kg. Scales shall be
designed and built so that accuracy within the maximum
tolerance of ± 0.4% of the net load in the hopper will be
maintained.
10 When a beam scale is used for weighing cement a
tare shall be provided and the weigh beams shall be
capable of being lifted out of the weighing position so that
the tare weight of the hopper can be checked after each
weighing operation to determine if all the cement has
been discharged into the batch.
11 Scales shall be housed or otherwise protected
against the effect of wind in a manner meeting the
approval of the Engineer.
12 Ten standard 10kg weights shall be available on Site
for use in calibrating and testing weighing equipment.
Weights will not be required when scales are calibrated by
trained scale personnel with adequate scale testing
equipment and the calibration is observed by the Engineer.
13 Means of access for inspection purposes shall be
safe and shall meet the approval of the Engineer. In the
case of permanently located batching plants, means of
access shall be an inclined stairway with a handrail
located so that its upward flight will end on the scale
operator’s platform. It shall be firmly attached to the
supporting members of the bin. The weigh platform shall
have a floor of metal grid or 50mm thick timber planks.
19.14.2 Automatic Concrete Batching Plants
1 Automatic equipment for weighing, measuring,
batching and mixing materials for concrete shall conform
to Sub-section 19.11 except as modified and extended by
the following provisions.
2 Each batch shall be mixed for the full period required
after all the materials have entered the mixer and
recharging the mixer shall not occur before the previous
batch has been discharged; When batching plants are
used for successive batches of the same size, the mixing
time adjusting control shall be capable of being locked.
3 Cement and mixing water shall be weighed or
otherwise measured within the tolerance of ±1% of the
required quantity. Each of the aggregates, whether
weighed separately or cumulatively, shall be weighed
within the tolerance of ± 1.5% of the respective required
masses. Interlocks shall be set so that the amounts of
materials will be delivered within the tolerance stated.
copy 249
4 The arrangement shall be such that the scales of the
system can be conveniently checked for accuracy. Scales
shall be designed and built so that when drag due to the
weighing control device is included, accuracy within ±0.4%
of the net load in the hopper will be maintained.
5 When mixing water is measured volumetrically
provision shall be made for by-passing measured water
into a container for checking the accuracy of delivery. If
water is measured during the course of its flow into the
batch, means shall be provided to show at any time
during the flow, the amount that has entered. Devices for
volumetric measurement of mixing water shall
automatically reset at the initial position immediately after
delivery of the measured amount and be ready for the
next batch cycle.
6 The dispenser for an admixture shall provide a visual
indication that the admixture is actually entering the batch.
The tube through which it is conducted into the stream of
the mixing water shall be transparent, or shall have a
translucent section.
7 The plant shall be provided with gates, valves or
other suitable devices, which, when activated by a single
starting mechanism, shall set in motion the charging of
weigh hoppers or other containers and which, in weighing
or measuring any given material, shall end the charging
when the desired amount has been attained. It shall be
capable of having quantities preset on a central control
panel that will result in the correct measurement of the
material for each batch. Control adjustments shall be
capable of being performed on the same panel.
8 An over and under indicating device shall be
provided to show whether the amount of material
weighed is within the allowable tolerance. An interlock
shall be provided, firstly so that the charging device can
open or start only when the scale indicates zero load and
when the weigh hopper or container discharging gate or
valve is closed, and secondly so that the discharge gate or
valve can open only when the desired mass within the
allowable tolerance is in the weigh hopper or container
and when the charging device is closed or stopped. If
different kinds or classes of aggregates are weighed
cumulatively into the same hopper, control and interlock
shall be provided with respect to each increment of mass,
as required for material weighed into an individual hopper.
Mixing water and admixture may be measured
volumetrically.
9 Automatic batching equipment for weighing or
measuring batch quantities in increments shall be
provided with an automatic repeater having a counter that
can be set for the number of increments required and
allowing the required number of increments to be
accurately delivered and discharged into each batch.
10 The batching system shall be activated by a single
starting mechanism and be completely interlocked so that
the discharge gates or valves can open only when the
mixer is in the proper position for receiving material.
11 The interlocking system shall allow the batch to enter
the mixer so that some water is in advance of the
remainder of the batch. Water shall then enter uniformly
while mixing is continued and all water shall be in the
drum by the end of the first 15 seconds of the mixing
period.
12 Means shall be provided for easy adjustment from
preset quantities of aggregates and mixing water. Suitable
equipment indicating the amount of free water in fine
aggregate as it is being batched shall be provided and the
quantities of fine aggregate and mixing water shall be
adjusted concurrently as concrete is being produced.
13 The weighman shall not interfere with the operation
of any part of the scale mechanism during the weighing
process for the purpose of circumventing the interlock or
causing malfunction of the equipment. The Engineer may
require that equipment be provided with a positive means
for preventing such interference.
14 Automatic and semi-automatic batching plant may
be constructed so that it can be switched to manual
control. However, when switching to manual control is
necessary, batching operations shall continue only until
repairs can be made, but not for a period exceeding 72
hours. If provision is made for switching to manual
operation, then the scale or a scale follower shall be
placed within view of the operator, but not further then 6m
from the location from which the manual batching is being
performed.
15 Batching plant that does not fully comply with the
requirements prescribed for automatic batching shall be
considered as semi-automatic. The minimum requirement
for semi-automatic batching shall be gates, valves or other
suitable devices which open or start separately when
actuated by individual starting mechanisms to permit
material to be weighed or measured, and close or stop
automatically when the desired amount has been attained.
19.15 Equipment for Concrete Pavement
19.15.1 General
1 Flexible or curved forms of proper radius, made of
either metal or wood, shall be supplied for use on curves
of 30m radius or less. Straight side forms shall be of metal.
They shall be of adequate cross section and supplied in
sections not less than 3m in length. They shall have a
height not less than the edge thickness of the pavement to
be constructed, a base width equal to or greater than the
height and not less than 6mm in thickness, except that a
minimum thickness of 5mm will be permitted if the form is
of trapezoidal cross section. They shall have flange braces
extending outward on the base not less than 2/3 the
height of the form and spaced not more than 1.5m apart.
Sections shall have a steel pin at each end and at least one
intermediate pin; provision shall be made to lock pins to a
true grade. Locked joints shall be provided between form
♦ 19-9 ♦
copy 249
sections which are free from play or movement and which
provide support and connection.
2 Forms shall withstand impact and vibration of the
compacting and finishing equipment without visible
springing or settlement. They shall be straight edged and
free from warp. Forms with an upper edge out more than
1mm in 1.5m from a straight line will be rejected. The
longitudinal axis of an upstanding leg shall not vary more
than 2mm in 1m from a straight line.
3 When used, wood forms not of marine ply shall be
made of well seasoned, surfaced plank not less than
50mm nominal thickness, and shall be the full depth of the
concrete slab. Provision shall be made for rigid, smooth
connections and suitable means for securely fastening in
place to lines and profiles given.
4 The supply of forms shall be sufficient to permit their
remaining in place not less than 48 hours after concrete
has been placed, or longer if deemed necessary by the
Engineer.
5 Mechanical form graders, if used, shall be so
designed that they may be adjusted and controlled to cut
to a given profile and produce a subgrade for the
pavement forms or for slip-form paver track as shown on
the drawings.
19.15.2 Subgrade Preparation Equipment
1 Subgrade planers shall be of steel and shall be
mounted on rollers when forms are used, or wheels or
tracks when slip-form paving is being employed. They
shall be equipped with steel cutting edges or cutting
rollers so designed that they may be accurately adjusted
vertically. A subgrade planer shall be of sufficient mass so
as not to rise under pressure from the material being
planed. The subgrade planer shall be capable of producing
cross sections in accordance with the Drawings and shall
develop a centre deflection of not more than 3mm.
2 Subgrade finishing machines shall be of steel
mounted on crawler tracks and shall be equipped with
steel cutting edges so designed that they may be
accurately adjusted vertically and held in place firmly. The
subgrade machines shall weigh not less than 3175kg and
have such strength and rigidity that changing the supports
from wheels to centre will develop a deflection of not
more than 3mm.
3 Heavy subgrade templates shall be made of steel and
designed so that they can be moved backwards and
forwards in a vertical position. They shall be mounted on
rollers, wheels or tracks, adjustable vertically, and have a
total mass not less than 225kg for widths of 5m or more.
Test points shall be spaced not more than 150mm centre
to centre and be adjustable so that they may be set to
conform to the cross section of the subgrade.
4 Water supply equipment shall be of such capacity
and design as to provide an ample supply and adequate
pressure simultaneously for all the requirements of
machinery, mixing, curing, wetting subgrade and other
features of the work.
♦ 19-10 ♦
19.15.3 Mechanical Concrete Spreaders and
Finishers
1 When pavement forms are used, mechanical
spreaders shall operate on the forms and when formless
paving is constructed they shall operate on wheels or
tracks. Spreaders shall be self-propelled and capable of
spreading the concrete mix to the desired cross sections.
They shall be easily adjustable to spread different
thicknesses of concrete.
2 Full width vibrators of the surface pan type, or
internal type with multiple spuds, may be attached to the
spreader finishing machine or may be mounted on a
separate carriage but shall not come in contact with joints,
load transfer devices, reinforcement, subgrade, subbase
or side forms. Vibrating impulses shall be applied through
apparatus designed for this purpose, and constructed to
operate satisfactorily ahead of the finishing machine.
Vibratory impulses shall be transmitted through the
concrete with sufficient intensity to compact it throughout
its entire depth and width. The pavement vibrator shall not
be used to level or spread pavement concrete.
3 Surface pan vibrators shall be designed so that
vibrating impulses are applied directly to the surface of
the concrete. They shall be equipped with at least two
vibrating elements for each 3m width of pavement
vibrated. The operating frequency shall be not less than
50Hz.
4 Internal vibrators shall be of a suitable design with a
minimum operating frequency of 100Hz. Vibrating
elements shall be so spaced that the concrete will be
compacted throughout its entire depth and width, with a
maximum vibrator spacing of 600mm.
5 Finishing machines shall be power driven and
equipped with at least 2 screeds fully and accurately
adjustable to produce a crowned, sloping or flat surface as
required. They shall be designed and operated to strike off,
screed and compact. The machine shall have ample
strength and sufficient power, and be geared to operate
consistently and smoothly.
6 Concrete finisher floats shall be either self-propelled
or attached to the finishing machine. They shall be fitted
with independent wheels which ride on the forms and be
of sufficient mass not to flex under the pressure of
concrete. The floats shall be easily adjustable from crown
to flat. They shall be at least 750mm long with at least
600mm in contact with the concrete. They shall be
designed to prevent tearing of the concrete surface or
rolling of the aggregate under the float. The float pan shall
be suspended from the frame, and be capable of
adjustment in both height and width. Once adjusted, it
shall hydraulically or by other suitable means be raised
from the operator's platform. When lowered it shall
automatically return to its present position.
copy 249
7 Longitudinal float machines shall be so constructed quality bass or bassine fiber not more than 120mm in
that travel of the floating mechanism can be adjusted to length. The handle shall be at least 300mm longer than
conform to the pavement cross section shown on the half the width of the slab and be readily adjustable.
Drawings or formed by the finishing machine. 10 Edging tools shall have a radius of 6mm.
8 Formless pavers shall be self-propelled and fitted
with suitable devices for distributing, finishing and 19.16 Method of Measurement and
spreading concrete to the full-width and thickness as
Basis of Payment
shown on the Drawings. The tracks shall be of sufficient
length and width to properly support the machine and its
1 Plant and equipment used in the works will not be
load without causing depressions. They shall be equipped
separately measured for payment, unless provided under
with a strike-off screed and internal vibrators of sufficient
a Dayworks arrangement, but will be considered
quantity to provide complete compaction regardless of the
subsidiary to the construction work items for which they
depth of concrete placed.
are being used and which are contained in the Bill of
Quantities.
19.15.4 Miscellaneous Minor Equipment for
Concrete Pavements
1 Hand vibrators shall be of the internal type,
adequately powered to operate under full load at a
frequency of at least 75Hz and shall have an intensity and
period of vibration sufficient to obtain thorough
compaction of concrete.
2 Headers shall be shaped to conform to the cross
section shown on the Drawings. They shall be of wood or
metal and of sufficient thickness and rigidity to provide a
vertical construction joint. Headers for continuous
reinforced pavement shall be of wood or metal, split
longitudinally to provide for the proper depth of
continuous reinforcing steel in accordance with the
Drawings.
3 Footbridges shall be durably constructed, readily
movable and so designed that no part of the bridge will
come in contact with the pavement at any time.
4 Hand operated longitudinal floats shall be not less
than 3.5m in length and 150mm in width. Floats shall be
properly stiffened to prevent flexing and warping, and be
provided with handles.
5 Long-handled floats shall have a blade at least 1m
long and 150mm wide. The handle shall be long enough
to permit operation of the float from the shoulder.
6 Vibrating screeds used to strike off and compact
concrete by the hand method shall be durably constructed,
and shaped to provide the cross section shown on the
Drawings. They shall be 600mm longer than the width of
the pavement, sufficiently strong and rigid to retain shape
under all working conditions and be provided with
handles. If of wood, they shall be at least 70mm thick and
steel shod.
7 Standard 3m straightedges shall be made of suitable
material and maintained in accurate alignment. They shall
be fitted with a handle long enough to permit operation of
the straightedge from the shoulder.
8 Belts shall be of canvas or canvas/rubber
composition, 2 to 4 ply, at least 150mm wide and 600mm
longer than the width of pavement.
9 Brooms shall be of the push type at least 450mm
wide. They shall contain no more than 3 rows of good

♦ 19-11 ♦
copy 249
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Ref. Title Page No.

20.1 Preamble 20-1

20.1.1 Materials 20-1
20.1.2 Quantities 20-1
20.1.3 Descriptions 20-1
20.1.4 Symbols, Abbreviations
and Definitions 20-2
20.1.5 Work of Special Types 20-3

copy 249
copy 249
20.1 Preamble
20.1.1 Materials
a) The rules contained in this Method of
Measurement apply equally to both proposed
and executed works.
b) The Bills of Quantities are to be read and
construed in association with the Drawings, the
Specification and this Method of Measurement.
Information which is given on the Drawings
and/or in the Specification is identified by
cross-references included in the descriptions of
work in the Bills of Quantities.
c) Where work cannot be fully described or where
the quantity of work required cannot be
accurately determined, it is given as a unit and
priced as a Provisional Sum. (P.S.)
d) Unless the term meter, used in this Method of
Measurement, is preceded by the words square
or cubic it is deemed to be linear.
20.1.2 Quantities
a) Quantities set out in the Bills of Quantities are
the estimated quantities and they shall not be
taken as the actual and correct quantities for
ordering or purchasing of materials.
b) Works shall be measured net as fixed in
position in accordance with the rules contained
in this Method of Measurement or except
where otherwise stated in a measurement rule
applicable to the work.
c) Dimensions used in calculating quantities are
taken to the nearest 1 mm. (i.e. 0.5 mm and
over is regarded as 1 mm. Less than 0.5 mm is
disregarded).
d) Quantities measured in tonnes are given to
three (3) places of decimals. Other quantities
are given to the nearest whole unit except that
any quantity less than one unit is given as one
unit.
e) Unless otherwise stated, where minimum
deductions for voids are dealt with in this
Method of Measurement they refer only to
openings which are within the boundaries of
measured areas. Openings which are at the
boundaries of measured areas are always
deducted irrespective of size.
20.1.3 Descriptions
a) Headings to groups of items in the Bill of
Quantities are to be read as part of the
descriptions of the items to which the headings
apply. General directions and descriptions of
items of work given elsewhere in the Tender
Documents are not generally repeated in the
Bill of Quantities. Reference must be made to
the Drawings, Specification and Conditions of
Contract for this information
b) Dimensions are stated in descriptions generally
in the sequence length, width, height. Where
ambiguity could arise, the dimensions are
identified.
c) Dimensions given in descriptions are in
millimetres unless otherwise indicated.
d) Unless otherwise specifically stated in the Bill
of Quantities or herein, the costs of the
following are deemed to be included in the
rates for measured work:
i. Labor and all costs in connection
therewith, including transport,
ii. Materials, products, goods and all costs in
connection therewith including transport,
iii. Contractor’s equipment and temporary
works, including but not limited to
construction plant, scaffolding, tools,
vehicles and the like, and all costs in
connection therewith, including
maintaining, adapting, relocating, clearing
away and making good,
iv. assembling, fitting and fixing materials,
products and goods in position,
v. any method of fixing, fixing to any nature
of base or background including
preparation and providing fixing
materials,
vi. breaking down for transport and
installation and subsequent re-assembly
of composite items manufactured off site,
vii. waste of materials, and for consumable
materials.
viii. square, raking and curved cutting,
ix. work at any location or height,
x. work in small, isolated quantities,
xi. protection of all work,
xii. protection of all existing structures,
utilities, site improvements, trees and
vegetation, features, pavements and other
facilities on and adjacent to the site,
which are to remain upon completion of
the work,
all other enabling tasks, associated and
subsidiary components and items of
♦ 20-1 ♦
copy 249
 work, which are indicated or reasonably
inferred from the Drawings and/or the
Specification and necessary to perform
and complete the work described,
xiii. establishment and overhead charges and
profit.
e) Except where items are included in the Bill of
Quantities and are priced separately by the
Contractor therein, the costs of the following
are deemed to be included in the rates for
measured work:
i. site administration and security,
ii. insurances,
iii. bonds and guarantees,
xviii. setting out and survey work as required in
the Contract,
xix. samples of materials and testing of
materials, including providing equipment
for testing,
xx. design drawings, working drawings, road
cross sections, shop drawings, co-
ordination, installation and as-built record
drawings, operation and maintenance
manuals and the like,
xxi. preparation and submittal of reports,
records, certificates, notices, proposals,
designs, details, calculations and other
information and data required by the
Specification,

iv. water for the works, xxii. cost of work items for which there are no
direct payments and which are
v. lighting and power for the works, considered in the Specification and other
contract documents as subsidiary to other
vi. temporary facilities and temporary
items in the Bill of Quantities,
accommodation for the use of the
Contractor and the Engineer, xxiii. allowance in unit rates for all other
requirements services, provisions,
vii. temporary telephones, faxes and
liabilities and obligations contained in the
photocopying equipment for the use of
General Requirements and Conditions of
the Contractor and the Engineer, and the
Contract.
cost of local calls,

viii. temporary roads, hardstandings, 20.1.4 Symbols, Abbreviations and

crossings and the like, Definitions
ix. temporary fencing, hoardings, screens,
a) The following symbols and abbreviations are
fans, foot- ways, guardrails, gantries and
used in this Method of Measurement and in the
the like,
Bills of Quantities:
x. giving notices and making applications to
lin.m. = linear meter
all Concerned Authorities and owners,
including the payment of fees, royalties, sq.m = square meter
taxes and charges in connection
therewith, cu.m = cubic meter

xi. safety, health and welfare of workpeople, cm = centimeter

xii. compliance with traffic regulations, mm = millimeter

xiii. maintenance of public and private roads, nr = number

services and adjoining property, kg = kilogramme
xiv. control of noise and pollution, prevention t = tonne (metric)
of fire and compliance with all other
statutory and general obligations, % = percentage

xv. removing rubbish, protective casings and L.S. = lump sum

coverings and cleaning the works on
dn = nominal diameter
completion,
Qty = quantity
xvi. drying the works,
Drg = drawing.
xvii. testing and commissioning of service
installations including providing fuel, Mpa = Mega Pascal

PS = Provisional Sum

♦ 20-2 ♦
copy 249
 b) The following definitions apply to all work:

i. 'horizontal' means level or sloping work

not exceeding 15 degrees from the
horizontal,

ii. 'sloping' means sloping work exceeding

15 degrees but not exceeding 80 degrees
from the horizontal,

iii. 'vertical' means work exceeding 80

degrees from the horizontal,

iv. 'curved' means curved in any direction or

in more than one direction and to any
radius or radii, and includes curved work
to domes, vaults and the like.

20.1.5 Work of Special Types

a) Work of each of the following special types is

separately identified:

i. work on or in existing buildings (i.e.

buildings existing before the current
project),

ii. work to be carried out and subsequently

removed (other than temporary works),

iii. work outside the boundaries of the site,

iv. work carried out in, or under, water (i.e.

canal, river or sea water),

v. work carried out in compressed air.

♦ 20-3 ♦
copy 249
copy 249
 PROJECT TITLE
Subsection (If necessary)
BILL OF QUANTITIES
BILL (I) PRELIMINARIES

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

CONDITIONS OF CONTRACT
The Contractor is deemed to have carefully studied and understood and taken
into account the provisions and requirements of the General and Particular
Conditions of Contract. The rates and prices stated in the Bill of Quantities shall
include for all costs of compliance with the Conditions except for the costs of
the items given in this Section 1 and for which a separate amount is stated
herein.

1 GENERAL

1.3 Project Site

1.3.5(i) Soil investigation and report LS

1.4 Contractor's Site Facilities

1.4.3(i) Mobilization and demobilization of Contractor's
Contractor s site facilities LS
1.4.3(ii) Maintenance of Contractor's site facilities month

1.5 Engineer's Facilities

1.5.13(i) Provision of Engineer's offices (type) (No of units) month
1.5.13(ii) Maintenance of Engineer's offices (type) (No of units) month
1.5.13(ii) Provision of surveying equipment for the Engineer month
1.5.13(iv) Maintenance of surveying equipment for the Engineer month
1.5.13(v) Provision of Engineer's accommodation (type) (No of units) month
1.5.13(vi) Maintenance of Engineer's accommodation (type) (No of units) month
1.5.13(vii) Provision of site laboratory (type) month
1.5.13(viii) Maintenance of site laboratory month

page I-I CARRIED TO SUMMARY

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Oman Standard Specifications for Road and Bridge Construction 2010
 PROJECT TITLE
Subsection (If necessary)
BILL OF QUANTITIES
BILL (I) PRELIMINARIES (continued)

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

1 GENERAL (continued)

1.7 Control of Traffic and Access

1.7.6(i) Maintenance and protection of traffic month
1.7.6(ii) Supply and compaction of sub-base on diversions where ordered
by the Engineer cu. m
Supply and compaction of bituminous base course on diverions where ordered
1.7.6(iii) cu.m.
by the Engineer
1.7.6.(iv) Prime coat (rate of application) sq.m.

1.10 Management Procedures

1.10.6(i) Provision of five sets of photographs as specified month
1.10.6(ii) Provision of two sets of video recordings as specified month

1.11 Submittals
Provision of As-built drawings, record drawings, record specifications and
1.11.8(i) LS
miscellaneous records as specified

1.14 Contractor's Temporary Works and Services

1.14.7(i) Provision, erection, relocation, maintenance and removal of
project signboards (type) nr

1.15 Commemorative Plaque and Opening Ceremony

1.15.4(i) Provision and erection of commemorative plaque LS
1.15.4(ii) Opening ceremony including all facilities LS

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Amount
Item No Description R.O. R.O.
Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
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BILL (II) EARTHWORKS

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

2 EARTHWORKS

2.1 Clearing and Grubbing

2.1.5 (i) Clearing and Grubbing sq.m.
2.1.5 (ii) Removal and delivery of trees of 300mm trunk diameter or greater nr.

2.2 Removal of Structures and Obstructions

2.2.5 (i) Removal of existing building (type and description) nr.
2.2.5 (ii) Removal of reinforced concrete (type, location, dimensions) cu.m.
2.2.5 (iii) Removal of mass concrete (type, location, dimensions) cu.m.
2.2.5 (iv) Removal of prestressed concrete (type, location, dimensions) cu.m.
2.2.5 (v) Removal of curbs lin.m.
2.2.5 (vi) Removal of tiles sq.m.
2.2.5 (vii) Removal of pipe culverts (diameter) lin.m.
2.2.5 (viii) Removal of existing pavement (description, type) cu.m.
2.2.5 (ix) Removal of reusable Road Studs nr.
2.2.5 (x) Removal of steel safety barrier including posts and foundations lin.m.
2.2.5 (xi) Removal of concrete barrier lin.m.
2.2.5 (xii) Removal of sign boards (size) nr.
2.2.5 (xiii) Removal of floodway marker posts and foundations nr.
2.2.5 (xiv) Removal of reusable concrete safety barrier lin.m.
2.2.5 (xv) Removal of re-usable steel safety barrier (dims) (type) lin.m.
2.2.5 (xvi) Removal of re-usable sign board , posts and foundations (size) nr.
2.2.5 (xvii) Removal of re-usable sign crossing marker posts nr.
2.2.5 (xviii) Removal of drainage protection works (type) cu.m.
2.2.5 (xix) Removal of existing fences and gates (description, type, ) lin.m.
2.2.5 (xx) Removal of existing block and masonry walls cu.m.
2.2.5 (xxi) Removal of ditches (type/size) lin.m.
2.2.5 (xxii) Removal of bridges (type, description and dimensions) nr.
2.2.5 (xxiii) Removal of rocks/boulders larger than 0.2 cu.m. or 500 kg (description) cu.m.
2.2.5 (xxiv) Removal of wells and shafts (description and location) nr.
2.2.5 (xxv) Removal of sand dunes (location) (description) cu.m.
2.2.5 (xxvi) Removal of lighting poles, cable and foundations (size) nr.

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Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

2 EARTHWORKS (continued)

2.3 Roadway Excavation

2.3.6 (i) Unclassified excavation cu.m.
2.3.6 (ii) Excavation of unstable material outside Right-of-Way cu.m.
2.3.6 (iii) Unclassified excavation under water cu.m.
2.3.6 (iv) Excavate and stockpile suitable topsoil and recompact as directed cu.m.

2.4 Borrow Materials

2.4.6 (i) Borrow excavation cu.m.

2.6 Sub-grade Construction

2.6.6 (i) Subgrade preparation in cut sq.m.
2.6.6 (ii) Drainage blanket cu.m.
2.6.6 (iii) Subgrade construction on Sabkha sq.m.
2.6.6 (iv) Subgrade construction on top of dune sand sq.m.

2.7 Excavation and Backfilling for Structures

2.7.6 (i) Unclassified structural excavation (depth 0 to 2.0m) cu.m.
2.7.6 (ii) Unclassified structural excavation (depth > 2.0m <4.0m) cu.m.
2.7.6 (iii) Unclassified structural excavation (depth > 4.0m) cu.m.
2.7.6 (iv) Unclassified structural excavation (under water) cu.m.

2.8 Earthwork for Pipe Trenches

2.8.6.(i) Trench excavation and backfilling (depth 0 to 2.0m) cu.m.
2.8.6.(ii) Trench excavation and backfilling (depth > 2.0m < 3.0m) cu.m.
2.8.6.(iii) Trench excavation and backfilling (depth >3.0m < 4.0m) cu.m.
2.8.6.(iv) Trench excavation and backfilling (depth > 4m) cu.m.

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Amount
Item No Description R.O. R.O.
Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
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BILL (III) GRANULAR SUB-BASE, AGGREGATE BASE COURSE AND STABILIZED BASE COURSES

Unit Rate Amount

Item Estimated
Description Unit R.O. Bz R.O. R.O.
No Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

3 GRANULAR SUB-BASE, AGGREGATE BASE COURSE

AND STABILIZED BASE COURSES.

3.2 Granular Sub-base Course

3.2.6 (i) Granular sub-base course (Class A) cu.m.
3.2.6 (ii) Granular sub-base course (Class B) cu.m.
3.2.6 (iii) Granular sub-base course (Class C) cu.m.

3.3 Aggregate Base Course

3.3.6 (i) Aggregate base course (Class A) cu.m.
3.3.6 (ii) Aggregate base course (Class B) cu.m.
3.3.6 (iii) Aggregate base course (Class C) cu.m.

3.4 Stabilized Base Courses

3.4.6 (i) Cement stabilized base course (thickness) cu.m.
3.4.6 (ii) Bitumen stabilized base course (thickness) cu m
cu.m.
3.4.6 (iii) Lime stabilized base course (thickness) cu.m.
3.4.6 (iv) Curing seal cu.m.

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Amount
Item
Description R.O. R.O.
No Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
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BILL (IV) BITUMINOUS PAVEMENT

Unit Rate Amount

Item Estimated
Description Unit R.O. Bz R.O. R.O.
No Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

4 BITUMINOUS PAVEMENT

4.2 Bituminous Materials for Prime and Tack Coats

4.2.8 (i) Bituminous prime coat sq.m.
4.2.8 (ii) Bituminous tack coat sq.m.
4.2.8 (iii) Polymer modified tack coat sq.m.

4.4 Bituminous Base Course

4.4.14 (i) Bituminous base course (Class A/B) cu.m.
4.4.14 (ii) Polymer modified bituminous base course (Class A/B) cu.m.

4.5 Bituminous Binder and Wearing Courses

4.5.14 (i) Bituminous binder course cu.m.
4.5.14 (ii) Bituminous wearing course (Class A/B)) cu.m.
4.5.14 (iii) Polymer modified bituminous binder course cu.m.
4.5.14 (iv) Polymer modified bituminous wearing course (Class A/B ) cu.m.

4.6 Bituminous Seal Coats - Surface Dressing

4.6.10 (i) Single bituminous surface treatment sq.m.
4.6.10 (ii) Double bituminous surface treatment sq.m.
4.6.10 (iii) Bituminous slurry seal coat sq.m.

4.7 Bituminous Leveling Course and Patching Work

4.7.14 (i) Bituminous leveling course cu.m.
4.7.14 (ii) Bituminous patching work cu.m.

4.8 Bituminous Cold Mix Courses

4.8.14 (i) Bituminous cold mix course cu.m.

4.9 Pavement Repairs and Reinstatement

4.9.10 (i) Surface milling sq.m.
4.9.10 (ii) Crack sealing lin.m.
4.9.10 (iii) Pavement repairs (overlay and surface preparation) sq.m.
4.9.10 (iv) Pavement repairs (complete reconstruction) sq.m.
4.9.10 (v) Trench reinstatement sq.m.

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Unit Rate Amount

Item Estimated
Description Unit R.O. Bz R.O. R.O.
No Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

4 BITUMINOUS PAVEMENT (continued)

4.10 Pavement Widening

4.10.6 (i) Pavement widening sq.m.

4.11 Recycled Bituminous Mixes

4.11.14 (i) Recycled bituminous base course cu.m.

4.12 Surface Rideability Measurement

4.12.10 (i) International roughness index (IRI) for bituminous pavement lin.m
4.12.10 (ii) International roughness index (IRI) for concrete pavement lin.m

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Amount
Item
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No Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
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SUMMARY
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BILL (V) CONCRETE AND CONCRETE STRUCTURES

Unit Rate Amount

Item Estimated
Description Unit
No Quantity R.O. Bz R.O. R.O. Bz Bz
(Omani Riyal) (Omani Baiza) (Number) - Omani Riyal (Words) - Omani Riyal (Number) Omani Baiza (Words) Omani Baiza

5 CONCRETE AND CONCRETE STRUCTURES

5.1 Concrete Materials and Mixes

5.1.7 (i) Concrete (Class) in (type of structure), (location) and (finish) cu.m.

5.2 Reinforcing Steel

5.2.6 (i) Mild steel bar reinforcement of any diameter t.
5.2.6 (ii) High tensile steel bar reinforcement of any diameter t.
5.2.6 (iii) Fabric wire mesh reinforcement of any size t.

5.4 Prestressed Concrete Structures

5.4.6 (i) Prestressing wires (state size and type) t.
5.4.6 (ii) Prestressing strands (state size and type) t.
5.4.6 (iii) Prestressing bars (state size and type) t.

5.7 Cement Concrete Pavement

5.7.6 (i) Unreinforced cement concrete pavement cu.m.
5.7.6 (ii) Reinforced cement concrete pavement cu.m.

5.10 Waterproofing for Structures

5.10.6 (i) Tar or bituminous paint (state type, number of coats) sq.m.
5.10.6 (ii) Membrane waterproofing (state type, thickness) sq.m.
5.10.6 (iii) Epoxy coating to internal surfaces of concrete (state type, thickness) sq.m.

5.12 Load Testing of Bridges

5.12.7 (i) Bridge Loading Test nr.

6 STRUCTURAL STEEL AND OTHER METAL WORK

6.6 (i) Structural Steel (grade) t.

6.6 (ii) Railings (type) (height) lin.m.

7 PAINT

7.6 (i) Painting of Existing Concrete Structure (type) (Structure Reference) sq.m.
7.6 (ii) Painting of Existing Steel Structure (type) (Structure Reference) sq.m.
7.6 (iii) Painting of Existing Steel Railings (type) (Structure Reference) lin.m.

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Unit Rate Amount

Item Estimated
Description Unit
No Quantity R.O. Bz R.O. R.O. Bz Bz
(Omani Riyal) (Omani Baiza) (Number) - Omani Riyal (Words) - Omani Riyal (Number) Omani Baiza (Words) Omani Baiza

8 DRAINAGE

8.1 Pipe Culverts

8.1.6 (i) Unreinforced precast concrete pipe culvert (diameter) lin.m.
8.1.6 (ii) Reinforced precast concrete pipe culvert (diameter) lin.m.
8.1.6 (iii) Reinforced precast concrete arch culvert (size) lin.m.
8.1.6 (iv) Reinforced precast concrete elliptical culvert (size) lin.m.
8.1.6 (v) Corrugated steel pipe culvert (diameter) (coating) lin.m.
8.1.6 (vi) Corrugated steel pipe arch culvert (size) (coating) lin.m.
8.1.6 (vii) Cast in-situ concrete pipe or arch culverts (state type) lin.m.

8.2 Storm Sewers

8.2.6 (i) Storm sewer (type) (diameter) lin.m.

8.3 Manholes and Inlets

8.3.6 (i) Manhole (size and type) nr.
8.3.6 (ii) Grated Inlet (type) nr.
8.3.6 (iii) Curb inlet (type) nr.
8.3.6 (iv) Ditch inlet (type) nr.
8.3.6 (v) Ditch outlet (type) nr.
8.3.6 (vi) Grated Channel (width and depth) lin.m.

8.4 Drainage of Structures

8.4.6 (i) Gully grate and frame (type) nr.
8.4.6 (ii) Drainage pipe in structure (type) (diameter) (location) lin.m.
8.4.6 (iii) Permeable backing sq.m.
8.4.6 (iv) Granular backfill cu.m.

10 PILING

10.1 Piling General

10.1.6 (i) Setting up at each pile nr.
10.1.6 (ii) Piling (type)(length)(size) lin.m.
10.1.6 (iii) Expendable piles (type)(length)(size) lin.m.

10.2 Pile Testing

10.2.6 (i) Static load testing of expendable piles (type)(length)(size) nr.
10.2.6 (ii) Static load testing of working piles (type)(length)(size) nr.
10.2.6 (iii) Non-destructive Integrity Test (type) nr.

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Unit Rate Amount

Item Estimated
Description Unit
No Quantity R.O. Bz R.O. R.O. Bz Bz
(Omani Riyal) (Omani Baiza) (Number) - Omani Riyal (Words) - Omani Riyal (Number) Omani Baiza (Words) Omani Baiza

11 BRIDGE ACCESSORIES

11.1 Bearings – General

11.1.6 Bridge Bearing (type), vertical and horizontal loads (kN), movement (mm) nr.

11.2 Elastomeric Bearings

11.2.6 Elastomeric Bearing (type), vertical and horizontal loads (kN) nr.

11.3 Pot Bearings

11.3.6 Pot Bearing (type), vertical and horizontal loads (kN), movement (mm) nr.

11.4 Bridge Expansion Joints

11.4.6 (i) Buried Joint Movement range ( ) lin.m.
11.4.6 (ii) Elastomeric (waterproof) Joint Movement range ( ) lin.m.
11.4.6 (iii) Modular joint with neoprene insert Movement range ( ) lin.m.
11.4.6 (iv) Metallic finger joint with neoprene insert Movement range ( ) lin.m.
11 4 6 (v) Metallic finger joint no insert Movement range ( )
11.4.6 lin m
lin.m.
11.4.6 (vi) Asphaltic Plug Joint Movement range ( ) lin.m.

11.6 Bridge Parapets and Railings

11.6.6 (i) Concrete bridge parapet (state type) lin.m.
11.6.6 (ii) Concrete bridge parapet with metal rail (state type) lin.m.
11.6.6 (iii) Steel bridge parapet lin.m.
11.6.6 (iv) Aluminum bridge parapet lin.m.
11.6.6 (v) Steel pedestrian railing lin.m.
11.6.6 (vi) Aluminum pedestrian railing lin.m.

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Amount
Item
Description R.O. R.O.
No Bz Bz
(Number) Omani (Words) Omani
(Number) Omani Baiza (Words) Omani Baiza
Riyal Riyal

SUMMARY
Page V-I
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Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

9 SLOPE PROTECTION AND STABILIZATION

9.1 Riprap
9.1.6 (i) Loose stone riprap (class) cu.m.
9.1.6 (ii) Mortared stone riprap (class) cu.m.
9.1.6 (iii) Filter material (thickness) sq.m.
9.1.6 (iv) Filter membrate sq.m.

9.2 Gabions
9.2.6 (i) Gabions (size) cu.m.
9.2.6 (ii) Mastic asphalt grout cu.m.
9.2.6 (iii) Sand-cement grout cu.m.

9.3 Slope Netting

9.3.6 (i) Wire netting slope protection sq.m.

9.4 Rock Bolts, Anchors and S

Sprayed C
Concrete
9.4.6 (i) Rock bolts lin.m.
9.4.6 (ii) Rock Anchors lin.m.
9.4.6 (iii) Shotcrete cu.m.
9.4.6 (iv) Gunite cu.m.
9.4.6 (v) Wire netting for shotcrete sq.m.
9.4.6 (vi) Reinforcing mesh sq.m.
9.4.6 (vii) Painting sq.m.

9.5 Rock Grouting

9.5.6 (i) Drillholes for grouting rock (diameter)(length) lin m
9.5.6 (ii) Rock grout cu.m.

9.6 Reinforced Concrete Slope Protection

9.6.6 (i) Reinforced concrete slope protection cu.m.

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Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

9.7 Sacked Concrete Revetment

9.7.6 (i) Sacked concrete revetement cu.m.

9.8 Paving Tile Slope Protection

9.8.6 (i) Paving tile slope protection sq.m.

9.9 Ditch Lining

9.9.6 (i) Paving slab protection and ditch lining (type) (thickness) sq.m.
9.9.6 (ii) Grouted stone ditch lining (type) (thickness) sq.m.
9.9.6 (iii) Grouted stone wash checks (type) (thickness) sq.m.

9.10 Filter Layers

9.10.6 (i) Granular filter layer (thickness) sq.m.
9.10.6 (ii) Fabric membrane sq.m.

9 11 Barriers for Sand Dunes

9.11
9.11.6 (i) Fences for dune stabilization (type) (height) lin.m.
9.11.6 (ii) Bituminous stabilization of dunes sq.m.
9.11.6 (iii) Vegetative stabilization of dunes sq.m.
9.11.6 (iv) Dune stabilization with blankets sq.m.

9.12 Mechanically Stabilized Earth Retaining Walls

9.12.7 (i) Mechanically Stabilized Earth Retaining Walls (MSERWs) sq.m.
9.12.7 (ii) Standard Coping for MSERWs lin.m.
9.12.7 (iii) Concrete Barrier Parapet for MSERWs lin.m.

9.13 Coastal Protection

9.13.6 (i) Underlayer cu.m.
9.13.6 (ii) Quarry run cu.m.
9.13.6 (iii) Rock armour cu.m.
9.13.6 (iv) Dredging cu.m.
9.13.6 (v) Fabrics and Membranes (type) sq.m.

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Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

12 SIDEWALKS, PAVED AREAS AND CURBS

12.1 Sidewalks, paved areas and curbs

12.1.7 (i) Precast concrete tile paving (type) sq.m.
12.1.7 (ii) Precast concrete block paving (type) sq.m.
12.1.7 (iii) Natural stone paving (type) sq.m.
12.1.7 (iv) In situ concrete paving (type) (thickness) sq.m.
12.1.7 (v) Precast concrete curb/edging,/channel (type and size) lin.m.
12.1.7 (vi) Cast in-situ curb (type) lin.m.

13 SAFETY BARRIERS AND FENCES

13.1 Roadside Barriers

13.1.7 (i) W-Beam Guardrail standard section (type) lin.m.
13.1.7 (ii) W-Beam Guardrail transition section (type) lin.m.
13 1 7 (iii)
13.1.7 W-Beam Guardrail terminal (end type) nr.
13.1.7 (iv) Thrie Beam Guardrail standard section lin.m.
13.1.7 (v) Thrie Beam Guardrail transition section lin.m.
13.1.7 (vi) Thrie Beam Guardrail terminal (end type) nr.
13.1.7 (vii) Concrete Barrier, single face (type) lin.m.
13.1.7 (viii) Concrete Barrier, double face (type) lin.m.
13.1.7 (ix) Concrete Barrier, transition section (type) lin.m.
13.1.7 (x) Impact Attenuator (type) nr.

13.2 Fences
13.2.7 (i) Chain link fence (type) (height) lin.m.
13.2.7 (ii) Fence (type) (height) lin.m.
13.2.7 (iii) Wire fence (type) (height) lin.m.
13.2.7 (iv) Gate (type) sq.m

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Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

14 TRAFFIC SIGNS AND ROAD MARKINGS

14.1 Traffic Signs

14.1.7 (i) Highway sign, triangular, (height - mm) nr.
14.1.7 (ii) Highway sign, circular, (diameter - mm) nr.
14.1.7 (iii) Highway sign, rectangular - size (finished sign area) sq.m.
14.1.7 (iv) Highway sign, octgagonal, (height - mm) nr.
14.1.7 (v) Sign post support assembly including foundation (type) nr.
14.1.7 (vi) Breakaway sign post support assembly including foundation (type) nr.
14.1.7 (vii) Overhead sign support including foundation (type) nr.

14.2. Road Markings

14.2.6 (i) Traffic line (type) (material) (mechanical application) sq.m.
14.2.6 (ii) Raised rib road markings sq.m.
14.2.6 (iii) Special markings (type) (material) (hand applied) sq.m.
14.2.6 ((iv)) p g
Curb painting q
sq.m.
14.2.6 (v) Removal of markings sq.m.

14.3 Road Studs

14.3.6 (i) Reflecting road studs (type and colour) nr.
14.3.6 (ii) Non-reflecting road studs nr.

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Subsection (If necessary)
BILL OF QUANTITIES
BILL (VI) INCIDENTAL CONSTRUCTION SUMMARY

Amount
Item No Description R.O. R.O.
Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
Page VI-I
Page VI-II
Page VI-III
Page VI-IV

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 PROJECT TITLE
Subsection (If necessary)
BILL OF QUANTITIES
BILL (VII) ROAD LIGHTING AND ELECTRICAL INSTALLATIONS

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

15 ROAD LIGHTING AND ELECTRICAL INSTALLATIONS

15.1 General
15.1.20 (i) Power supply connection to the feeder pillar. nr.
15.1.20 (ii) Spare Parts (5%) as per the approved list LS.

15.2 Medium Voltage Switching Stations

15.2.6 (i) Medium voltage intake switching station (type) (voltage) (rating) (dwg) nr.

15.3 Package Sub-stations

15.3.6 (i) Package sub-station (type) (reference) (rating) (voltage) nr.

15.4 Package Medium Voltage Switching Stations

15.4.6 (i) Package medium voltage switching station (type) (reference) (voltage) nr.

15.5 33kV and 11kV Pole Mounted Transformer Sub Stations

Pole mounted transformer sub-station 33kV/415V/240V, 3-phase, 4-wire, solidly

15.5.6 (i) nr.
earthed neutral (Reference as shown on drawings)
Pole mounted transformer sub-station 11kV/415V/240V, 3-phase, 4-wire, solidly
15.5.6 (ii) nr.
earthed neutral (Reference as shown on drawings)

15.6 Feeder Pillars

15.6.6 (i) Feeder pillar (size, rating (A)) (No.of ways, type and ref.) (415V/240V) nr.

15.7 Electrical Cables

15.7.6 (i) Electrical cable (type) (voltage) (size) lin.m.

15.8 Road Lighting Masts, Columns and Luminaires

15.8.6 (i) High mast assembly (type) (height) (No & type of luminaires) ref.dwg. nr.
15.8.6 (ii) Lighting columns (type) (No of arms) (height) (type of luminaire) ref.dwg nr.
15.8.6 (iii) Column/High Mast Testing L.S

15.9 Traffic Sign Illumination

15.9.6 (i) Overhead sign lighting (gantry or cantilever) (ref. dwg.) nr.
15.9.6 (ii) Roadside sign lighting (sign ref. no.) (ref. dwg.) nr.

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BILL OF QUANTITIES
BILL (VII) ROAD LIGHTING AND ELECTRICAL INSTALLATIONS (continued)

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal
15 ROAD LIGHTING AND ELECTRICAL INSTALLATIONS
15.10 Under Bridge Lighting
15.10.6 (i) Under bridge surface mounted luminaire (type) (ref. drwg.) nr.
15.10.6 (ii) Under bridge recessed lighting luminaire (type) (ref. drwg.) nr.

15.11 Traffic Signals

15.11.6 (i) Traffic signal installations (type and location as shown on drawings) nr.
15.11.6 (ii) Overhead traffic signal support including foundation (type) nr.

15.12 Overheight Vehicle Detection Systems

Overheight vehicle detection and warning system (system complete) (location
15.12.8 (i) nr.
shown on drawings)

15.13 Emergency Roadside Telephone System

15.13.9 (i) Emergency roadside telephone system ( Road ref. No.) nr.

15.14 Public Lighting Management and Control System (PLMCS)

PLMCS installation at each feeder pillars and all related communication and
15.14.8 (i) central control facilities. nr.

15.15 Earthing
15.15.7 (i) Twin rod earthing installation (location) nr.
15.15.7 (ii) Single rod earthing installation (location) nr.

15.17 Civil Works for Electrical Installations

15.17.6 (i) Building for medium voltage intake switching station ( ref. drawing and detail) nr.
15.17.6 (ii) Concrete foundation for packaged substation (ref. drawing and detail) nr.
15.17.6 (iii) Building for packaged med. voltage switching station (ref. drawing and detail) nr.
H type concrete foundation for 33kV/low voltage pole mounted transformer
15.17.6 (iv) nr.
station (reference drawing and detail)
H type concrete foundation for 11kV/low voltage pole mounted transformer
15.17.6 (v) nr.
station (reference drawing and detail)
15.17.6 (vi) Concrete base for feeder pillar (ref.dwg) nr.
15.17.6 (viii)a Trench for low voltage cable for one cable lin.m.
15.17.6 (vii)b Trench for low voltage cable for two cables lin.m.
15.17.6 (vii)c Trench for low voltage cable for three cables lin.m.
15.17.6 (viii)a Trench for medium voltage cable for one cable lin.m.

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Subsection (If necessary)
BILL OF QUANTITIES
BILL (VII) ROAD LIGHTING AND ELECTRICAL INSTALLATIONS (continued)

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

15 ROAD LIGHTING AND ELECTRICAL INSTALLATIONS

15.17.6 (viii)b Trench for medium voltage cable for two cables lin.m.
15.17.6 (ix) Lighting column concrete foundation(Type, ref. dwg) nr.
15.17.6 (x) High Mast concrete foundation(Type, ref. dwg) nr.
15.17.6 (xi) uPVC duct (size and nr) lin.m.
15.17.6 (xii) uPVC duct, in concrete encasement (size and nr) lin.m.
15.17.6 (xiii) Cable marker (as per MEW details) nr.
15.17.6 (xiv) Manhole (type, dimension) (ref. dwg) nr.
15.17.6 (xv) Handhole / Drawpit (type, dimension) (ref. dwg) nr.
15.17.6 (xvi) Cast aluminium breakaway transformer base for column (height) (details, dwg.ref nr.

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Subsection (If necessary)
BILL OF QUANTITIES
BILL (VII) ROAD LIGHTING AND ELECTRICAL INSTALLATIONS SUMMARY

Amount
Item No Description R.O. R.O.
Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
Page VII-I
Page VII-II
Page VII-III

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Subsection (If necessary)
BILL OF QUANTITIES
BILL (VIII) LANDSCAPING AND IRRIGATION

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

16 LANDSCAPING AND IRRIGATION

16.1 Landscaping
16.1.7 (i) Excavating to reduce levels cu.m.
16.1.7 (ii) Excavating topsoil for preservation cu.m.
16.1.7 (iii) Filling to make up levels cu.m.
16.1.7 (iv) Topsoil filling to make up levels and for planting cu.m.

16.1.7 (v) Grass seeding sq.m.

16.1.7 (vi) Grass sods (turf) sq.m.
16.1.7 (vii) Grass plugs sq.m.
16.1.7 (viii) Grass sprigs sq.m.

16.1.7 (xi) Trees (type, size) nr.

16.1.7 (x) Palms (type, size) nr.
16.1.7 (xi)
( ) Shrubs (type,
( yp , size)) nr.
16.1.7 (xii) Ground cover plants (type) nr.
16.1.7 (xiii) Climbers (type) nr.

16.2 Irrigation System

16.2.6 (i) Pipe (type, class and diameter) lin.m.
16.2.6 (ii) Valves (type and diameter) nr.
16.2.6 (iii) Irrigation Program Controller (type) nr.
16.2.6 (iv) Irrigators (type and size) nr.
16.2.6 (v) Drip emitter distribution tubing (type and diameter) lin.m.
16.2.6 (vi) Spares for Irrigation System (type, class and size) nr.

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BILL (VIII) LANDSCAPING AND IRRIGATION SUMMARY

Amount
Item No Description R.O. R.O.
Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
Page VIII-I

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Subsection (If necessary)
BILL OF QUANTITIES
BILL (IX) PUMPING STATIONS AND UTILITIES

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

17 PUMPING STATIONS

17.2 Materials
17.2.9 (i) Metalwork (Type) LS

17.2.9 (ii) Ductile iron pressure pipe (size) lin.m.

17.2.9 (iii) uPVC pressure pipe (size) lin.m.

17.2.9 (iv) Gate valves (size) nr.

17.2.9 (v) Butterfly valves (size) nr.
17.2.9 (vi) Check valves (size) nr.
17.2.9 (vii) Silent type check valves (size) nr.
17.2.9 (viii) Control valves (size) nr.
17.2.9 (ix) Surge Control Valves (size) nr.
17.2.9 (x) Cushioned Type Check Valves (size) nr.

17.3 Equipment
17.3.9 (i) Submersible Drainage Pumps nr.
17.3.9 (ii) Horizontal Pumps nr.
17.3.9 (iii) High Pressure Booster Pumping Set Employing Membrane Tank nr.
17.3.9 (iv) High Pressure Booster Pumping Set Employing Variable Speed Pumps nr.
17.3.9 (v) Duplex Sump Pumps nr.

17.3.9 (vi) Monorail System LS

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Subsection (If necessary)
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BILL (IX) PUMPING STATIONS AND UTILITIES (continued)

Unit Rate Amount

Estimated
Item No Description Unit R.O. Bz R.O. R.O.
Quantity Bz Bz
(Omani (Omani (Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Riyal) Baiza) Omani Riyal Omani Riyal

17 PUMPING STATIONS (continued)

17.3.9 (vii) Fertilizer Injection Equipment LS

17.3.9 (viii) Electrical works LS
17.3.9 (ix) Instrumentation and Contols LS

18 UTILITIES

18.1 Locating and Protecting Existing Utilities

18.1.6 (i) Split Pipe (diameter) lin.m.

18.2 Removing and Disposing of or Relocationg Existing Utilities

18.2.6 (i) Remove and dispose of (utility) (size/description) lin.m.
18.2.6 (ii) Remove and relocate (utility) (size/description) lin.m.
18.2.6 (iii) Provide and install new (utility) (size/description) lin.m.

18.3 Future Utility Crossing Ducts

18.3.6 (i) Sleeves/Ducts (type), (diameter) lin.m.

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Subsection (If necessary)
BILL OF QUANTITIES
BILL (IX) PUMPING STATIONS AND UTILITIES SUMMARY

Amount
Item No Description R.O. R.O.
Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
Page IX-I
Page IX-II

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Subsection (If necessary)
BILL OF QUANTITIES
Bill No (X) GRAND SUMMARY

Amount
Item No Description R.O. R.O.
Bz Bz
(Number) (Words)
(Number) Omani Baiza (Words) Omani Baiza
Omani Riyal Omani Riyal

SUMMARY
Bill No 1
Bill No 2
Bill No 3
Bill No 4
Bill No 5
Bill No 6
Bill No 7
Bill No 8
Bill No 9

page X-I GRAND SUMMARY

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 Sultanate of Oman, Standard Specifications for Road & Bridge Construction 2010

Copyright

These Specifications have been prepared, printed and serial numbered by:
The Ministry of Transport and Communications - Directorate General of Roads and Land Transport.
This Document, or parts thereof, may not be reproduced in any form without the written permission of the
Ministry of Communications.

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