Standard Specification JKR Road PDF

FOR INTERNAL USE ONLY
Standard Specification For Road Works
KERAJAAN MALAYSIA
JABATAN KERJA RAYA MALAYSIA
STANDARD SPECIFICATION
FOR
ROAD WORKS
CAWANGAN JALAN
IBU PEJABAT JABATAN KERJARAYA MALAYSIA
JALAN SULTAN SALAHUDDIN,
50582 KUALA LUMPUR.
Cawangan Jalan, Ibu Pejabat JKR, K.L
KETUA PENGARAH KERJARAYA

JABATAN KERJARAYA MALAYSIA
JALAN SULTAN SALAHUDDIN
50582 KUALA LUMPUR
Page 1
ADDENDUM NO. 1
This Addendum shall be made part of the JKR Standard Specification For Roads Works
1. Table 4.8
- Gradation Limit For Asphaltic Concrete Clause 4.2.4.2, page S4 21

should read as follows :
Mix Type
Wearing Course
Binder Course
Mix
Designation
ACW 20
ACB 28
B.S Sieve
% Passing by weight
37.5 mm
100
28.0 mm
100
80 - 100
20.0 mm
76 - 100
72 - 93
14.0 mm
64 - 89
58 - 82
10.0 mm
56 - 81
50 - 75
5.0 mm
46 - 71
36 - 58
3.35 mm
32 - 58
30 - 52
1.18 mm
20 - 42
18 - 38
425 um
12 - 28
11 - 25
150 um
6 - 16
5 - 14
75 um
4 - 8
3 - 8
2. Table 4.9- Design Bitumen Contents Clause 4.2.4.3, page S4 - 23 should read as follows :
ACW 20 - Wearing Course

ACW 28 - Binder Course
4.5 - 6.5 %
4.0 - 6.0
Page 2
ADDENDUM NO. 2
6.2.5.5 Sign Faces
Sign faces for permanent traffic sign shall be as
shown on the Drawing and shall comply with
the Malaysian Standard Specification for
Reflective Sign Faces Materials (MS 1216). All
retro-reflective sheeting shall be fixed in accordance with the manufacturers instruction.
Unless otherwise agreed by the S.O., sign
faces shall be formed from a single piece of
retro-reflective sheeting.
Where, with the aggrement of the S.O., more
than one retro-reflective sheeting is used, the
number of sheets shall be kept to a minimum.
All faces up to 1 m in size shall be produced
with a single sheet and no joint will be
accepted.
Only vertical and horizontal joint shall be permitted and all join in retro-reflective shetting
shall be overlapped by not less than 6 mm. The
overlap in the horizontal joint shall be from the
top and the vertical joint shall be from the left;
but joints will be only be accepted for prismatic
retro-reflective sheeting.
Retro-reflective sheeting shall be applied
evenly over the whole surface of the sign plate
and shall adhere fully. it shall be free from
twists, cracks, folds or cuts, air bubbles and
other blemishes.
where shetting is applied to the extruded

section by pressure roller, it shall extend over
the top and bottom edges of this sections by not
less than 3 mm.
Any cut-outlet 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
manufacturers instruction.
The finish of all sign faces shall be capable of
passing the tests described in MS 1216, and
and standard of fabrication and workmanship
shall be such that under normal conditions of
service and proper maintenance, the sign faces
shall last not less than 5 years without any
seriousblemishes or defects for Engineering
Grade retro-reflective sheeting and 8 years for
High Intensity and prismatic retro-reflective
sheeting.
The Contractor shall furnish to the S.O. a letter
of warranty for the specified period for all sign
faces from the manufacturer of the sheeting or
the sign fabricator.
The retro-reflective sheeting manufacturer shall
furnish the S.O. written warranty that the fluorescent colours shall be durable for a minimum
3 years for temporary signs.
All retro-reflective sheeting used on the same

sign shall be carefully matched for colour to
produce a uniform appearance both by day and
by night. Non-uniform shades of colour on any
one sign will not be accepted.
The edges of all the retro-reflective sheeting
shall be properly fitted to ensure no
delimination of the sheeting from the base
substrate.
Page 3
ADDENDUM NO. 3
6.2.6.1
6.2.6.1.1
FLUORESCENT ORANGE WIDE ANGLE PRISMATIC RETROREFLECTIVE SHEETING FOR THE WORK ZONE
Description
6.2.6.1.2
The flurescent orange wide angle prismatic

retro-reflective sheeting is specifically designed
for use on rigid substrade work zone signs to
provide high visual impact under nighttime and
daytimedriving condition, including low
visibility periods such as dawn, dusk, and
overcast days. The sheeting shall consist of
prismatic lenses formed in a transparent
flurescent orange synthetic resin, sealed, and
baked with and aggressive presure sensitive
adhesive protected by a removable liner. The
sheeting shall have a smooth surface with a
distinctive interlocking diamond seal pattern
and orrientation marks visible from the face.
i)
Requirements
Photometric - Coefficient of
Retroreflection RA
when the sheeting applied on aluminium
test panels is measured in accordance
wth ASTM E 810, it shall have
minimum coefficient of retro-reflective
value as shown in Table I. The rotation
angle shall be *90 , the observation
angles shall be 0.2 and 0.5, the
entrance angles and +50, and the
entrance angle (component 1) shall be
- 4, +30, and +50, and the entrance
angle component 2 = 0.
TABLE I
Minimum Coefficient of Retroreflection RA

(Candelas per footcandle per square foot)
(90 Rotation Angle*)
Observation Angle ( )
Entrance Angle ( )
Orange
0.2
0.2
0.2
-4
+30
+50
200
120
50
1.5
0.5
0.5
-4
+30
+50
80
50
20
* The datum mark (arrow) imprinted on the face of the sheeting shall be the datum mark for test
purposes. For the specified 90 rotation angle, the sheeting shall be positioned on the goniometer
so that the direction of this datum mark is perpendicular to the observation plane (this geometry is
equivalent to a 90 orientation angle with a presentation angle of 0 in the measurement geometry
described in Fed. Test Method Standard 370).
Page 4
i)
Daytime Color
Color shall conform to the reqiurement
of Table II. Daytime color and
maximum spectral radiance factor (peak
reflectance) of sheeting mounted on
aluminium test panels shall be
determined instrumentally in accordance
with ASTM E 991.
The value shall be determined on a HunterLab

Labscan 6000 0/45 spectrocolorimeter with
option CMR 559 [or approved equal 0/45
(45/0) instrument withcircumferential viewing
(illumination)]. Computation shall be done in
accordance with ASTM E 308 for the 2
observer.
TABLE II
Color Specification Limit ** (Daytime)
Color
Orange
(New)
Orange
(Weathered)
Reflectance
Limit Y (%)
Min.
Max.
.583
.416
.523
.397
.560
.360
.631
.369
30
.583
.416
.523
.397
.560
.360
.631
.369
20
45
Maximum spectral radiance factor, new : 110%, min.

weathered : 60%, min.
** The four pairs of chromaticity coordinates determine the acceptable color in terms of the CIE
1931 standard colorimetric system measured with standard illuminatant D65.
iii) Nighttime Color.
Nighttime color of the sheeting applied to alumium test panel shall be determined
instrumentally in accordance with ASTM E 881 and calculated in the u, v coordinate
system in accordance with ASTM E 308. Sheeting shall be measured at 0.33 observation
and - 4 entrance at 90 rotation. Color shall conform to the requirements of Table III.
TABLE II
Color Specification Limit ** (Nighttime)
Color
Orange
(New and
Weathered)
.400
.540
.475
.529
.448
.522
.372
.534
Page 5
iv) Resistance to Accelerated Weathering.

The retro-reflective surface of the sheeting
shall be weather resistant and show no
appreciable cracking, blistering, crazing, or
dimensional change after 1 years
unprotected outdoor exposure in south
Florida, south-facing and inclined 45
from the vertical, or after 1500 hours
exposure in a xenon arc weatherometer in
accordance with ASTM G 26, Type B,
Method A. Following exposure, panels
shall be washed in a 5% HCL solution for
45 seconds, rinsed throughly with clean
water, blotted with a soft clean cloth and
brought to equilibrium at standard
conditions. After cleaning, the coefficient
of retroreflection shall be not less than 100
when measured as in D.2, below, and the
color is expected conform to the
requirements of Table II and III for
weathered sheeting. The sample shall :
a) Show no appreciable evidence of
cracking, scaling, pitting, blistering,
edge lifting or curling or more than 1/32
inch (0.08 cm) shrinkage or expansion.
b) Be measured only at angles of 0.2
observation, - 4 entrance and 90
rotation. Where more than one panel of
a color is measure, the coefficient or
retroreflection shall be the averange of
all determinations.

vi) Resistance to Heat.
The retroreflective sheeting, applied to a
test panel as in E., above and conditioned
for 24 hours, shall be measured in
accordance with paragraph. A. at 0.2
observation and - 4 entrance angles at 90
rotation and exposed to 170 + 5F (77 +
3C) for 24 hours in an air circulating
oven. After heat exposure the sheeting
shall retain a minimum of 70% of the
original coefficient of retroreflection.
vii) Field Performance

Retroreflective sheeting processed and
applied to sign blank materials in
accodance with the sheeting
manufacturers recommendations, is
expected to perform effectively for a
minimum of 3 years. the retroreflective
sheeting will be considered unsatisfactory
if it has deteriorated due to natural causes
to the extent that : (1) the sign is ineffective
for its intended purposed when viewed
from a moving vehicle under normal day
and night driving conditions; or (2) the
coefficient of retroreflection is less than
100 when measured at 0.2 observation
and - 4 entrance at 90 rotation. All
measurements shall be made after sign
cleaning according to the sheeting
manufacturers recommendations.
v) Impact Resistance.
The retroreflective sheeting applied
according to the sheeting manufacturers
recommendations to a test panel of alloy
6061-T6, 0.040 (0.10 cn) by 3 (7.6 cm)
by 5 (12.7 cm) and conditioned for 24
hours, shall show no cracking outside the
impact of 100 inch-pounds (11.3Nm) using
a weight with a 5/8 in. (15.8 mm) diameter
rounded tip dropped from a height
necessary to generate an impact of 100
inch-pounds, at test temperatures of both
32 F (0 C) and 72 F (22 C).
Page 6
STANDARD SPECIFICATION FOR ROADS WORKS
CONTENT
PAGE
SECTION 1
General
S1-11 to S1-31
SECTION 2
Earthworks
S2-1 to S2-20
SECTION 3
Drainage Works
S3-1 to S3-31
SECTION 4
Flexible Pavement
S4-1 to S4-55
SECTION 5
Portland Cement Concrete Pavement
S5-1 to S5-21
SECTION 6
Road Funiture
S6-1 to S6-22
SECTION 7
Street Lighting
S7-1 to S7-19
SECTION 8
Traffic Signals
S8-1 to S8-33
SECTION 9
Concrete
S9-1 to S9-39
SECTION 10
Piling Works
S10-1 to S10-35
Page 7
SECTION 1
GENERAL
Page 8
SECTION 1 - GENERAL
Page
1.1
1.2
1.3
1.3.1
1.3.2
1.3.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.20.1
1.20.2
1.20.3
1.20.4
1.20.5
1.21
1.22
1.23
1.24
1.25
1.26
1.27
GENERAL DESCRIPTION OF THE PROJECT

SCOPE OF WORKS
NOTES, ABBREVIATIONS AND UNITS OF MEASUREMENT
Notes
Abbreviations
Units of Measurement
PROGRAMME OF WORKS
LIMITATION OF SITE
SUPPLY OF MATERIALS
MATERIALS OF MALAYSIAN ORIGIN
SETTING OUT
DIMENSIONS AND LEVELS
PROTECTION OF WORKS
DESIGN OF TEMPORARY WORKS BY THE CONTRACTOR
CONTRACTOR'S SUPERINTENDENCE
INSPECTION AND TESTS
COVERING UP OF WORK
OFFICE ACCOMMODATION FOR S.O. AND HIS STAFF
VEHICLES FOR THE S.O.'S STAFF
CONTRACTOR'S OFFICE AND ACCOMODATION
MATERIAL TESTING LABORATORY AND STAFF
PROVISION FOR SURVEY INSTRUMENTS AND CHAINMEN
MAINTENANCE OF EXISTING ROADS AND PROTECTION
OF TRAFFIC
Maintenance of Existing Roads, Bridges, Culverts, etc.
Temporary Diversions
Half-width Construction and Traffic Control
Temporary Traffic Signs
Temporary Works
LOCATION, TEMPORARY PROTECTION AND TEMPORARY
DIVERSION OF PUBLIC UTILITY INSTALLATIONS AND
OTHER SERVICES
WATER AND ELECTRICITY SUPPLY
PROJECT SIGNBOARD
PHOTOGRAPHIC RECORD OF WORKS
AS-BUILT DRAWINGS AND MICROFILMING
CLEARING UP OF SITE
OPPORTUNITIES FOR OTHER CONTRACTORS
S1-11
S1-11
S1-11
S1-11
S1-11
S1-11
S1-12
S1-12
S1-12
S1-12
S1-13
S1-13
S1-13
S1-13
S1-14
S1-14
S1-14
S1-14
S1-16
S1-16
S1-16
S1-17
S1-17
S1-17
S1-17
S1-18
S1-19
S1-19
S1-19
S1-20
S1-20
S1-20
S1-21
S1-21
S1-21
Page 9
Page
APPENDIX 1A
GENERAL DESCRIPTION OF PROJECT
S1-22
APPENDIX 1B
SCOPE OF WORKS
S1-23
APPENDIX 1C
VEHICLES FOR S.O. AND HIS STAFF
S1-24
APPENDIX 1D
LIST OF LABORATORY EQUIPMENT
(a)
(b)
(c)
Soil Testing Equipment

Concrete Testing Equipment
Flexible Pavement Testing Equipment
S1-25
S1-27
S1-27
APPENDIX 1E
SURVEY EQUIPMENT
S1-30
FIGURE 1-1
APERTURE CARD FOR MICROFILM
S1-31
Page 10
SECTION 1 - GENERAL
1.1

iv) The terms "Engineer" and
"Superintending Officer" shall be
synonymous.
GENERAL DESCRIPTION OF
THE PROJECT
1.3.2 Abbreviations
The general description of the project is as

given in Appendix 1A.
1.2
SCOPE OF WORKS
The Works covered in this Contract comprise

the provision by the Contractor at his own risk
and cost of all materials, tools, plants, labour,
transport and everything else necessary for the
construction and completion of the Works as
given in Appendix 1B all to the approval of the
S.O.
1.3
NOTES, ABBREVIATIONS AND

UNITS OF MEASUREMENT
a) M.S. means Malaysian Standards

published by the Scientific and
Industrial Research Institute of
Malaysia (SIRIM).
b) B.S. means British Standards
published by the British Standard
Institution.
c) A.A.S.H.T.O. means The American
Association of State Highway and
Transportation Officials.
d) A.S.T.M. means The American
Society for Testing and Materials.
1.3.1 Notes
i)
Any clause in this Specification which

relates to work or materials not included
in the Works shall be deemed not
applicable.
e) M.D.D. means Maximum Dry

Density.
f) O.M.C. means Optimum Moisture
Content.
ii) Unless stated to the contrary, any

dimension of material described means
the finished or fully compacted
dimension.
g) C.B.R. means California Bearing

Ratio.
iii) All Standards and Codes of Practice

referred to in this Specification shall be
deemed to be the editions current at the
time of Tender. If the Malaysian
Standard exists, which the S.O. deems to
be equivalent to the British or other
Standard specified, then the Malaysian
Standard shall be followed.
i) B.Q. means Bill of Quantities.
In the event of any discrepancy between

the provision of this Specification and
the provision within the relevant
Standards or Codes of Practice as
mentioned in this Specification, then the
provision of this Specification shall take
precedence.
h) S.O. means Superintending Officer.
1.3.3 Units of Measurement

All units of measurement used in this
Specification and in the Bill of
Quantities shall be in accordance with
the metric system unless otherwise
stated.
Where British Imperial units are shown
or stated the following conversions shall
apply :-
Page 11
1 inch
1 foot
1 lb
1 gallon
1 lb/sq.in
1.4
=
=
=
=
=
25.40
millimetres
0.3048 metres
0.4536 kilograms
4.5461 litres
6.895 x 10-3 N/sq.mm
Should the Contractor require additional

land outside the Site for his workyards,
stores, offices, temporary haul roads or
any other temporary structures, he shall,
on his own, purchase or rent any
additional area he may need.
PROGRAMME OF WORKS
Within thirty (30) days after the receipt
of the Letter of Acceptance of Tender,
the Contractor shall submit to the S.O.
for his approval a programme showing
the order of work activities and time
schedule in which the Contractor
proposes to carry out the Works and
shall, whenever required by the S.O. or
the S.O.'s representative, furnish in
writing, particulars of the Contractor's
arrangement for carrying out such works
and of the construction plants and
temporary works, if any, which the
Contractor intends to supply, use or
construct as the case may be. The
submission to and approval by the S.O.
or the S.O.'s representative of such a
programme or the furnishing of such
particulars shall not relieve the
Contractor of any of his duties or
responsibilities under the Contract.
Areas or area to be rendered as part of

the Site shall be subject to the S.O.'s
approval.
1.6
The Contractor shall place orders for

specified materials at such times as
will enable him to execute the Works in
accordance with his approved
programme.
If the Contractor's failure to supply any
material causes any interruption or delay
in the progress of the Works, the
Government may supply any portion
or all of the materials and the cost
borne by the Contractor shall be either
that as calculated at the current market
rates or the actual cost to the
Government at the date of supply,
including overheads or any other
charges, whichever is the greater.
If at any time it should appear to the

S.O. that the actual progress of the
Works does not conform to the approved
programme referred to herein before, the
Contractor shall submit for approval, a
revised programme showing the
modifications to the previously
approved programme necessary to
ensure the completion of the whole
Works within the time set for
completion.
Any costs incurred under this Section

shall be deducted from the Contract
Sum. No claim for loss of profit under
the conditions of this Contract shall be
deemed to have arisen. No action taken
under this Section shall in any way
affect or modify the right of the
Government to claim for damages in the
event of the Contractor's failure to
complete the Works by the agreed date.
1.7
1.5
SUPPLY OF MATERIALS
MATERIALS OF MALAYSIAN
ORIGIN
LIMITATION OF SITE
The Contractor shall ensure that all his
plants, materials, temporary workshops,
stores and offices are kept within the
Site at locations approved by the S.O.
Materials of Malaysian origin where

available must be used by the Contractor
to the exclusion of imported materials
and this requirement shall be allowed
for in his tender.
Page 12
Under no circumstances shall the

Contractor be permitted to use imported
materials unless he can prove to the
satisfaction of the S.O. that the
materials are not available locally, or if
available are not of an acceptable
standard.
1.8
SETTING OUT
Before commencing the Works at any
location, the Contractor shall provide
and install precast concrete reference
beacons on both sides of the road
centre-line at a spacing of 300 metres.
The beacons shall be firmly sited at right
angles to the centre-line at a distance
from the centre-line of 15 metres or such
other distance as directed by the S.O.
The beacons shall be not less than 75
mm square in plan and shall project at
least 600 mm above the surrounding
ground. Each beacon shall be clearly
marked with its chainage and elevation
above datum.
The Contractor shall take all practicable
steps to safeguard the beacons including
fencing and concreting-in where
necessary in the opinion of the S.O. and
shall immediately replace any damaged
beacons. The Contractor shall give the
S.O. not less than 24 hours notice of his
intention to set out or give levels for
any part of the Works in order that
arrangements may be made for
checking.
1.9
DIMENSIONS AND LEVELS

All temporary benchmarks, reference
markers and levels as shown on the
Drawings shall be checked on the Site
by the Contractor at his own expense
and be confirmed by the S.O.

Before the Works or any part thereof are
commenced, the Contractor shall verify
the levels of the existing ground surface
within areas where earthworks are to be
performed and the locations and bed
levels of water-courses. These may
differ from the locations and levels
shown on the Drawings owing to
changes which could have taken place
during the interval between the original
survey and construction.
The levels and dimensions taken by the
Contractor jointly with the S.O. shall
form the basis of measurement of the
relevant work quantities.
1.10 PROTECTION OF WORKS

From the commencement of the Works
to the date the Works are taken over by
the Government, the Contractor shall
take full responsibility for the care there
of together with all temporary works
and in case any damage, loss or injury
shall happen to the Works or to any part
thereof or to any temporary works from
any cause whatsoever, he shall at his
own cost repair and make good the
same so that at completion, the Works
shall be in good order and condition and
in conformity in every respect with the
requirements of the Contract and the
S.O.'s instructions. The Contractor shall
also be liable for any damage to the
Works occasioned by him in the course
of any operations carried out during the
Defects Liability Period.
1.11 DESIGN OF TEMPORARY
WORKS BY THE CONTRACTOR
Unless otherwise provided in the
Drawings, the Contractor shall submit to
the S.O. for his approval, 2 copies of all
working or shop drawings produced by
him including all drawings made by his
approved sub-contractors for all
temporary works.
Page 13
Such submission shall be made at least

two weeks before the temporary work is
scheduled to commence.
Notwithstanding the approval by the
S.O., the Contractor is solely responsible
for the adequacy and safety of his work
and for any necessary modification or
addition whenever found necessary by
the S.O.
1.12 CONTRACTOR'S
SUPERINTENDENCE
The Contractor shall provide all
necessary superintendence during the
execution of the Works and as long
thereafter as the S.O. may consider
necessary for the proper fulfillment of
the Contractor's obligations under the
Contract.
A competent Site Agent, whose
appointment shall be approved by the
S.O., shall be employed by the
Contractor for management on Site.
The Site Agent shall have the authority
to receive instructions from the S.O. and
to act on behalf of the Contractor. The
Site Agent shall be stationed on Site for
the whole duration of the Contract and
shall not be replaced without the
approval of the S.O.
If the Site Agent needs to be absent from
Site for more than three (3) consecutive
days, he shall give prior notice to the
S.O. who may require the Contractor to
temporarily appoint another Site Agent.

The Contractor shall provide the
necessary attendance whenever required
by the S.O. or his representative.
Notwithstanding any tests which may
have been carried out off the Site, the
S.O. shall be empowered to order
further tests of any materials or goods to
be made on the Site and to reject such
materials or goods should they fail to
pass such tests on Site.
When required by the S.O., the
Contractor shall submit a copy of the
result of any quality control test carried
out by the Contractor on his own during
the progress of the Works.
1.14 COVERING UP OF WORK
Before any part of the Works is
permanently covered up, the Contractor
shall give due notice to the S.O. for the
inspection and measurement of
dimensions. The S.O. shall attend
without unreasonable delay for the
purpose of examination and
measurement unless he considers it
unnecessary and advises the Contractor
accordingly.
1.15 OFFICE ACCOMMODATION FOR
S.O. AND HIS STAFF
The Contractor shall provide and
maintain a site office for the use of the
S.O. and his supervisory staff, all in
accordance with the relevant Drawings
inclusive of all furniture and fittings as
shown on the Drawings.
1.13 INSPECTION AND TESTS

The S.O. or his representative may at
any stage of the Works carry out
inspection, measurement and tests on
any part of the Works to ensure
compliance with the requirements of this
Specification and of the Drawings.
The Contractor is permitted to provide a

relocatable site office as an alternative to
the JKR designed type shown on the
Drawings.
Page 14
The quality of such a relocatable site

office shall be of equivalent standard but
not inferior to the JKR designed type
and shall be equipped with similar
furniture and fittings as indicated in the
JKR designed site office.
Where a relocatable site office is to be
provided, the Contractor shall submit
details of the relocatable site office
together with his tender. Such details
should include the name of the
manufacturer, floor area and layout, list
of furniture and fittings and brochures if
available. The Contractor shall also
indicate whether the proposed site office
is new or otherwise.
Unless otherwise shown on the
Drawings, the site office is to be sited,
constructed and positioned as approved
by the S.O.
The Contractor shall make proper
arrangements for and pay all charges in
connection with conservancy. The site
office shall comply with local building
by-laws. It shall be erected or provided
by the Contractor within four (4) weeks
from the date of possession of Site.
On completion of the Works, the
Contractor shall further maintain the site
office till the end of the Defects Liability
Period unless otherwise directed by the
S.O. and thereafter remove from the Site
the site office with all furniture and
fittings which become the property of
the Contractor.
Where electricity and piped water are
available from public utility authorities,
the Contractor shall arrange for the site
office to be connected to the electricity
and water supplies.Otherwise, the
Contractor shall supply the site office
with electric power from generators and
shall provide an adequate supply of
water for washing and potable filtered
water for drinking purposes.

Sanitary facilities with disposal to
septic tanks located not nearer than 5 m
from the building shall be provided.
The office shall be illuminated by
fluorescent fittings giving a general level
of illumination of at least 2 lumens/
sq.m. Additional lighting in the form of
wall or deck lamps shall be provided
where required by the S.O. Lighting to
toilets and corridors may be by tungsten
filament bulbs.
Thermostatically controlled airconditioners capable of maintaining a
temperature below 23C in the office
shall be provided.
The Contractor shall arrange for the
installation of a telephone with a
separate connection to the telephone
exchange for the exclusive use of the
S.O. at all times. The telephone shall
also be be fitted with 4 extensions unless
not required by the S.O. The Contractor
shall be responsible for the connection
to such exchange and the payment of
rental for the telephone services but the
Government shall reimburse the
Contractor for the cost of making calls.
Where a telephone exchange is not
within practical distance, an automatic
mobile telephone such as the ATUR
(Automatic Telephone Using Radio)
service shall be provided.
The Contractor shall keep the offices
accessible at all times and in every way
habitable for working purposes
throughout the duration of the Contract.
The Contractor shall also provide such
labour and cleaning materials as are
required to maintain the site office in a
thoroughly clean and sanitary condition.
Page 15
1.16 VEHICLES FOR THE S.O.'S

STAFF
The Contractor shall provide new
vehicles as listed in the B.Q. and
Appendix 1C for the sole use of the S.O.
and his staff at all times. All necessary
fuel, oil and lubricants, general
maintenance, comprehensive insurances
and roadtax shall be provided by the
Contractor together with a licensed and
competent driver for every vehicle.
Replacement vehicles shall be provided
when normal vehicles are not available
such as during periods of servicing,
maintenance or repair. The vehicles will
revert to the Contractor at the
completion of the Contract unless
otherwise stated in the B.Q.
1.17 CONTRACTOR'S OFFICE AND
ACCOMODATION
maintain a suitable office for himself
and his staff in a position or positions to
be approved by the S.O.
In addition, the Contractor shall provide
and maintain temporary accomodation
and living facilities, stores, workshops,
etc., including all necessary services for
water supply, drainage and lighting for
his staff. Before any work can
commence the Contractor shall submit
to the S.O. details of the proposed
buildings and services and shall obtain
the S.O.'s approval together with any
necessary approval in writing from the
relevant statutory authority.
The Contractor shall be responsible for
all fees and other charges or expenses
incurred in connection with such office
and housing and shall keep the whole
area in a clean, tidy and well drained
condition.

When instructed by the S.O., the
Contractor shall remove all such
buildings and appurtenant works from
the Site, clean up the area and restore it
to its original condition.
The Contractor shall provide adequate
first aid facilities appropriate to the size
and composition of his staff and labour
force. The Contractor shall afford the
S.O.'s site staff full use of the services
and facilities as and when required.
1.18 MATERIAL TESTING
LABORATORY AND STAFF
maintain a laboratory at the Site
throughout the duration of the Contract.
Earthworks and pavement construction
will not be permitted to commence until
the laboratory and necessary equipment
have been provided.
The said laboratory shall be in
accordance with the Drawings and shall
be equipped as indicated in Appendix
1D. It shall be maintained in a clean
and tidy condition to the satisfaction of
the S.O. The laboratory shall be
adequately supplied with water and
electricity.
The laboratory shall be used exclusively
by the S.O. and his staff. However the
Contractor shall provide helpers to assist
the S.O. as and when requested.
All laboratory equipment shall become
the property of the Contractor on
completion of the Works.
building shall be removed from the Site
and the Site left in a neat and tidy
condition.
Page 16
1.19 PROVISION FOR SURVEY

INSTRUMENTS AND CHAINMEN
The Contractor shall provide for the sole
use of the S.O. and his staff all such
instruments, equipment and chainmen as
the S.O. may require to enable him to
check the accuracy of the Contractor's
setting out and any measurements taken.
The chainmen shall have knowledge of
Bahasa Malaysia or English and as far
as possible the same men shall be
provided throughout the Contract
period.
The instruments and equipment to be
provided are as listed in Appendix 1E.
The Contractor shall be responsible
throughout the Contract period for all
such instruments, equipment and
chainmen and shall ensure that the
instruments and equipment are at all
times in good working condition and
adjustment. All instruments and
equipment shall remain the property of
the Contractor on completion of the
Works.
1.20 MAINTENANCE OF EXISTING

ROADS AND PROTECTION
OF TRAFFIC
1.20.1 Maintenance of Existing Roads,
Bridges, Culverts, etc.
The Contractor shall maintain all
sections of existing roads and all
bridges, drains and culverts included
therein within the Site to the
conditions at the time of possession
of Site for the full duration of the
Contract. Such maintenance shall
include routine activities such as
grass cutting, clearing of drains,
patching of potholes, etc.

He shall also be responsible for
maintaining the free flow of traffic on
these sections of existing road.
The Contractor shall arrange for the
conveyance of materials and plants so as
to cause minimum damage to existing
roads and installations and minimum
inconvenience to the public. He shall
not deposit any earth, rubbish or
materials upon any road, street,
pavement or footway to cause hindrance
or obstruction of vehicles or pedestrians.
any damage caused by any work carried
out by him or by construction traffic to
any existing roads or installations from
whatsoever cause arising thereof and
shall repair, maintain and reinstate the
same to their original condition to the
satisfaction of the S.O. The Contractor
shall also keep such roads clear of
slurry, boulders and loose earth which
may be dropped in the course of
transportation.
Upon failure on the part of the
Contractor to fulfill his obligations
under this Section, the S.O. may take
whatever action and any means
necessary to satisfy the requirements
and all costs incurred by the S.O. shall
be deducted from any monies due or to
become due to the Contractor under this
Contract.
1.20.2 Temporary Diversions
Temporary diversions shall be
constructed wherever the Site is
intersected by existing roads, footpaths,
cycle tracks, access to properties, etc.
Such diversion ways shall be of a
standard of construction at least
equivalent to that of the original road,
path, track or access.
Page 17
They shall be constructed in advance

of the closure of the existing ways
and regularly maintained, for as long
as required, in a satisfactory
condition. On completion of the
work, the original ways shall be
reinstated to their original condition
to the approval of the S.O. At least
fourteen (14) days notice in writing
of any proposed temporary
diversions of traffic shall be given to
the S.O. for his approval.
Where access roads are to be
permanently closed by the
construction of the Works, as shown
on the Drawings, diversion ways
shall not be required. Such
closures shall not be effected until
any specified alternative access has
been provided and only with the
written approval of the S.O.
The Contractor shall maintain
reasonable access to all properties
adjoining the Works where such
access exists during construction,
and shall ensure that all the
necessary fences, planking and
gangways are adequately lit to the
satisfaction of the S.O.
Where the Contractor proposes to
use existing local streets as
temporary diversion ways, he shall
give at least fourteen (14) days
notice in writing of his proposal to
the S.O. for his approval. The
Contractor shall maintain and/or
reinstate these temporary diversion
ways to their original condition
throughout the entire duration of the
temporary diversion, all to the

If the Contractor fails to maintain
and/or reinstate these temporary
diversion ways to the satisfaction of
the S.O., the S.O. shall have the right
to carry out these works himself and
all costs incurred shall be deducted
from the Contract Sum.
Where, in the opinion of the S.O., a
detour is not feasible, construction
on existing public roads shall be
undertaken only over half of the full
width of the roadway at any time.
The lengths of such half-width
construction shall be kept as short as
is practicable.
For all temporary diversions, the
Contractor shall provide, install and
maintain adequate temporary
construction signs in accordance
with Sub-Section 1.20.4.
1.20.3 Half-width Construction and Traffic
Control
Where half-width construction is
necessary, work on culverts shall be
completed and the embankment
adjacent to them must be reinstated
so that at least half the full width
shall be available for use by the
public at all times.
In the event of the operation of
single-way traffic becoming
necessary and when approved by the
S.O. on any particular length of the
Works or on the Works or on the
approaches to the Works, the
Contractor shall maintain through
traffic routes by providing a width of
at least 3 metres for single-way
traffic. He shall also provide
approved electrically operated
signals for traffic control on each of
the affected lengths and any
additional traffic signs as may
be directed.
Page 18
The electrical signal lights shall be

automatic in operation, but the
S.O. may, at any time, require them
to be hand operated by a competent
operator.
The Contractor shall make suitable
arrangements for emergency
servicing of the electrically operated
traffic signals to be available at all
times. Manually operated "Stop/Go"
signs shall only be used with the
prior approval of the S.O.; and shall,
if so approved, be of the size, colour
and type as shown on the Drawings
and complying with the requirements
of the ARAHAN TEKNIK(JALAN)
2C/85 (Manual on Traffic Control
Devices for Temporary Signs and
Work Zones Control), published by
Cawangan Jalan, Ibu Pejabat JKR,
Kuala Lumpur.
At least fourteen (14) days notice in
writing of any proposed single-way
traffic system shall be given to the
S.O. for his approval before such a
system can be implemented.

Construction and excavation shall be
sign posted and, during periods of
darkness, shall be lit to the approval
of the S.O.
Temporary traffic signals shall
comply with the requirements of the
ARAHAN TEKNIK (JALAN)
2C/85 published by Cawangan
Jalan, Ibu Pejabat JKR, Kuala
Lumpur and shall be reflectorised
and kept clean and legible at all
times.
The Contractor shall position, cover
or remove these signs as may be
directed by the S.O.
1.20.5 Temporary Works
The Contractor shall provide,
maintain and remove on completion
of the Works all temporary works
including diversion ways, tracks,
staging, bridging, etc., and shall
make them safe and suitable in every
respect for carrying all plants and
materials and for all purposes related
to the Works.
1.20.4 Temporary Traffic Signs

The Contractor shall at all times take
full and sufficient precautions to
ensure the safety of all traffic
through and around the Work Site
and of traffic that is diverted owing
to the Works.
To this end the Contractor shall erect
and maintain on the Site and at
prescribed points on the approaches
to the Site, all traffic signs, signals
and warning lights necessary for the
direction and control of traffic. The
sizes of all such signs and the
lettering and wording thereon shall
be as shown on the Drawings and
approved by the S.O. before erection.
1.21 LOCATION, TEMPORARY

PROTECTION AND
TEMPORARY DIVERSION OF
PUBLIC UTILITY
INSTALLATIONS AND OTHER
SERVICES
locating the positions of all public utility
installations, including water mains,
overhead and underground cables, pipes,
sewers and drains and all service
connections to buildings, and where
necessary, shall adopt such methods of
excavation as may be required by the
appropriate authorities or owners to
ensure that no damage is caused to
them.
Page 19
The Contractor shall make good, at his

own expense, any damage caused by him
to the existing services to the approval of
and in accordance with the instruction of
the appropriate authority or owner
concerned, and shall keep the Government
indemnified at all times from all claims,
costs and expenses which may arise on
account of any damage (whether
permanent, temporary or recurring) to the
said services.
All such installations which are
encountered in the course of the Works
shall be adequately supported, slung-up,
strutted or otherwise protected from injury
to the satisfaction of the respective
authority.
The temporary diversion or relocation of
any service within or outside the Works to
permit the construction of the Works shall
be the responsibility of the Contractor.
Where a service is required to be
interrupted or relocated the Contractor
shall inform and obtain the approval of the
S.O. who shall notify the appropriate
authority or owner of the required removal
and/or relocation.
Temporary diversion shall mean works
involved in the diversion of services that
will be reinstated to their original position
and condition on completion of the works
in the affected areas. In planning his work
for the diversion or relocation of services,
the Contractor shall make reasonable
allowance for the time necessary to obtain
the S.O.'s approval for the work and for the
appropriate authorities or owners to
authorise the work, obtain the necessary
materials and carry out the work.
The Contractor shall not be entitled to any
extension of time due to his failure to
allow for a reasonble period of time
necessary for obtaining approval and
completing the work.

1.22 WATER AND ELECTRICITY
SUPPLY
The Contractor shall provide at his own
risk and cost all water, lighting and
electric power where required for use in
the Works and shall pay all costs, fees
and charges and comply with all safety
regulations and statutes in connection
therewith.
The Contractor shall also provide and
maintain temporary water storage
together with any distribution piping
which may be necessary.
1.23 PROJECT SIGNBOARD

The Contractor shall provide, erect and
maintain signboards at locations to be
decided by the S.O. and pay all charges
in connection with this, including
obtaining permission, licences and fees,
etc. Each sign board shall comply with
the design and specification as shown on
the Drawings. On completion of the
project, the Contractor shall dismantle
and clear away the signboards as
1.24 PHOTOGRAPHIC RECORD OF
WORKS
The Contractor shall provide a camera
of reasonable quality for the purpose of
taking record photographs and slides of
the Works as and when directed by the
S.O. The Contractor shall bear the costs
of providing the film, development of
film, printing two (2) copies of each
exposure in 3R size and documenting
the photographs in suitable albums.
The negatives of the photographs shall
be the property of the Government and
no prints from these negatives may be
supplied to any person or persons except
with the approval of the S.O.
Page 20
A suitably typed caption shall be affixed

to the reverse side of each photograph
describing the subject and the time at
which it was taken. One copy of each
photograph shall be signed by the
Contractor and the S.O.
1.25 AS-BUILT DRAWINGS AND

MICROFILMING
Drawings for recording as-built
construction details of the Works shall
be prepared by the Contractor and shall
be certified by the S.O. or his
representative. The originals, in good
quality transparencies, and two (2)
printed copies of all as-built drawings
shall be supplied by the Contractor to
the S.O. progressively as sections of the
Works become completed. All drawings
shall be completed within one month
after the completion of the respective
section.

Contractor shall remove all rubbish,
debris and surplus materials from the
Site and leave the whole Site in a neat
and tidy condition to the satisfaction of
the S.O.
1.27 OPPORTUNITIES FOR OTHER

CONTRACTORS
The Contractor shall, when required by
the S.O., afford all reasonable
opportunity to any other Contractors
employed by the Government and their
workmen and to the workmen of the
Government and of any other duly
constituted authorities who may be
employed in the execution on or near
the Site of any work not included in the
Contract.
As-built drawings shall be A1 size (838

mm x 584 mm) unless otherwise
approved by the S.O.
The Contractor shall also microfilm the
as-built drawings using 35.0 mm film
with the aperture card format as shown
in Figure 1-1 and submit the same to the
S.O.
1.26 CLEARING UP OF SITE

The Contractor shall make every effort
to keep the Site in a reasonably clean
and tidy condition for the duration of the
Works. He shall, in addition, from time
to time on the completion of any area of
the Works or where directed by the S.O.,
remove rubbish, surplus materials, or
any other construction debris from such
areas as may be attributable to his work
under this Contract and generally leave
them in a satisfatory condition, to the
Page 21
APPENDIX 1A
GENERAL DESCRIPTION OF PROJECT
Page 22
APPENDIX 1B
SCOPE OF WORKS
Page 23
APPENDIX 1C
VEHICLES FOR S.O. AND HIS STAFF
All vehicles shall be NEW and of the types listed below :Type A
- 2000 c.c. four-door, air-conditioned saloon car;
Type B
- 1600 c.c. five-door, air-conditioned estate car;
Type C
- 1500 c.c. four-door, air-conditioned Proton Saga;
Type D
- 2000 c.c. four-wheel-drive, air-conditioned Trooper or equivalent with hard top;
Type E
- 2250 c.c. four-wheel-drive, air-conditioned long-wheel- base Land Rover or

equivalent with hard top.
Page 24
APPENDIX 1D
LIST OF LABORATORY EQUIPMENT
The Contractor shall provide and maintain the following testing laboratory equipment which shall
become the property of the Contractor at the end of the Contract :No.
(a) Soil Testing Equipment
(1) Moisture content tins - 76 mm x 25 mm with lids.
25
(2) Electric balance of 1 kg capacity, accurate to 0.1 g with a tare correction of

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

No.
(15)
Standard compaction mould as specified in B.S. 1377.
(16)
Compaction mould extruder as specified in B.S. 1377.
(17)
Steel scoop.
(18)
Rubber mallet.
(19)
Measuring flasks - 1000 c.c.
(20)
Vernier calipers - 152 mm.
(21)
Steel rule - 305 mm.
(22)
Compression machine suitable for laboratory and field C.B.R.'s with all
fittings necessary for field and laboratory operation as specified in B.S. 1377.
C.B.R. moulds fitted with collars and base plates for compaction and soaking
and tripods for small measurement fitted with dial gauges having 0.01 mm
divisions and 25 mm travel as specified in B.S. 1377.
10
(24)
2.26 kg surcharge weights - ring type.
(25)
2.26 kg surcharge weights - horseshoe type.
(26)
Complete field density kit, sand replacement type suitable for volume
measurement of 0.005 cu.m to an accuracy of not less than 0.0001
cu.m as specified in B.S. 1377.
Hand auger suitable for boring to depths of 3 m and supplied with 100 mm
diameter heads suitable for boring in cohesive and cohesionless soils.
(23)
(27)
(28)
Crowbar, pick and spade.
(29)
Drying pans - 406 mm x 406 mm x 76 mm.
(30)
British Standard 1377 - "Methods of Test for Soils for Civil Engineering
Purposes", latest edition.
1 of each
Page 26
(b) Concrete Testing Equipment

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

cubes in layers not more than 50 mm deep.
(c) Flexible Pavement Testing Equipment

(1) Metal tray, 0.6 m square or similar suitable for measuring spray rates of
bituminous materials and spread rates of cover aggregate for surface dressing.
(2) Metal thickness gauge (or set of slotted sleeves) as specified in M.S. 30 for
determination of aggregate flakiness index.
Additional items required for asphaltic concrete and/or bituminous Macadam :-
(3) Balance of 2 kg capacity, accurate to 0.1 g suitable for weighing samples

suspended in liquid.
(4) Steel moulds for Marshall test specimens (100 mm diameter) with base,
extension collar, extraction collar and extraction plate as specified in B.S. 598.
(5) Extractor for removing Marshall test specimens from moulds without distortion
or shock as specified in B.S. 598.
(6) Compaction hammer and automatic compactor for Marshall test specimens as
specified in B.S. 598.
1 of each
(7) Compaction pedestal and mould holder for Marshall test as specified
in B.S. 598.
1 of each
(8) Thermostatically controlled hot plate.
(9) Thermometers for use in laboratory and in asphaltic mixes for Marshall test as
2 of each
Page 27
No.
(10)
Rubber and heat resistant gloves.
2 pairs of each
(11)
Filter papers - 100 mm diameter.
As needed
(12)
Containers for heating aggregates and bituminous materials.
As needed
(13)
Pavement coring machine of the thin-walled diamond bit type for

obtaining 100 mm diameter samples of bituminous surfacings.
(14)
100 mm diameter thin-walled diamond bits for use with pavement

coring machine.
As needed
(15)
Tools for cutting and trimming pavement cores.
As needed
(15)
Metal bottles of suitable capacity for bitumen extraction by direct

determination as specified in B.S. 598.
As needed
(16)
Machine to rotate the bottles about their longitudinal axes at a speed of

between 10 rev/min to 30 rev/min as specified in B.S. 598.
(18)
Volumetric flasks of suitable capacity.
(19)
Centrifuge capable of developing an acceleration of 25,000 m/sq.

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

(20)
(21)
Recovery apparatus for extraction of bitumen by direct determination

as specified in B.S. 598.
(22)
Pressure filter of appropriate size, air pump and funnel for extraction
of bitumen by direct determination as specified in B.S. 598.
As needed
1 of each
Page 28
No.
Further items required for asphaltic concrete :-
(23)
Wire basket of 6.5 mm or smaller mesh with wire hanger as specified in

M.S. 30, for determination of specific gravity and water absorption
of aggregates.
(24)
Airtight container of similar capacity as wire basket above.
(25)
Gas jar - 1.5 litre.
(26)
Pyconometer - 1 litre.
(27)
Warm air blower.
(28)
Mechanical mixer of 2 kg capacity, for preparation of asphaltic concrete mixtures.
(29)
Thermostatically controlled water bath for Marshall test specimens as

(30)
Steel Marshall testing head as specified in B.S. 598.
(30)
Compression testing machine with proving ring, capable of applying loads of

up to at least 22 kN at a constant rate of strain of 50 mm + 3 mm per minute
and recording the maximum load achieved as specified in B.S. 598.
Dial gauge and mounting assembly for measuring Marshall test flows of up to
10 mm with accuracy of + 0.1 mm as specified in B.S. 598.
(31)
Testing which is specifically required in the Contract and any test defined in quoted British
Standard Specifications which are required to ensure compliance with the Contract but cannot be
done in the Site testing laboratory shall be carried out at approved laboratories off the Site. These
tests shall be carried out as directed by the S.O. The cost incurred by the Contractor shall be
deemed to have been included in the tendered rates.
Page 29
APPENDIX 1E
SURVEY EQUIPMENT
The Contractor shall provide and maintain the following instruments and equipment for the
purpose of measurements and setting out. These shall become the property of the Contractor at the
end of the Contract :-
1 No. Theodolite of direct read out accurate to 1 second.

2 No. Automatic levels - Wild NA2 or Koni 007 or equivalent.
2 No. Levelling staves - 5 m aluminium.
1 No. 50 m x 5 mm steel measuring band divided throughout and numbered at 5 m intervals.
Divided over first 30 m at 1 m intervals. Divided over first 5 m at 50 mm intervals.
1 No. Repair set for the same.
2 No. 30 m steel box tapes, white face.
2 No. 30 m fibreglass box tapes.
10 No. 2.5 m ranging rods.
2 No. 1 m spirit level, steel or aluminium.
2 No. Survey umbrellas.
Templates, straightedges, canvas bags, pegs, hammers, parangs, etc.
Page 30
Figure 1.1
APPERTURE CARD FOR MICROFILM
Page 31
SECTION 2
EARTHWORKS
Page 32
SECTION 2 - EARTHWORKS
Page
2.1
CLEARING, GRUBBING AND STRIPPING TOPSOIL
2.1.1
2.1.1.1
2.1.1.2
2.1.1.3
2.1.2
2.1.2.1
2.1.2.2
2.1.2.3
2.1.2.4
2.1.2.5
2.1.2.6
2.2
Description
Clearing
Grubbing
Stripping Topsoil
Construction Methods
Areas To Be Cleared
Areas To Be Cleared, Grubbed and Stripped Of Topsoil
Topsoil
Timber
Structures
Disposal Of Material
EARTHWORKS
S2-35
S2-35
S2-35
S2-35
S2-35
S2-35
S2-35
S2-36
S2-36
S2-36
S2-37
S2-37
S2-38
2.2.1
Definitions
S2-38
2.2.2
General Requirements
S2-39
2.2.3
2.2.3.1
2.2.3.2
2.2.3.3
2.2.3.4
2.2.3.5
2.2.3.6
2.2.3.7
2.2.3.8
2.2.3.9
2.2.3.10
2.2.3.11
Roadway Excavation
Dimensional Tolerances
Separation and Stockpiling of Suitable Material
Removal of Excavated Material From Site
Removal of Unsuitable Material
Replacement of Unsuitable Material Under Standing Water
Widening Cuts
Excavation of Rock
Storage and Handling of Explosives
Blasting
Safety Measures
Insecure Material
S2-39
S2-39
S2-40
S2-40
S2-40
S2-40
S2-40
S2-41
S2-42
S2-42
S2-42
S2-43
2.2.4
2.2.4.1
2.2.4.2
2.2.4.3
2.2.4.4
Earth Embankment
Material
Borrow Pits
Placement of Fill Material
Compaction
S2-43
S2-43
S2-43
S2-43
S2-44
2.2.5
Rock fill Embankment
S2-45
Page 33
Page
2.2.6
2.2.6.1
2.2.6.2
2.2.6.3
2.2.6.4
Embankment Over Soft Ground

Foundation Treatment
Surcharge and Staged Construction
Settlement Markers
Settlement Records
S2-46
S2-46
S2-46
S2-46
S2-47
2.2.7
Subgrade
S2-47
2.2.8
Protective Vegetation for Erosion Control
2.2.8.1 Topsoil
2.2.8.2 Turfing
2.2.8.3 Seeding
S2-48
S2-48
S2-48
S2-48
Page 34

Clearing shall also include the
levelling of obsolete dikes,
terraces, ditches, etc., unless
otherwise directed by the S.O.
SECTION 2 - EARTHWORKS
2.1
CLEARING, GRUBBING AND

STRIPPING TOPSOIL
2.1.1.2 Grubbing
2.1.1
Description
This work shall consist of clearing,
grubbing and stripping topsoil in the
areas designated hereunder and/or
shown on the Drawings and/or
directed by the S.O., and of clearing
only in other areas designated here
under and/or shown on the Drawings
and/or directed by the S.O., all as
specified herein and as required by
the S.O. The work shall also include
the demolition and disposal of
structures in said areas, except where
otherwise provided for in the
Contract, as specified herein and as
required by the S.O.
Grubbing shall consist of the

removal and disposal of surface
vegetation, the bases of stumps,
roots, the underground parts of
structures, and other obstructions
to a depth of at least 0.50 metre
below ground level, all to the
2.1.1.3 Stripping Topsoil
Stripping topsoil shall consist of
the removal of topsoil to an
average depth of at least 100 mm
below ground level, and its
stockpiling for use in the Works,
and/or its disposal, as directed by
the S.O.
2.1.1.1 Clearing
Clearing shall consist of the
cutting and/or taking down,
removal and disposal of
everything above ground
level, including objects
overhanging the areas to be
cleared such as tree branches,
except such trees, vegetation,
structures or parts of structures,
and other things which are
designated in the Contract to
remain, or be removed by others,
or which the S.O. directs are to
be left undisturbed. The material
to be cleared shall include but not
necessarily be limited to trees,
stumps (parts above ground),
logs, brush, undergrowth, long
grasses, crops, loose vegetable
matter and structures (except
those structures whose removal
or clearance is otherwise
provided for in the Contract).
2.1.2
2.1.2.1 Areas To Be Cleared

The entire road reserve area shall
be cleared as described above,
unless otherwise shown on the
Drawings and/or directed by the
S.O.
Clearing shall be carried out to
the extents deemed necessary and
approved or directed by the S.O.
in areas outside the road reserve
where channel excavation or
other work is required.
In areas which are to be cleared
only, and in which grubbing and
stripping topsoil are not required,
the methods of work shall be
such as will not unduly damage
the surface vegetation and
topsoil, and care shall be taken
Page 35
not to disturb the topsoil and the

root systems of grasses and other
surface vegetation. No topsoil
shall be removed from such
areas, except as directed by the
S.O., and any topsoil, grasses and
other surface vegetation other
wise removed or disturbed shall
be replaced and made good at the
Contractor's own expense, all to
the satisfaction of the S.O.
2.1.2.2 Areas To Be Cleared,Grubbed
and Stripped Of Topsoil
Except as otherwise shown on
the Drawings and/or directed by
the S.O., clearing, grubbing and
stripping topsoil shall be carried
out in all areas of roadway
excavation and in all areas where
embankment is to be constructed,
except that grubbing and
stripping topsoil shall not be
carried out in those areas where :i) embankment is to be
constructed on earth
designated as swamp or soft
ground;
ii) embankment is to be
constructed to a height at the
centre-line of 1.50 metres or
more on ground with a
cross-slope of not more than 1
(vertical) to 30 (horizontal).
Clearing, grubbing and stripping topsoil shall
be carried out to the extents deemed necessary
and approved or directed by the S.O. in areas
both inside and outside the road reserve where
channel excavation or other work is required.
Except where further excavation is required,
holes and cavities in the ground surface after
clearing, grubbing and stripping topsoil shall be
filled with materials similar to the adjacent
ground, and such fill shall be compacted to a
dry density similar to that of the surrounding
material, all to the satisfaction of the S.O.

This work shall be considered
incidental to the work of clearing,
grubbing and stripping topsoil,
and shall not be measured for
payment.
2.1.2.3 Topsoil
Topsoil to be stockpiled for the
Works shall be sufficiently fertile
to promote and support the
growth of vegetation, and shall be
taken from such areas where
clearing, grubbing and stripping
topsoil is required as approved or
directed by the S.O. Before
stockpiling, topsoil shall be
separated from objectionable
materials, all to the satisfaction of
the S.O. The Contractor shall
arrange for stockpile sites either
within or outside the road
reserve, at his own expense, and
all to the satisfaction of the S.O.
Otherwise, topsoil removed
during grubbing and stripping
operations shall be separated
from objectionable materials and
spread within the road reserve or
borrow areas, or otherwise
disposed of, as approved or
2.1.2.4 Timber
The ownership of timber is
vested in the Government.
Saleable timber shall be trimmed
and stacked in accordance with
the requirements of the
appropriate Government agency,
in accessible places within the
road reserve as approved or
The Contractor shall have the
right to use unsaleable timber (or
saleable timber when permission
is granted in writing by the
Page 36
appropriate Government agency

or authority) for his own
purposes in connection with the
Contract, always provided that he
shall comply with the
requirements of the S.O. agency
or authority) for his own
purposes in connection with the
Contract, always provided that he
requirements of the S.O.
2.1.2.5 Structures
Major structures are those which
cannot practicably be cleared by
bulldozer and/or hydraulic
excavator, whose demolition
requires pneumatic tools,
explosives and/or other
specialised equipment. A brief
description of each major
structure (if any) and depth to
which extent it shall be
demolished is given in the Bill of
Quantities.
All fences, buildings, structures,
and encumbrances of any
character within the limits of the
road reserve, except those to be
removed by others or designated
to remain, shall be demolished
and removed by the Contractor.
Materials designated in the
Contract or directed by the S.O.
to be salvaged, shall be carefully
removed and stored, and shall be
the property of the Government.
2.1.2.6 Disposal Of Material
Unwanted material from clearing,
grubbing and stripping topsoil
(including the demolition of
structures) shall be disposed of as
approved or directed by the S.O.

Combustible material
including all timber (except
timber to be salvaged or
used), all brush, stumps,
roots, vegetation and other
combustible refuse may be
piled up within the road
reserve and burned, where
burning is allowed.
All burning shall be subject
to the prior approval of the
relevant Government
authorities, and shall be
carried out in conformance
with all pertinent
regulations. Burning shall
also be carried out at such
places and at such times and
in such a manner as to
prevent fire from damaging
vegetation and property
within the road reserve
designated to be preserved,
and from spreading to areas
adjoining the road reserve
and damaging vegetation
and property therein.
Should the clearing,
grubbing and stripping of
topsoil be carried out at a
time when burning is not
permitted, the Contractor
may pile up combustible
materials within the road
reserve outside the limits of
the road works, and burn it
at a time when burning is
permitted.
Where burning is not
permitted at any time, or the
Contractor elects not to burn
unwanted material,
combustible material shall
be disposed of together with
incombustible material.
Page 37
Incombustible material, including

where appropriate the remains of
burning, shall be disposed of in a
safe and tidy manner at solid
waste dumps outside the Site,
unless otherwise approved or
directed by the S.O. The
Contractor shall be solely
responsible for making the
necessary agreements, and paying
expenses and claims arising from
the use of such solid waste
dumps whether on Government
or private land.
2.2

ii) any material
- consisting of highly
organic clay and silt;
- which is clay having a
liquid limit exceeding
80% and/or a plasticity
index exceeding 55%;
- which is susceptible to
spontaneous combustion;
- which has a loss of weight
greater than 2.5% on
ignition;
EARTHWORKS
2.2.1
Definitions
- containing large amounts

of roots, grass and other
vegetable matter.
(a) Formation Level

Formation level means the top
surface of the subgrade.
(b) Subgrade
Subgrade means that part of the
embankment or existing ground
in cutting which is immediately
below the subbase or lower
subbase of the road pavement
and shoulders.
Materials that are soft or unstable

merely because they are too wet
or too dry for effective
compaction are not to be
classified as unsuitable, unless
otherwise classified by the S.O.
(e) Suitable Materials
Suitable materials shall mean
those materials other than the
unsuitable materials defined in
Sub-Section 2.2.1 (d) above.
(c) Common Excavation

(f) Rock
Common excavation shall mean
excavation in any materials
which are not rock or artificial
hard materials as defined in
Sub-Sections 2.2.1 (f) and (g).
(d) Unsuitable Materials
Unsuitable materials shall
include :i) running silt, peat, logs,
stumps, perishable or toxic
material, slurry or mud, or
Rock shall mean material found

in ledges or masses in its original
position which would normally
have to be loosened either by
blasting or by pneumatic tools or,
if excavated by hand, by wedges
and sledge hammers. It shall not
include material which can be
loosened with a track-type tractor
with mounted and drawn ripper
of the following descriptions :-
Page 38
i) Tractor Unit : Equipment with a

minimum weight of 20 tonnes
and nett horse power rating of
200 brake horse power or more.
The tractor unit is to be in good
condition and operated by
experienced personnel skilled in
the use of ripping equipment;
ii) Ripping Unit : The ripper to be
attached to the tractor shall be the
most efficient parallelogram type
recommended by the tractor or
ripper manufacturer. The ripper
shall have a single shank in good
working condition with
sharpened cutting point.
Boulders or detached pieces shall only be
regarded as rock if they individually
exceed 0.5 cubic metre.
(g)
The Contractor shall provide where

necessary temporary water courses,
ditches, drains, pumping or other means of
maintaining the earthworks free from
water. Such provision shall include
carrying out the work of forming the
cuttings and embankments in such a
manner that their surfaces have at all times
a sufficient gradient to enable them to shed
water and prevent ponding.
In pumping out excavations and in the
lowering of water tables the Contractor
shall pay due regard to the stability of all
structures.
Adequate means for trapping silt shall be
provided on all temporary drainage
systems. Similar arrangements shall be
made for all earthworks including
excavations whether for pile trenches,
foundations or cuttings.
Artificial Hard Material

This shall mean any hard artificial
material which would require the use
of blasting or approved pneumatic
tools for its removal but shall
exclude individual masses less than
0.5 cubic metre.
2.2.2
The work shall include the
excavation of all types of material,
backfilling, compaction, forming
embankments and slopes, etc., as is
necessary for the completion of the
Works up to the formation levels, in
accordance with the lines, grades,
dimensions, shapes and typical
cross- sections shown on the
Drawings and to the approval of the
S.O.
Should the surface of completed areas be

damaged by erosion or by any other cause
the Contractor shall at his own cost make
good such areas to the satisfaction of the
S.O.
The Contractor shall exercise care in
preventing wastage of suitable material
needed for embankment or fill
construction.
2.2.3
Roadway Excavation
2.2.3.1 Dimensional Tolerances

Slopes in cutting shall be
trimmed mechanically to neat
and even surfaces which shall
have gradients not steeper than
that shown on the Drawings.
Widths of excavations shall not
exceed the dimensions shown on
the Drawings by more than 300
mm, unless otherwise approved
by the S.O.
Page 39
2.2.3.2 Separation and Stockpiling of

Suitable Material
Where excavation reveals a
combination of suitable and
unsuitable materials, the
Contractor shall, wherever the
S.O. considers it practicable,
carry out the excavation in such a
manner that the suitable materials
are excavated separately for use
in the Works without
contamination by the unsuitable
materials. The Contractor shall
stockpile separately material for
subgrade as specified in SubSection 2.2.7.
2.2.3.3 Removal of Excavated Material
From Site
No excavated material shall be
removed from the Site except on
the direction or with the approval
of the S.O. Should the
Contractor be permitted to
remove suitable materials from
the Site to suit his operational
procedure, then he shall make
good any consequent deficit of
fill material arising there from, at
his own expense. Unless
designated dump sites have been
shown on the Drawings, the
Contractor shall dispose of
surplus suitable material at his
own dump areas outside the Site
as approved by the S.O. In doing
so, the Contractor shall comply
with statutory requirements such
as payment of royalties, environ
mental protection, etc.

2.2.3.4 Removal of Unsuitable Material
Unsuitable material shall be
excavated to such depth and over
such area as directed by the S.O.
and be transported and disposed
of in an approved manner. Unless
approval of the S.O. to dump and
spread the unsuitable materials
within the Site is obtained, the
Contractor shall be responsible
for providing his own dump site
for such unsuitable materials.
The Contractor shall comply with
statutory requirements such as
payment of royalties,
environmental protection, etc.
Voids created due to removal of
unsuitable material shall be
backfilled with suitable material
compacted to a dry density not
less than that of the surrounding
material or that specified for the
respective part of the earthworks
or as directed by the S.O.
2.2.3.5 Replacement of Unsuitable
Material Under Standing Water
Where it is decided by the S.O.
that replacement of unsuitable
material shall be done under
standing water, voids created due
to removal of unsuitable material
shall be backfilled with hard
clean crushed rock, natural gravel
or sand having grading within the
respective limits specified in
Table 2.1.
2.2.3.6 Widening Cuts
The S.O. may instruct the
Contractor or the Contractor
himself may elect to obtain
material for the Works by
widening cuts. In the latter case,
the Contractor shall first request
permission in writing from the
S.O.
Page 40
TABLE 2.1 -
GRADING LIMITS OF
MATERIALS FOR
REPLACEMENT OF
UNSUITABLE MATERIAL
B.S. Sieve Size
% Passing By
Weight
Crushed Rock or
Gravel
63.0 mm
37.5 mm
20.0 mm
10.0 mm
100
85 - 100
0 - 20
0-5
Sand
10.0 mm
5.0 mm
1.18 mm
300 um
150 um
100
90 - 100
45 - 80
10 - 30
2 - 10
2.2.3.7 Excavation of Rock

Rock excavation shall be carried
out by methods appropriate to
Site requirements as approved by
the S.O. Where explosives shall
be used, the relevant security
regulations dealing with
purchase, transport, handling,
storage and usage of explosives
shall be complied with.
All material from rock
excavations shall be used as far
as is practicable in the Works.
Where the rock is of satisfactory

quality, the Contractor may elect to
crush and screen it to produce
aggregates required for concrete,
roadbase, subbase, or other purposes.
Excavated rock needed for earth
work construction which the
Contractor elects so to use for
producing select materials shall be
replaced at the Contractor's own
expense by borrow of satisfactory
quality approved by the S.O.
Otherwise, excavated rock shall be
used in the construction of
embankment and fill, to the fullest
practical extent, in either of the two
following ways :-
i) excavated rock shall be broken

down to a maximum particle size
of 400 mm and used as rock fill
as described in Sub-Section 2.2.5;
ii) excavated rock shall be broken
down to a maximum particle size
of 150 mm, blended with suitable
earth fill material in a proportion
not exceeding 1 rock to 1 earth,
and used as common fill.
The Contractor may only waste
excavated rock with the approval of the
S.O. Excavated rock needed for
earthwork construction which the
Contractor elects to waste shall be
replaced at the Contractor's own expense
by borrow of satisfactory quality
Page 41
2.2.3.8
Storage and Handling of

Explosives
Proper buildings or
magazines, with separate
compartments for detonators,
in suitable positions for the
storage of explosives in
manner and quantities to be
approved shall be provided.
The prevention of any
unauthorised issue or
improper use of any explosive
brought on the Works shall be
the responsibility of the
Contractor and only
experienced and responsible
men shall be employed to
handle explosives for the
purpose of the Works.
2.2.3.9
Blasting
Explosives shall be used in
the quantities and manner
recommended by the
manufacturers. Blasting shall
be restricted to such periods
as the S.O. may prescribe. If,
in the opinion of the S.O.,
blasting would be dangerous
to persons or property or to
any finished work, or is being
carried on in a reckless
manner, he may prohibit it,
and order the rock to be
excavated by other means.
The use of explosives in large
blasts, i.e. exceeding 9 kg of
explosive, as in seams, drifts,
shafts, pits, or large holes, is
prohibited unless authorised
in writing by the S.O. Such
authorisation shall not in any
way relieve the Contractor of
his liabilities under the
Conditions of Contract.
All necessary precautions shall be

taken to preserve in the soundest
possible condition the materials
below and beyond the lines of all
excavations. Delayed blasting to
reduce shock waves shall be used
to avoid damage to concrete and
other works already completed.
As the excavation approaches its
final lines, blasting shall be
carried out by means of parallel
drill holes perpendicular to the
toe of the excavation and parallel
to the finally required face.
2.2.3.10
Safety Measures
When blasting is carried out close
to properties or roads, appropriate
safety rules shall be strictly
adhered to. Where necessary or
as directed by the S.O., the use of
heavy mesh blasting mats shall
be used to ensure that no damage
is caused to persons or property
on or off Site. Special care shall
be taken in wet ground to ensure
that individual explosions are
reduced to such size as to
preclude damage to any buildings
or structures. Plaster shooting
will not be permitted within 400
metres of any building or
structure. If traffic on any road
or railway has to be interrupted
for blasting operations, the
Contractor shall obtain approval
of his schedule for such
interruption from the appropriate
authorities and shall prove to the
S.O. that he has obtained it, prior
to the interruption.
Page 42
2.2.3.11 Insecure Material

2.2.4.2
The slopes of cuttings shall be

cleared of all rock fragments
which move when prised with
a crow-bar. Where, in the
slopes of cuttings, layers of
rock and soft material
alternate and the S.O.
considers that the slope,
immediately after dressing,
will not permanently
withstand the effect of
weather, the Contractor shall
excavate any insecure
material to an approved depth
and build up the resulting
spaces with grade 15P/20
concrete or masonry using
rock similar to the adjoining
natural rock so as to ensure a
solid face.
The Contractor shall be

responsible for locating
borrow pits. Designated
borrow pits shown on the
Drawings only indicate to the
Contractor potential areas for
borrow. Whether the
Contractor obtains materials
from the designated or his
own borrow pit, it shall be his
responsibility to ascertain the
suitability of the pit with
respect to the quantity and
quality of the materials, which
shall be subject to the
approval of the S.O. The
Contractor shall pay all
necessary fees, taxes or
royalties to the appropriate
authorities and observe all
relevant regulations. The
Contractor shall keep the
borrow pits free from ponding
water and the excavation neat
and tidy and shall carry out
necessary erosion protection
measures as instructed by the
S.O.
2.2.4 Earth Embankment

2.2.4.1
Material
Fill materials for use in
forming embankments shall
be the suitable material
obtained from excavation in
cuttings. Where the quantity
of such materials is
inadequate, the Contractor
shall obtain suitable materials
from the designated borrow
pits or from his own borrow
pits which have been
Borrow Pits
2.2.4.3
Placement of Fill Material

All fill materials shall be
deposited in layers. The loose
depth for each layer of fill
shall be determined from the
trial compaction. Each layer
shall extend over the full
width of the fill area and shall
be compacted in accordance
with the requirements of SubSection 2.2.4.4. Each
compacted layer shall be
maintained at all times with a
sufficiently even surface in
order to drain away the
sur face water.
Page 43
Where embankment is to be
constructed on ground with a
cross-slope flatter than 1
(vertical) to 10 (horizontal) but
steeper than 1 (vertical) to 30
(horizontal), the foundation
material, except where this is
rock, shall be scarified to a depth
of 100 mm, blended with
embankment fill material and
compacted as described in SubSection 2.2.4.4.
Where embankment is to be
constructed against existing
embankment or on ground with a
cross-slope of 1 or more (vertical)
to 10 (horizontal), the foundation
shall be excavated in all materials
(including hard rock) to form
benches with horizontal and
vertical faces from which con
struction of the embankment shall
proceed. The benches shall be
contiguous beneath the full width
of the embankment, and shall be
of a suitable width to accomodate
construction equipment such as
motor-graders, trucks, rollers, etc.
Scarifying of the horizontal and
vertical faces of the benches shall
not normally be required, and the
material excavated in forming the
benches may normally be used as
fill in the embankment as
2.2.4.4 Compaction
(a) General
All materials used in
embankments and as fill
elsewhere shall be compacted
as soon as practicable after
being placed and spread.

Compaction shall be
undertaken to the
requirements of this Section
by plant approved by the S.O.
All compaction requirements
shall be controlled by means
of field density measurement.
For compaction of
embankment slope, the
Contractor may either extend
each compacted layer beyond
the design slope surface by at
least 600 mm and then trim
back to the required slope
angle, or he may employ a
tow type roller to compact the
sloping surface.
(b) Compaction Trials
The B.S. 1377 Compaction
Test (4.5 kg rammer method)
shall be used in determining
the moisture versus density
relation of soil.
The Contractor shall submit to
the S.O. for his approval the
proposed method of
compaction for each main
type of material to be used in
the embankment. This shall
include the type of
compaction plant for each
type of material and the
number of passes in relation
to the loose depth of material
to achieve desired
compaction. The maximum
compacted thickness for fill
shall be limited to 300 mm
unless otherwise approved by
the S.O. The Contractor shall
carry out field compaction
trials, supplemented by any
necessary laboratory
investigations, as required by
the S.O.
Page 44
This shall be done by using the

procedures proposed by the
Contractor for earthworks and
shall satisfy the S.O. that all the
specified requirements regarding
compaction can be achieved.
Compaction trials with the main
types of material likely to be
encountered shall be completed
before the works with the
corresponding materials will be
allowed to commence. Each trial
area shall be not smaller than
8 m x 15 m.
(c) Degree of Compaction
The whole of the embankment
below the top 300 mm of the
subgrade shall be compacted to
not less than 90% (for cohesive
material) or 95% (for
cohesionless material) of the
maximum dry density determined
in the B.S. 1377 Compaction Test
(4.5 kg rammer method).
(d) Field Density Testing
Field density tests on each layer
of compacted earth fill shall be
carried out using the sand
replacement method in
accordance with B.S. 1377 or by
using other means of testing of
comparable accuracy approved
by the S.O.
(e) Moisture Control
Each layer of earth fill shall be
processed as necessary to bring
its moisture content to a uniform
level throughout the material,
suitable for compaction. The
optimum moisture content as
determined by the B.S. 1377
Compaction Test (4.5 kg rammer
method) shall be used as a guide
in determining the proper

moisture content at which each
soil type shall be compacted.
Water shall be added, or the
material aerated and dried to
adjust the soil to the proper
moisture content to obtain the
required density. A satisfactory
method and sufficient equipment
as approved by the S.O. shall be
used for the furnishing and
handling of water.
If the natural water content of
suitable materials is too high for
the proper compaction to be
carried out, the Contractor can
either bring down the moisture
content by aeration or drying or
alternatively replace it with
suitable materials of compactable
moisture range at his own cost.
2.2.5 Rock fill Embankment
Rock used in rock fill
embankments shall be of maximum
particle size of 400 mm so that it can
be deposited in horizontal layers,
each not exceeding 500 mm in
compacted depth and extending over
the full width of the embankment
except for any specified external
cover to slopes or new formation
level. The materials shall be spread
and levelled by a crawler tractor
weighing not less than 15 tonnes.
Each layer shall consist of
reasonably well graded rock and all
large voids shall be filled with
broken fragments before the next
layer is placed. The top surface and
side slopes of embankments so
formed shall be thoroughly blinded
with approved fine graded material
to seal the surface.
Page 45
There shall be a transition layer

between rock fill and earth fill or the
top 300 mm of subgrade of at least
300 mm compacted thickness. This
shall consist of uniformly graded
crushed rock between 6 mm and 150
mm as approved by the S.O.
Each layer of rock used as rock fill
in embankments shall be
systematically compacted by at least
12 passes of a vibrating roller with a
static load per 25 mm width of roll
of at least 45 kg or a grid roller with
load per 25 mm width of roll of at
least 200 kg or other approved plant.
2.2.6 Embankment Over Soft Ground
2.2.6.1
Foundation Treatment
Prior to forming embankment
over soft ground, the soil over
which fill material shall be
placed shall be given strength
improvement treatment as
specified and to the details as
shown on the Drawings or as
directed or approved by the
S.O. Treatment by means of
replacement of unsuitable
material shall be as specified
in Sub-Sections 2.2.3.4 and
2.2.3.5.
The first layer or layers of fill
materials shall be deposited
over the full width of the
embankment and berms in
thicknesses and compacted as
approved by the S.O. The
Contractor shall provide
compaction plant suitable for
working over soft ground.

2.2.6.2 Surcharge and Staged
Construction
Where indicated in the Contract
or directed by the S.O., the
embankment shall be built to
different heights in stages with or
without surcharge with allowance
for consolidation time periods in
between stages, all in accordance
with the Contract. Where sur
charge is specified, the
for the provision of surcharge
material and the removal and
disposal of excess material on
completion of consolidation or
when directed by the S.O.
2.2.6.3 Settlement Markers
Markers shall be provided and
installed by the Contractor in the
positions indicated on the
Drawings for the purpose of
measuring settlements taking
place under the embankments
during and after the construction
period. The design of markers
shall be as shown on the
Drawings and the Contractor
shall be responsible for supplying
and installing such markers and
for extending the markers as the
work proceeds. Adjustments to
the height of markers shall be
made when required by the S.O.
Each marker shall be identified
by painting on it the chainage of
its position.
The Contractor shall take all
necessary measures to protect
markers from damage by plant
and vehicles at all times and shall
repair any such damage to the
satisfaction of the S.O. Readily
visible barriers shall be installed
around each marker.
Page 46
2.2.6.4
Settlement Records
Joint measurement of
settlement shall be taken
weekly while fill is being
placed in the vicinity of the
markers. Thereafter, readings
shall be taken fortnightly for a
period as directed by the S.O.
The readings shall be
submitted on an approved
printed form to be supplied by
the Contractor.
For the measurement of the
volume that has settled below
the original level of the
foundation of the
embankment, the measured
settlement of each marker
shall be used for volume
computation following the
method shown on the
Drawings.
2.2.7
Subgrade
Material for the top 300 mm of
subgrade shall have a minimum
California Bearing Ratio (CBR)
as shown on the Drawings when
compacted to 95% of the
in the B.S. 1377 Compaction
Test (4.5 kg rammer method)
under 4 days soaked condition.
Throughout the top 300 mm of
subgrade, the material shall be
compacted to not less than 95%
(for cohesive material) or 100%
(for cohesionless material) of the
In cut area, the top 300 mm of
the subgrade shall be scarified
and recompacted to 95% (for
cohesive material) or 100%

(for cohesionless material) of the
maximum dry density determined in
the B.S. 1377 Compaction Test (4.5
kg rammer method). If the S.O. is
fully satisfied that the subgrade in its
natural state possesses a density
exceeding the requirements, then the
surface of the subgrade shall be
trimmed and rolled to obtain a
smooth finish.
Where the material in cut area is
found to be unsuitable for use in the
top 300 mm of subgrade it shall be
removed and replaced with suitable
material which shall be compacted as
indicated above.
The subgrade shall be finished in a
neat and workmanlike manner, and
the widths of embankments and cuts
shall be everywhere at least those
specified or shown on the Drawings
on both sides of the centreline. The
top surface of the subgrade shall
have the required shape,
superelevation, levels and grades and
shall be finished everywhere to with
in + 10 mm and minus 30 mm of the
required level.
i) Where rock surface extends over
the whole width of the
formation :The rock surface shall be
trimmed to a free draining
profile, at or below formation
levels. No high spot shall
protrude above the formation
levels.
Any voids or cavities more than
0.5 metre below the formation
level shall be filled up with
approved lean concrete having
7-day cube strength greater than
7 N/sq.mm. The rock surface
shall then be brought up to the
formation levels with approved
Page 47
crushed rock or gravel, regulated

and blinded.
ii) Where rock outcrop occurs over
part of the formation only:The rock outcrop shall be cut
down to a level not less than 300
mm below the formation level.
The surface shall then be brought
up to level with suitable subgrade
material.
2.2.8 Protective Vegetation for Erosion
Control
2.2.8.1 Topsoil
Topsoil stockpiled for the Works
in accordance with Sub- Sections
2.1.1.3 and 2.1.2.3 shall be spread
and lightly compacted to an even
thickness of 50 mm as directed
by the S.O. in areas to be turfed
and/or seeded, or used as the S.O.
shall otherwise direct for tree
planting and other purposes.

Turf sods shall be stacked and
watered when they cannot be
laid immediately after cutting.
The surfaces to be turfed shall
be trimmed and thoroughly
wetted. The turf shall then be
carefully laid to form a complete
and uniform cover as shown on
the Drawings. Turf laid on slopes
steeper than 1 (vertical) and 3
(horizontal) shall be pegged
down with bamboo stakes
approximately 250 mm in length.
Approved fertiliser shall be
applied after placing of turf at
suitable times and at rates of
application approved by the S.O.
All turf shall be regularly
watered and fertilised to the
satisfaction of the S.O. until
the vegetation is satisfactorily
established. Any dead turf
shall be replaced with new
turf at the Contractor's own
expense.
2.2.8.2 Turfing
2.2.8.3 Seeding
Turfing shall be carried out as
soon as practicable on all earth
slopes and other areas as shown
on the Drawings and/or where
directed by the S.O. The type of
turf shall be as indicated on the
Drawings or other alternative
type as approved by the S.O. and
shall be free of lallang and
essentially free of weeds.
Turf shall be obtained in
unbroken sods with a substantial
amount of topsoil and shall be
approximately 250 mm x 250
mm in size and 100 mm thick,
from an approved source, and
shall be placed in position as
soon as practicable after cutting.
Seeding or hydroseeding shall be

carried out as soon as practicable
on slopes and other areas as
shown on the Drawings and/or
the S.O. for his consideration and
approval, at least four (4) weeks
in advance of the proposed work,
full details of his proposed
method of seeding or
hydroseeding. The information
submitted shall include, but not
necessarily be limited to, a full
description of the following
aspects of the work :-
Page 48
i) the preparation of the areas to be

seeded or hydroseeded, including
if appropriate the amount of top
soil to be used and its method of
application;
ii) the details and results of
investigations to determine which
types of grass and legume are
compatible with the soil in the
areas to be seeded;
iii) the types of grass and legume (if
any) and strains of seed to be
used, and the function, root and
growth characteristics of each
type;
iv) the rates of application of the
grass and legume seeds;

xii)
the cultivation and after-care of

the seeded areas, including rates
and frequencies of watering,
fertilising, grass cutting and
general maintenance for at least 1
year after seeding;
xiii)
the time after seeding required for

establishing permanent, dense
growth of grasses, which will
require minimal maintenance;
xiv)
guarantees of the success of the

seeding work.
All grass shall be regularly watered until

the vegetation is satisfactorily
established to the satisfaction of the S.O.
Any dead grass shall be replaced at the
Contractor's own expense.
v) the composition of fertiliser to be

used at the time of seeding and its
rate of application;
vi) the composition of fertiliser to be
used after seeding, the times of
application after seeding, and the
rates of application;
vii) the type of mulch to be used and
its method and rate of
application;
viii) the amounts of lime or other
chemicals (if any) to be applied
to improve the soil before,
during and/or after seeding;
ix) the type and amounts of binding
agent to be applied with the
seeds, mulch, fertiliser, etc.,
as appropriate.
x) the proportions and methods of
preparation of the seeding mix;
xi) the equipment and methods to be
used in preparing and placing the
seeding mix and other materials;
Page 49
SECTION 3
DRAINAGE WORKS
Page 50
SECTION 3 - DRAINAGE WORKS

Page
3.1
GENERAL
S3-54
3.2
EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS
S3-54
3.2.1
Description
S3-54
3.2.2
3.2.2.1
3.2.2.2
3.2.2.3
3.2.2.4
3.2.2.5
3.2.2.6
Materials
Excavation
Granular Bedding Material
Concrete Bedding
Ordinary Backfill Material
Granular Backfill Material
Concrete Backfill
S3-54
S3-54
S3-54
S3-54
S3-54
S3-54
S3-55
3.2.3
Excavation
S3-55
3.2.4
Backfilling with Ordinary or Granular Backfill Material
S3-56
3.3
CHANNEL EXCAVATION
S3-57
3.3.1
Description
S3-57
3.3.2
Materials
S3-57
3.3.3
S3-58
3.4
SURFACE DRAINAGE
3.4.1
Surface Drainage Types
3.4.2
Surface Drain Construction
3.4.2.1 Unlined Drains
3.4.2.2 Cast In Situ Concrete Drains
3.4.2.3 Precast Concrete Drain Sections
3.5
STONE PITCHING
3.5.1
Description
3.5.2
Materials
3.5.2.1 Stone
3.5.2.2 Cement Mortar
S3-58
S3-58
S3-58
S3-58
S3-59
S3-59
S3-60
S3-60
S3-60
S3-60
S3-60
Page 51

Page
3.5.3
3.5.3.1 Grouted Stone Pitching
3.5.3.2 Ungrouted Stone Pitching
3.6
GABIONS
3.6.1
Description
S3-60
S3-60
S3-61
S3-61
S3-61
3.6.2
Materials
3.6.2.1 Wire Mesh Gabions
3.6.2.2 Polyvinyl Chloride Coating
3.6.2.3 Stone
S3-61
S3-61
S3-62
S3-62
3.6.3
S3-63
3.7
BRICKWORK
S3-63
3.7.1
Description
S3-63
3.7.2
3.7.2.1
3.7.2.2
3.7.3
3.7.3.1
3.7.3.2
Materials
Common Bricks
Cement Mortar
Brick Laying
Plastering Brickwork
S3-63
S3-63
S3-63
S3-63
S3-63
S3-64
3.8
SUBSOIL DRAINS
3.8.1 Description
3.8.2
Materials
3.8.2.1 Pipes
3.8.2.2 Filter Material
3.8.2.3 Filter Cloth
3.8.3
3.9
R.C. PIPE CULVERTS
3.9.1
Description
3.9.2
Materials
3.9.2.1 Pipes
3.9.2.3 Bedding Material
S3-64
S3-64
S3-64
S3-64
S3-64
S3-65
S3-65
S3-65
S3-66
S3-66
S3-66
S3-66
S3-66
S3-66
Page 52

Page
3.9.3
Excavation and Backfilling for R.C. Pipe Culverts
3.9.3.1 Excavation
3.9.3.2 Backfilling
S3-67
S3-67
S3-68
3.9.4
3.9.4.1
3.9.4.2
3.9.4.3
3.9.4.4
S3-68
S3-68
S3-68
S3-69
S3-70
Installation of R.C. Pipe Culverts

General
Butt Ended Pipe Culverts with Precast Concrete Collars
Rebated Pipe Culverts
Spigot and Socket Pipe Culverts
3.10 CORRUGATED METAL PIPE CULVERTS
S3-70
3.10.1
Description
S3-70
3.10.2
3.10.2.1
3.10.2.2
3.10.2.3
3.10.2.4
3.10.2.5
Materials
Pipes
Bitumen Coating
Bolts and Nuts
Cement Mortar
Bedding Material
S3-70
S3-70
S3-71
S3-71
S3-71
S3-71
3.10.3
Excavation and Backfilling for Corrugated Metal Pipe Culverts
S3-72
3.10.4
Installation of Corrugated Metal Pipe Culverts
3.10.4.1 General
3.10.4.2 Mortar Lining
3.11
PRECAST BOX CULVERTS
S3-72
S3-72
S3-72
S3-72
3.11.1
Description
S3-72
3.11.2
3.11.2.1
3.11.2.2
3.11.2.3
Materials
Precast Box Culverts
Cement Mortar
Bedding Material
S3-72
S3-72
S3-72
S3-72
3.11.3
3.11.3.1
3.11.3.2
3.11.4
Excavation and Backfilling

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

3.12.2 Extension of Box Culverts
S3-74
S3-74
S3-74
Page 53
SECTION 3 - DRAINAGE WORKS

3.2.2
Materials
3.2.2.1 Excavation
3.1
GENERAL
This work shall consist of the
construction of surface drains, subsoil
drains, pipe culverts, box culverts,
sumps and other drainage structures in
accordance with this Specification or
as directed by the S.O. Drainage works
shall be constructed to the lines, levels,
grades and cross-sections shown on the
Drawings or as directed by the S.O.
3.2
EXCAVATION AND
BACKFILLING FOR DRAINAGE
WORKS
3.2.1
Description
This work shall consist of excavation
for the construction of surface drains,
subsoil drains, cast in site box
culverts, and other drainage
structures, except pipe culverts, not
otherwise provided for in this
Specification, and shall include
furnishing, placing, compacting and
shaping foundation bedding
materials, backfilling excavations
against completed structures with
suitable material or granular backfill
where specified, and the removal and
disposal of all excess excavated
material, in accordance with this
Specification and as shown on the
Drawings and as required by the
S.O.
Excavation and backfill for pipe
culverts and precast box culverts
shall be in accordance with the
provisions of Sub-Section 3.9.
Material excavated shall be

classified as common excavation
or rock as defined in Section 2 of
this Specification.
3.2.2.2 Granular Bedding Material
Granular bedding material for the
foundations of structures shall be
suitably graded broken rubble,
crushed stone, crushed gravel,
sand or other material as
specified on the Drawings or as
3.2.2.3 Concrete Bedding
Concrete bedding or blinding for
the foundations of structures shall
conform to the requirements of
Section 9 of this Specification
for the class of concrete specified
on the Drawings or required by
the S.O.
3.2.2.4 Ordinary Backfill Material
Ordinary backfill material shall
be suitable material as defined in
Section 2 of this Specification.
The maximum particle size of the
backfill material shall be 50 mm.
3.2.2.5 Granular Backfill Material
Granular backfill material shall
be sand, crushed stone, crushed
gravel or a mixture of crushed
and natural aggregates, shall be
essentially free from vegetative
and other organic matter and clay,
and shall not contain lateritic or
concretionary materials.
Page 54
The material shall conform to the

following physical and
mechanical quality requirements:-
3.2.2.6 Concrete Backfill

Concrete backfill where
specified shall be of the
grade as shown on the
Drawings and shall con
form to Section 9 of this
Specification.
i) the fines shall be non-plastic;

ii) sand shall have a gradation
conforming to the envelope
shown in Table 3.1;
TABLE 3.1 - GRADING LIMITS FOR SAND
BACKFILL
B.S. Sieve Size
% Passing By Weight
10.0 mm
5.0 mm
1.18 mm
300 um
150 um
100
90 - 100
45 - 80
10 - 30
2 - 10
iii) material other than sand shall

have a gradation conforming
to one of the envelopes shown
in Table 3.2.
TABLE 3.2 - GRADING LIMITS FOR
GRANULAR BACKFILL OTHER THAN
SAND
B.S.
Sieve
Size
37.5mm
28.0mm
20.0mm
10.0mm
5.0mm
2.0mm
425um
75um
% Passing By Weight
A
B
100
70 100
60 90
45 75
30 60
20 50
10 30
02
100
70 - 100
45 - 75
35 - 65
25 - 50
10 - 30
02
C
100
45 75
30 60
15 35
02
3.2.3
Excavation
The Contractor shall notify the S.O.
sufficiently in advance of the
beginning of any excavation so that
cross-section elevations and
measurements may be taken of the
undisturbed ground. The natural
ground adjacent to the structure shall
not be disturbed without permission
of the S.O.
Trenches and foundation pits for
structures and structure footings and
underdrains shall be excavated to the
lines, grades and elevations shown
on the Drawings or as directed by
the S.O. Excavations must be kept
free from water and temporary
drains, sumps and pumps shall be
provided when necessary. The rate of
excavation and backfill shall be
approved by the S.O. The elevations
of the bottoms of footings shown on
the Drawings are approximate only
and the S.O. may order in writing
such changes in the dimensions or
elevations of footings as may be
deemed necessary to secure a satis
factory foundation.
Boulders, logs and other
objectionable materials encountered
in excavation shall be removed.
After each excavation is completed
the Contractor shall notify the S.O.
to that effect and no footing,
bedding material or structure shall be
placed until the S.O.
Page 55
to that effect and no footing,

bedding material or structure shall be
placed until the S.O. has approved
the depth of excavation and the
character of the foundation material.
All excavated material, so far as

suitable, shall be utilized as backfill
or embankment. The surplus
material, whether or not temporarily
allowed to be placed within a stream
area, shall be finally disposed of in
such a manner as not to obstruct the
stream nor otherwise impair the
efficiency or appearance of the
works, nor is it to endanger the
partly finished structure.
Rock and other hard foundation

material shall be cleared of all loose
material and cut to a firm surface,
either level or stepped or serrated, as
or directed by the S.O. All seams
and crevices shall be cleared out and
grouted with Portland cement grout
at the time the footing is placed.
All loose and disintegrated rock and
thin strata shall be removed. When
the footing is to rest on material
other than rock, special care shall be
taken not to disturb the bottom of the
excavation, and excavation to final
grade shall be deferred until just
before the footing is to be placed.
When, in the opinion of the S.O., the
foundation material is soft or mucky
or otherwise unsuitable, the
Contractor shall remove the
unsuitable material and insert
foundation fill material or concrete
as specified or shown on the
Drawings or directed by the S.O. If
foundation fill material is required it
shall be placed and compacted in
layers not more than 150 mm thick
or as directed by the S.O. The
degree of compaction shall be
equivalent to that of the surrounding
foundations.
All excavation surfaces and surfaces
of backfill material against which
concrete is to be placed shall be
even and firm and true to line and
level.
Excavated material suitable for use

as backfill may be deposited by the
Contractor in storage piles at points
convenient for rehandling of the
material during the backfilling
operation.
Excavated material shall be
deposited in such places and in such
a manner as not to cause damage to
highway, services or property either
within or outside the road reserve,
and so as to cause no impediment to
the drainage of the Site or
surrounding area.
3.2.4
Backfilling with Ordinary or

Granular Backfill Material
All spaces excavated under this
Specification and not occupied by a
permanent structure shall be
backfilled. Backfill material shall be
free from large lumps, wood and
other extraneous material.
Backfill not within the embankment
areas shall be placed in layers not
more than 250 mm in depth
(compacted measurement) and shall
be compacted to a density
comparable with the adjacent
undisturbed material.
Page 56
Backfill within the embankment

areas shall be made with approved
material placed in uniform layers not
to exceed 150 mm in depth
(compacted measurement) and each
layer shall be constructed in
accordance with Section 2 of this
Specification except that mechanical
tampers may be used for
compaction. Each layer of backfill
shall be wetted uniformly as
necessary and compacted to the
same requirements as the adjacent
earthwork as specified in Section 2
of this Specification. Unless
otherwise approved by the S.O.,
hand tamping will not be accepted.

Special care shall be taken to prevent
any unduly high pressures against
the structures.
The placing of embankment and the
benching of slopes shall continue in
such a manner that at all times there
will be a horizontal berm of
thoroughly compacted material for a
distance at least equal to the height
of the abutment or wall to be back
filled.
3.3 CHANNEL EXCAVATION
3.3.1 Description
This work shall consist of excavation
for waterway channels both inside
and outside the road reserve as
shown on the Drawings or directed
by the S.O., and shall include all
required excavation for widening,
training or permanently diverting
rivers, streams and irrigation and
drainage channels other than drains
and ditches appurtenant to the
roadway, except excavation of top
soil for use in the Works and
excavation required for clearing and
grubbing. This work shall also
include the backfilling of old
channels, haulage to their points of
utilization in the Works or the
removal and disposal of all
excavated materials, the construction
of appurtenant bunds, dikes and
berms, and the shaping and finishing
of all earthworks involved in the
construction of channels in accor
dance with the required lines, levels,
grades and cross-sections.
In placing backfill and embankment,

the material shall be placed insofar
as possible to approximately the
same height on both sides of the
structure. If conditions require
backfilling appreciably higher on one
side, the additional material on the
higher side shall not be placed until
permission is given by the S.O. or
until the S.O. is satisfied that the
structure has enough strength to
withstand any pressure created.
Backfill for embankment shall not be
placed behind the walls of box
culverts until the top slab is placed
for the required time and not less
than three days. Backfill and
embankment behind abutments held
at the top by superstructure shall be
carried up simultaneously behind
opposite abutments and side walls.
No backfilling shall be placed
against any structure until permission
shall have been given by the S.O.
Jetting of fill or other hydraulic
methods involving, or likely to
involve, liquid or semi-liquid
pressure shall be prohibited.
3.3.2
Materials
Channel excavation shall be
classified as common excavation or
rock as specified in Section 2 of this
Specification.
Page 57
3.3.3 Construction Methods

All suitable materials removed from
channel excavations shall be used for
backfilling waterways to be
abandoned and constructing bunds,
dikes and other earth appurtenances
as required. Surplus suitable
materials shall be used as far as is
practicable in constructing the
roadway. The Contractor shall
provide borrow of satisfactory q
quality and approved by the S.O.
should this be necessary to complete
the work. Borrow which is required
to replace suitable excavated
materials needed for construction
which the Contractor elects to waste
shall not be paid for.
Excavated unsuitable material,
suitable material surplus to that
needed for construction and suitable
material that the Contractor elects to
waste, shall be disposed of at
designated areas in such a manner as
to present a neat appearance and not
obstruct flow in any channels,
ditches or drains, nor cause damage
to highway works or property, all to
During construction, channel
excavations shall be kept drained as
far as is practicable and the work
shall be carried out in a neat and
workmanlike manner.
All channels and appurtenances shall
be excavated and constructed to the
lines, levels, grades and crosssections shown on the Drawings or
as directed by the S.O. Excavation
beyond the limits required shall not
be paid for and shall be backfilled at
the Contractor's expense as directed
by the S.O. should he deem it
necessary.
Sections of channel abandoned

owing to diversions shall be back
filled as directed by the S.O.
3.4
SURFACE DRAINAGE
3.4.1
Surface Drainage Types

Surface drains of the types shown on
the Drawings shall be constructed to
the lines, levels, grades and crosssections as specified or as directed
by the S.O. Surface drains shall
include interceptor drains, roadside
drains, embankment toe drains,
shoulder drains, bench drains, berm
drains, median drains, outfall drains,
cascade drains, etc.
Any of the above drains may be
constructed either unlined or lined
using cast in situ concrete, precast or
porous concrete drain sections, or
stone pitching.
3.4.2
Surface Drain Construction
3.4.2.1 Unlined Drains

Excavation for unlined drains
shall be trimmed to form a
smooth, firm surface to the
required lines, levels, grades and
cross-sections as shown on the
Drawings or as required by the
S.O.
Any areas of over excavation
shall be made good to the
satisfaction of the S.O., all at the
Contractor's expense.
Page 58
3.4.2.2 Cast In Situ Concrete Drains

Excavation shall be carried
out to the lines and levels as
specified and as shown on the
Drawings. Templates which
may be of timber or steel shall
then be provided to ensure the
thickness and shape of the
concrete drains. The concrete
shall be poured in sections not
exceeding 2 m in length and
shall be carried out between
end forms in alternate bays.
Construction joints shall not
be formed in the inverts.
All concrete shall be grade
20/20 concrete unless otherwise
specified and shall conform to the
requirements of Section 9 of this
Specification. Weep holes shall
be cast in situ as shown on the
Drawings or as directed by the
S.O.
3.4.2.3 Precast Concrete Drain
Sections
Precast concrete block inverts
shall be of the shapes and
dimensions as shown on the
Drawings and shall be of
grade 20/20 concrete conforming
to the requirements of Section 9
of this Specification or of
porous concrete unless otherwise
specified. The precast concrete
drain sections shall be
manufactured using good quality
moulds and the finished product
shall be round and have smooth
inside surfaces all to the approval
of the S.O. Ready made precast
concrete drain sections may be
used subject to the approval of
the S.O.

Ready made precast concrete
drain sections may be used
subject to the approval of the
S.O. Samples of ready made
drain sections shall be submitted
to the S.O. for his approval
before placing of orders.
Notwithstanding any approval
given by the S.O., any defective
or broken drain section shall be
replaced by the Contractor at his
own expense before or after
laying in position.
Precast concrete drain sections
shall be laid on concrete bedding
in trenches excavated to the lines
and levels as specified and
jointed to produce a neat even
alignment and gradient. The joint
shall be grouted with 1:3 cement
mortar complying with SubSection 3.5.2.2 and weep holes
shall be provided as shown on the
S.O.
Porous concrete shall comply
with the requirements of porous
concrete for pipes as described in
M.S. 525. Cement and
aggregates used in the
manufacture of the porous
concrete drain sections shall con
form to the requirements of
Mass concrete for bases shall be
of grade 10/25 concrete or as
specified and to the dimensions
and thicknesses as shown on the
Drawings.
Page 59
3.5
STONE PITCHING
3.5.1

Description
Cement mortar, unless otherwise

specified, shall contain 1 part
ordinary Portland cement to 3
parts fine aggregate by volume.
Water shall be added to the mix
to produce a suitable consistency
for the intended use, all to the
satisfaction of the S.O. The
constituent materials of the
mortar shall comply with the
appropriate requirements of

construction of all structures or parts
of structures to be composed of stone
pitching either grouted or ungrouted
as shown on the Drawings or as
directed by the S.O. including
erosion protection pavements and
aprons, drain linings, culvert inlets
and outlets, etc. The work shall be
carried out all in accordance with
this Specification and to the lines,
levels, grades, dimensions and crosssections shown on the Drawings and
as required by the S.O.
3.5.2
The ingredients for mortar shall

be measured in proper gauge
boxes and mixed on a clean
boarded platform or in an
approved mechanical batch
mixer.
Materials
3.5.2.1 Stone
Stone shall be clean rough quarry
stone, or pit or river cobbles, or a
mixture of any of these materials,
and shall be essentially free from
dust, clay, vegetative matter and
other deleterious materials.
Individual pieces of stone shall be
approximately cubical or
spherical and shall have least
dimensions in the range 100 to
150 mm and a maximum
dimension of 250 mm,
maximum, unless otherwise
specified. The stone shall be
hard, tough, durable and dense,
resistant to the action of air and
water, and suitable in all respects
for the purpose intended.
All mortar shall be used within

30 minutes of mixing and no
reworking of mortar shall be
permitted thereafter.
3.5.3
3.5.3.1 Grouted Stone Pitching

Prior to constructing grouted
stone pitching, the surfaces
against which it is to be placed
shall have been finished in
accordance with the appropriate
provisions of this Specification.
Notwithstanding any earlier
approval of these finished
surfaces, any damage to or
deterioration of them shall be
made good to the satisfaction of
the S.O. before grouted stone
pitching is placed.
Page 60
Construction of grouted stone

pitching shall commence at the
lowest part of each structure or
section of a structure and
continue progressively upward.
Long structures such as drain
linings and slope protection
pavements shall be constructed in
sections of practicable length, to
the satisfaction of the S.O. The
surface against which the work is
to be placed shall be moistened
with clean water a little in
advance of construction, and
covered with a layer of cement
mortar about 50 mm thick.
Stones shall then be firmly set by
hand into the mortar, densely
packed against adjacent stones
and built up to form a stone
structure of more or less uniform
thickness which shall nowhere be
less than 150 mm (measured per
pendicularly to the surface
covered). All the while that
stones are being placed, all voids
in the structure shall be packed
solidly with mortar and stone
spalls; however the surfaces of
stones in the exposed faces and
edges shall not be covered with
mortar. The exposed surfaces
and edges of the structure shall be
constructed such that they have
as large a proportion as
practicable composed of stone
faces. Weep holes shall be
provided as shown on the
S.O.
Mortar which has been mixed for
more than 30 minutes shall not be
used in the works. Nor shall
mortar be laid against the
supporting surface more than 2
minutes before pitching stone and

building up the structure to full
thickness is commenced on any
section of the work, as the con
struction advances.
The work shall be carried out and
finished all to the satisfaction of
the S.O.
3.5.3.2 Ungrouted Stone Pitching
Where shown on the Drawings,
ungrouted stone pitching shall be
hand set to provide maximum
interlocking effect. The stones,
the largest of which shall be used
at the bottom, shall be well
bedded on a 75 mm layer of
gravel or aggregate rammed to an
even surface. The whole work
shall be finished to the
satisfaction of the S.O
3.6
GABIONS
3.6.1
Description
construction of miscellaneous
erosion protection and retaining
structures to be composed of stone
filled wire mesh gabions. The work
shall be carried out all in accordance
with this Specification and as shown
on the Drawings and/or as approved
by the S.O.
3.6.2
Materials
3.6.2.1 Wire Mesh Gabions

Gabions shall be rectangular
baskets of the required
Drawings or ordered by the S.O.
Unless otherwise specified, they
shall be of the following standard
dimensions :-
Page 61
i) width - 1.00 metre;

ii) length - 1.00, 2.00 or 3.00
metres;
iii) height - 0.50 or 1.00 metre.
Gabions longer than 1.00 m shall
be divided into compartments of
equal length not exceeding 1.00
m by wire mesh diaphragms
securely tied along all edges.
Each gabion or compartment of a
gabion shall be provided with at
least 4 cross-connecting wires if
its height is 0.50 m or less, and
with at least 8 cross-connecting
wires if its height is in the range
0.50 to 1.00 metre.
Gabions shall be fabricated from
steel wire manufactured in
accordance with B.S. 1052 and
galvanised in accordance with
M.S. 407, or such similar
standards as the S.O. shall
approve. The galvanised wire
sizes used shall be in accordance
with Table 3.3.
TABLE 3.3 - GALVANISED WIRE SIZES
FOR GABIONS
Type of Wire
Minimum Diameter
Selvage (perimeter) wire
3.50 mm
Mesh wire
2.70 mm
Tying and connecting

wire
2.20 mm
Gabion mesh shall be triple

twisted and shall have a uniform
hexagonal pattern with openings
of 100 x 120 mm or less. The
mesh shall be securely tied to
selvage wires to form rectangular
panels which shall be securely
wired together to form the
completed gabion baskets. The
ties and connections for each
gabion basket shall comprise not
less than 8% of its total weight,
and the fabrication shall be all to
3.6.2.2 Polyvinyl Chloride Coating
When specified on the Drawings,
all wire used in the fabrication of
gabions and in the wiring
operation during construction
shall, after galvanising, have
extruded on to it a coating of
polyvinyl chloride (PVC). The
PVC coating, not inclusive of
galvanising, shall nowhere be less
than 0.55 mm in thickness.
3.6.2.3 Stone
Stone fill for gabions shall be
clean rough quarry stone, or pit
or river cobbles, or a mixture of
any of these materials, and shall
be essentially free from dust,
clay, vegetative matter and other
deleterious materials. Individual
pieces of stone shall have least
dimensions not less than 20 mm
larger than the gabion mesh
openings and greatest dimensions
not more than 250 mm. The stone
shall be hard, tough, durable and
dense, resistant to the action of
air and water, and suitable in all
aspects for the purpose intended.
The material shall be approved
by the S.O.
Page 62
3.6.3
Prior to placing gabions, the surface
on and against which they are to be
constructed shall have been prepared
and finished in accordance with the
relevant provisions of the appropriate
Sections of this Specification.
Notwithstanding any earlier approval
of these finished surfaces, any
damage to or deterioration of them
satisfaction of the S.O. before
gabions are placed.
Each gabion basket shall be put in
place in its turn, completely
fabricated except for the fastening
down of the lid, stretched to the
correct shape and dimensions, and
fastened securely to all contiguous
baskets along each edge with tying
wire. The basket shall then be tightly
packed with approved stone by hand
in such a manner that voids are kept
to a practicable minimum and are
uniformly distributed in the stone
mass. Finally, the lid of the basket
shall be securely fastened down with
tying wire along all hitherto
unfastened edges, all to the
satisfaction of the S.O. In no case
shall the weight of the finished
gabion be less than 1300 kg
per cubic metre.
As a gabion structure is built up,
backfilling against finished gabions
shall be carried out as necessary for
proper progressive construction, all
in accordance with the relevant
provisions of the appropriate
Sections of this Specification. Unless
otherwise specified, vertical joints
between gabions shall be staggered
in gabion structures in a pattern
similar to the joints in running bond
brickwork.

3.7
BRICKWORK
3.7.1
Description
This work shall include the laying of
brickwork to the lines, levels and
grades shown on the Drawings
and/or as directed by the S.O.
3.7.2
Materials
3.7.2.1 Common Bricks

Common bricks shall be sound,
hard, well burnt, of proper size
and clean and shall give a clear
ring when struck. They shall be
Class 3 standard format
complying with the requirements
of M.S. 76. Bricks shall be
obtained from manufacturers
Cement mortar for brickwork
requirements of Sub-Section
3.5.2.2.
3.7.3
3.7.3.1 Brick Laying

Brickwork shall be executed with
cement mortar and shall be of the
thickness and bonds as shown on
the Drawings. Bricks shall be
kept damp until used and shall be
laid on a full bed of mortar. The
brickwork shall be true to line
and plumb, and courses shall be
kept truly level. The thickness of
mortar joints shall not exceed 10
mm and shall be such that 4
courses of brickwork forms a
height of 300 mm.
Page 63
Newly laid brickwork shall be

protected from the harmful
effects of sunshine, rain, running
and surface water and shocks.
Any brickwork that is damaged
shall be taken down and rebuilt
and the joints raked out and
pointed as directed by the S.O.
Any such remedial work shall be
at the Contractor's own expense.

3.8
SUBSOIL DRAINS
3.8.1
Description
This work shall include the supply
and installation of subsoil drains
constructed in accordance with this
Specification at the locations and in
accordance with the lines, levels and
grades as shown on the Drawings
and/or as directed by the S.O.
3.7.3.2 Plastering Brickwork

3.8.2
All exposed brickwork surfaces
shall be plastered. The plaster
shall be applied in 2 coats
generally to a total thickness of
20 mm and shall be finished with
a steel trowel for internal surfaces
and with a wooden float for
external surfaces.
Plain plaster shall consist of 1
part masonry cement complying
with M.S. 794 to 3 parts of sand
by volume. where ordinary
portland cement is used,
plasticiser of a type approved by
the S.O. may be added to the mix
in accordance with the
manufacturer's instructions.
Ordinary Portland cement and
water shall comply with the
appropriate requirements of
Weep holes shall be provided as
Materials
3.8.2.1 Pipes
Porous concrete pipes for subsoil
drains shall comply with M.S.
525.
Clay pipes for subsoil drains shall
comply with B.S. 1196.
Polyvinyl Chloride (PVC) pipes
for subsoil drains shall comply
with Australian Standard
Specification 2439 or B.S. 3656.
3.8.2.2 Filter Material
Filter material used in the
construction of subsoil drains
shall consist of hard, clean sand
conforming to the grading limits
given in Table 3.4. The material
passing the 425 um sieve shall be
non-plastic when tested in
accordance with B.S. 1377.
TABLE 3.4 - GRADING LIMITS FOR
FILTER MATERIAL
B.S. Sieve
Size
10.0mm
5.0mm
2.36mm
1.18mm
600um
300um
150um
% Passing By
Weight
100
90 - 100
75 - 100
55 - 90
35 - 59
8 - 30
0 - 10
Page 64
3.8.2.3 Filter Cloth
(c) Filtration Requirement
The synthetic filter cloth shall be

a non-woven type of approved
manufacture having the following
properties :-
Equivalent opening size of the

filter cloth determined by sieving
as described in ASTM D422 shall
be less than the eighty-five
percentage size of the adjacent
soil.
(a) Chemical Composition

Requirements
(d) Permeability Requirement

Fibres used in the manufacture of
the engineering fabric shall
consist of a long chain synthetic
polymer, composed of at least
85% by weight of
polypropylene, -ethylene, esteramide or -vinylidene
chloride and shall contain
stabilisers and/or inhibitors added
to the base plastic (as necessary)
to make the fabric resistant to
deterioration from ultraviolet and
heat exposure.
The equivalent Darcy

Permeability of the filter cloth
shall be greater than 10 times
the Darcy Permeability of the
soil to be drained.
1:3 cement mortar for use in pipe
joints shall comply with SubSection 3.5.2.2.
3.8.3
(b) Physical Property

Requirements
The physical properties of the
filter cloth shall comply with
Table 3.5.
TABLE 3.5 - PHYSICAL PROPERTY
REQUIREMENTS FOR FILTER CLOTH
Grab Strength
(ASTM D1682)
0.9 kN
Puncture Strength
(ASTM D3787 - 80a)
0.4 kN
Burst Strength
(ASTM D3786 - 80a)
2100 kN/sq.m
Excavation for subsoil drains shall
be carried out all in accordance with
the appropriate provisions of SubSection 3.2.
Filter material as described in SubSection 3.8.2.2 above shall be placed
and uniformly compacted by a
suitable method approved by the
S.O. to form a firm, even bedding for
the pipe drain as shown on the
Drawings.
The pipe sections shall be set firmly
against the filter material bedding
with the flow lines in the design
position. For pipes with mating
joints, the receiving ends shall be
upgrade, and the pipe joints shall be
fully mated. For butt jointed pipes
with collars, the pipe sections shall
be fully contiguous, and the collars
properly centred over the joints.
Page 65
Joints shall be spot mortared as

necessary to hold the pipe sections
correctly centred and aligned, but not
so as to unduly restrict the infiltration
of water through the joints.
Slotted or perforated pipes shall be
tightly wrapped in filter cloth such
that the entire length of the mortared
pipe is covered by at least 2 layers of
cloth. All joints in both layers shall
have an overlap of at least 100 mm
and joints in the outer layer shall be
offset by at least 300 mm from joints
in the inner layer, all to the
After pipe laying and, if appropriate,
wrapping has been approved by the
S.O., the remainder of the filter
material shall be placed and
uniformly compacted by a suitable
method approved by the S.O. to
form a dense, even surround to the
pipe as shown on the Drawings. Care
shall be taken that the pipe is neither
damaged nor displaced.
Backfill shall then be placed and
compacted in accordance with the
appropriate provisions of SubSection 3.2.4.
3.9
R.C. PIPE CULVERTS
3.9.1
Description
This work shall comprise the supply
and installation of reinforced
concrete pipe culverts, inclusive of
excavation, backfilling, jointing,
bedding, construction of headwalls,
wingwalls, aprons and sumps and
channel protection works, all in
accordance with this Specification
and the details shown on the
Drawings.

3.9.2
Materials
3.9.2.1 Pipes
Reinforced concrete pipes shall
M.S. 881 and shall be supplied
by manufacturers approved by
the S.O.
Rebated pipes of diameter 600
mm and above shall be internally
rebated.
Collars shall be precast with
grade 25 concrete and shall be
suitably reinforced all
in accordance with Section 9 of
this Specification. The width of
the collar shall be not less than
150 mm and the minimum
thickness shall be 50 mm.
Rubber rings for spigot and
socket pipes shall comply with
the requirements of Type 2 as
1:3 cement mortar for jointing of
reinforced concrete pipes shall
Sub-Section 3.5.2.2.
Type A bedding shall consist of
grade 20/20 concrete complying
with Section 9 of this
Specification.
Type B bedding shall consist of
clean, natural sand or gravelly
sand of suitable gradation and
quality, approved by the S.O.
The material shall have a
maximum particle size of not
more than 12 mm.
Page 66
3.9.3
Excavation and Backfilling for R.C.

Pipe Culverts
3.9.3.1 Excavation
(a) General
Unless otherwise directed by
the S.O., prior to construction
of a pipe culvert, the earth
works at the required location
shall have been constructed
to a level at least 600 mm
above the top of culvert
design levels or to the top of
subgrade levels, whichever is
lower.
Pipe culverts specified to be
constructed in trench
conditions shall be excavated
in accordance with SubSection 3.9.3.1 (b) below.
Where drainage conditions or
other circumstances so
require, the S.O. may direct
the Contractor to construct the
pipe culvert without first
constructing the earthworks to
the level specified above, in
which case excavation and
foundation preparation shall
be in accordance with SubSection 3.9.3.1 (c) below.
(b) Trench Method
The trench to receive a culvert
pipe shall be of sufficient
width and depth to enable the
placing of bedding material
and construction of pipe joints
in accordance with this
Specification, and the bottom
of the trench shall be trimmed
to a suitably smooth plane
surface which shall be kept
free from water, all to the

Where rock or other hard
unyielding foundation
material is encountered in the
trench, it shall be excavated to
a depth below the bottom of
pipe design levels of at least
300 mm or 12.5 mm per 300
mm of fill to be placed over
the top of the pipe, whichever
is greater, up to a maximum
of 75% of the internal
diameter of the pipe. The
hard material so excavated
shall be replaced with suitable
material uniformly compacted
in layers of not more than 150
mm compacted thickness to
provide satisfactory support
for the pipe, all to the
(c) Open Ground Method
Where existing ground levels
are above top of bedding
material design levels and
firm foundation materials are
encountered, excavation and
be similar to that described
in the trench method above.
Otherwise a firm foundation
plane shall be prepared, which
shall be essentially free
draining along the line of the
culvert, by trimming the
existing ground, or such fill as
it is necessary to place and
compact, over a width
sufficient to permit
satisfactory construction of
the pipe bedding, all to the
satisfaction of the S.O. Hard
materials shall be excavated
from the pipe foundation over
a width equal to the outside
diameter of the pipe to the
same depth as specified in the
trench method, and shall be
replaced with suitable
Page 67
material uniformly compacted

in layers of not more than 150
mm compacted thickness to
Where soft or unstable soil is
encountered in the foundation,
it shall be excavated over a
width of at least 1.5 times the
outside diameter of the pipe
on each side of the culvert
centre-line to the depth
directed by the S.O., and
replaced with suitable
material uniformly
compacted in layers of not
more than 150 mm
compacted thickness to
3.9.3.2 Backfilling
Backfilling against reinforced
concrete pipe culverts and their
appurtenant structures shall be
carried out in accordance with the
construction methods described
in Sub-Section 3.2.4, using
material conforming to the
3.2.2.5. Special care shall be
taken to properly compact
backfill against the undersides of
culvert pipes without disturbing
or damaging the pipes and joints.
Backfill shall be built up evenly
on both sides of each pipe culvert
along its entire length.
Heavy plant and equipment shall

not operate within 1.5 m of any
pipe culvert until backfilling and,
where appropriate, pavement
construction has advanced to a
stage which provides at least 600
mm of cover to the culvert.
Subject to the approval of the
S.O., light compaction equipment
may be operated above pipe
culverts after a minimum of 300
mm of cover has been placed and
compacted.
3.9.4
Installation of R.C. Pipe Culverts
3.9.4.1 General
The type, size and class of pipe to
be installed at each location shall
be as shown on the Drawings or
as directed by the S.O. Culverts
shall not be installed at any
location until the type of pipe, the
exact location, the lines, levels
and grades, the length of pipe and
details of inlet and outlet
structures have been confirmed
by the S.O. In addition, special
requirements recommended by
the manufacturer with respect to
assembly and installation shall be
complied with.
Especially where elliptically
reinforced pipe sections are used,
care shall be taken to ensure that
the loading axes are positioned
exactly vertically.
3.9.4.2 Butt Ended Pipe Culverts with
Precast Concrete Collars
The pipes shall be laid on Type A
bedding in conformity with the
dimensions shown on the
Drawings. Before placing any
concrete bedding, the pipes shall
be assembled complete with
precast concrete collars to the
Page 68
correct levels and grades on precast

concrete spacing blocks of the same
class of concrete as the bedding
material and of sufficient size to
eliminate any risk of settlement of
the pipes before or during
concreting.
All joints shall be fully mortared
with 1:3 cement mortar before
concreting of the cradle, all to the
satisfaction of the S.O. The concrete
cradle shall be cast as one monolithic
unit. Alternatively, part of the
concrete cradle below the underside
of the pipe may be constructed
monolithically at least 24 hours
before the assembly and mortaring
up of the pipe sections and collars,
on condition that shear connectors
are provided across horizontal
construction joints to the satisfaction
of the S.O.
During installation, the ends of the
pipes shall be butted and the collar
centred about the joint using wedges
or other approved means. The
annular shall be completely filled
with 1:3 cement mortar with only
sufficient water added to ensure
adequate workability and the wedges
removed before finally fairing the
joint. Special care shall be taken to
ensure that excess cement mortar is
neatly cleaned off. For pipes over
900 mm in diameter the jointing
space shall be filled from inside the
pipe after completion of
embankment construction using 1:3
cement mortar. When installed, the
clearance between the outer
diameter of pipe and the inner
diameter of collar shall be at least
20 mm.

Following pipe assembly and
mortaring up as above, the
remainder of the cradle shall be
cast monolithically, all to the
Where vertical construction joints
in the concrete cradle are
unavoidable due to circumstances
on Site, transfer bars shall be
provided to the satisfaction of the
S.O.
Special care shall be taken when
placing the concrete cradle to
avoid the entrapment of air
underneath the pipe. To
eliminate this possibility,
concrete shall be placed to one
side of the pipe only until such
time as the level of the concrete
surface rises above the underside
of the pipe on the side remote
from that on which concrete is
being placed. The concrete shall
then be brought up at the same
level on both sides of the pipe.
3.9.4.3 Rebated Pipe Culverts
The pipes shall be laid on Type A
bedding in conformity with the
Drawings.
The method of construction shall
follow that described in SubSection 3.9.4.2 for butt ended
pipe culverts except for the
exclusion of precast concrete
collars.
The rebated joint shall be
internally flush and fully
mortared with 1:3 cement mortar,
Page 69
3.9.4.4 Spigot and Socket Pipe Culverts

The pipes shall be laid on Type
B bedding in conformity with the
Drawings. The bedding material
shall be accurately shaped by a
template to fit the lower part of
the pipe exterior for a height of at
least 10% of the outside diameter
of the pipe. Gaps shall be left in
the bedding material and recesses
dug in the earth foundation of
sufficient width and depth to
accomodate the socket without it
resting on the bottom of the
recess. The widths of the
recesses in the foundation and the
bedding shall both exceed the
width of the socket by more than
50 mm.
Jointing of the pipes shall be
carried out strictly in accordance
with the manufacturer's recom
mendations, all to the satisfaction
of the S.O.
Concrete pipes as specified above
shall be laid true to line and level,
each pipe being separately boned
between sight rails. Pipes shall
be laid in an upstream direction
with the sockets towards the inlet
and shall rest on even
foundations for the full length of
the barrel. Rubber ring joints
shall be installed strictly in
accordance with the
manufacturer's instructions. Prior
to jointing, rubber rings and
jointing surfaces shall be cleaned
of all contaminants except for
specified lubricants. The spigot
of each pipe shall be inserted
concentrically in the socket of the
one previously laid, and the pipe
then adjusted and fixed in its
correct position with the spigot
correctly entered in the socket.

Care shall be taken to see that the
rubber ring is adequately
compressed to seal the joint. All
pipes shall be laid to the
3.10 CORRUGATED METAL PIPE
CULVERTS
3.10.1 Description
and installation of bolted, corrugated
metal pipe culverts inclusive of
excavation, backfilling, jointing,
bedding, construction of headwalls,
Drawings.
3.10.2 Materials
3.10.2.1 Pipes
The pipe sections shall be
fabricated from zinc-coated
(galvanised) steel sheets
conforming to AASHTO M218
or from structural plates
conforming to AASHTO M167
depending on the pipe size
requirements.
The dimensions of the pipes shall
conform to AASHTO M36. All
pipes shall be clearly identified
by marking on each section the
following information :i) name of manufacturer;
ii) diameter of pipe;
iii) gauge number;
iv) date of manufacture.
The above markings shall have
been marked by the
manufacturer.
Page 70

the S.O. the material test
certificates from the manufacturer
showing the chemical
composition and mechanical
properties of the base metal and
the amount of zinc coating for
every lot of pipes supplied. The
S.O. may order further tests in the
sections supplied to Site at the
rate of not more than 1 in 100.
All costs on such tests shall be
borne by the Contractor.
3.10.2.2 Bitumen Coating
Where specified, the pipe
sections or plates shall be coated
with an approved bitumen
coating at the factory by the hotdip process for Type A as
specified in AASHTO M190.
Before coating, any damage to
the galvanising shall be made
good in a manner approved by
the S.O.
3.10.2.3 Bolts and Nuts
All bolts and nuts shall be of high
strength carbonated steel meeting
the provisions of ASTM A449
and ASTM A563 Grade `C'
respectively. The galvanising on
bolts and nuts must meet the
requirements of ASTM A153.

For pipe material conforming to
AASHTO M218 (corrugation 68
mm pitch x 13 mm depth) with
diameters of 1500 mm or smaller,
12 mm diameter bolts shall be
used. Bolt holes along
circumferential seams shall have
spacings of not more than 314
mm.
For pipe material conforming to
AASHTO M167 (corrugation
150 mm pitch x 50 mm depth)
with diameters of 1500 mm or
larger, 19 mm diameter bolts
shall be used. Four bolt holes per
300 mm of longitudinal seam
shall be provided and these shall
be staggered in rows 51 mm a
apart with holes in one row in the
trough and holes in the other row
in the crest of the corrugation.
Bolt holes in the circumferential
seams shall have spacings of not
more than 254 mm.
Notwithstanding the above, the
Contractor shall satisfy the S.O.
as to the adequacy of all bolted
connections.
1:3 cement mortar shall comply
with the requirements of SubSection 3.5.2.2.
Diameters of bolt holes in the

longitudinal seams, except those
at the plate corners, shall not
exceed the bolt diameter by more
than 3 mm. The bolt holes in the
circumferential seams, including
those at the plate corners, shall
not exceed the bolt diameter by
more than 6 mm. The minimum
distance from the centre of a hole
to the edge of a plate shall be
1.75 times the diameter of the
bolt.
Corrugated metal pipe culverts

shall be bedded on Type B
bedding as specified in SubSection 3.9.2.3.
Page 71
3.10.3
Excavation and Backfilling for

Corrugated Metal Pipe Culverts
Unless otherwise directed and/or
approved by the S.O., the pipe
culvert shall be laid in a trench
excavated in accordance with
Sub-Section 3.9.3.1 (b).

placed along the entire length
of the culvert. The lining
shall be constructed after
completion of earthworks and
wingwalls.
3.11 PRECAST BOX CULVERTS
3.11.1 Description
Where the open ground method

is approved, the work shall
comply with Sub-Section
3.9.3.1 (c).
3.10.4
Installation of Corrugated Metal

Pipe Culverts
3.10.4.1 General
The culvert sections shall be
assembled, strutted, and
protected during construction
Special attention shall be
given to the sequence of
tightening bolts and the
specified torque to be applied
during assembly. After
assembly the bitumen coating
shall, where damaged, be
repaired and made good with
further application of the
bitumen coating.
3.10.4.2 Mortar Lining

For corrugated metal pipe
culverts of 1800 mm diameter
or more, or where directed by
the S.O. for pipes of smaller
diameters, a 1:3 cement
mortar lining shall cover the
inverts of the pipes to a
thickness of 25 mm above the
crest of the corrugations over
a minimum of one third of the
circumference centrally

and installation of precast box
culverts inclusive of excavation,
backfilling, jointing, bedding,
construction of headwalls,
Drawings.
3.11.2 Materials
3.11.2.1 Precast Box Culverts
Precast box culverts shall be of
approved manufacture complying
with Australian Standard
Specification 1597 Part 1, or any
equivalent alternative standard
acceptable and approved by the
S.O.
1:3 cement mortar for jointing of
precast box culvert sections shall
Precast box culverts shall be
bedded on Type B bedding as
specified in Sub-Section 3.9.2.3.
Page 72
3.11.3
Excavation and Backfilling
Backfill shall be built up

evenly on both sides of each
box culvert along its entire
length.
3.11.3.1 Excavation for Precast Box

Culverts
Unless otherwise directed by
the S.O., prior to construction
of a precast box culvert, the
earthworks at the required
location shall have been
first constructed to a level at
least 600 mm above the top
of the culvert design levels or
to the top of subgrade levels,
whichever is lower, and the
precast box culvert shall then
be constructed in a trench
excavated in accordance with
Sub-Section 3.9.3.1 (b).
Where drainage conditions or
other circumstances so
require, the S.O. may direct
the Contractor to construct
the precast box culvert
without first constructing the
earthworks to the level
specified above, in which
case excavation and
be in accordance with SubSection 3.9.3.1 (c).
3.11.3.2 Backfilling
Backfilling against precast
box culverts and their
appurtenant structures shall
be carried out in accordance
with the construction
methods described in SubSection 3.2.4, using material
conforming to the
3.2.2.5. Special care shall be
taken to properly compact
backfill without disturbing or
damaging the precast box
culvert sections.
Unless otherwise approved by

the S.O., heavy plant and
equipment shall not operate
within 2.0 m of any precast
box culvert until backfilling
and, where appropriate,
pavement construction has
advanced to a stage which
provides at least 300 mm of
cover to the culvert.
3.11.4
Installation of Precast Box

Culverts
The type and size of precast box
culvert to be installed at each
location shall be as shown on the
S.O. Precast box culverts shall
not be installed at any location
until the exact location, the lines,
levels and grades, the length of
culvert and details of inlet and
outlet structures have been con
firmed by the S.O. In addition,
special requirements
recommended by the
manufacturer shall be complied
with.
Precast box culverts shall be
laid on Type B bedding as
specified in Sub-Section 3.9.4 in
conformity with the dimensions
shown on the Drawings. Where
specified on the Drawings or
directed by the S.O., Type B
bedding shall be laid on a layer of
crushed aggregate of maximum
particle size not exceeding 50
mm.
Page 73
All joints shall be fully mortared

with 1:3 cement mortar, all to the
satisfaction of the S.O. In
addition, a 3 mm layer of 1:3
cement mortar shall be spread on
top of the legs of the invert in
order to ensure uniform bearing
between the invert and lid.
Lifting holes shall be filled with
1:3 cement mortar.
3.12 EXTENSION OF CULVERTS
3.12.1 Extension of Pipe Culverts

The existing wingwalls, aprons and
concrete bedding shall be
demolished wherever indicated on
the Drawings to expose the existing
pipe culvert on the side(s) to be
extended. The end of the existing
pipe culvert to be extended shall then
be wire-brushed or some other
means employed to give a clean pipe
end.

3.12.2
Extension of Box Culverts

The existing wingwalls, aprons
and concrete bedding shall be
demolished wherever indicated
on the Drawings to expose the
existing box culvert on the side(s)
to be extended. The end of the
existing box culvert to be
extended shall then be wirebrushed or some other means
employed to give a clean sur
face.Extension joints shall be
formed as shown on the
Drawings by injecting Thioflex
600 - Gun Grade (manufactured
by Expandite) or its equivalent to
a thickness of not less than 25
mm in the 15 mm wide gap
between the existing box culvert
and the new box culvert section.
The remaining space in the gap
shall then be filled with Flexcell
Expansion Filler.
Bakau piles shall be installed as
shown on the Drawings, unless
Extension joints shall be formed as

shown on the Drawings by injecting
Thioflex 600 - Gun Grade
(manufactured by Expandite) or its
equivalent to a thickness of not less
than 25 mm in the 15 mm wide gap
between the existing pipe and the
new pipe. The remaining space in
the gap shall then be filled with
Flexcell Expansion Filler.
Bakau piles shall be installed as
shown on the Drawings, unless
Page 74
SECTION 4
FLEXIBLE PAVEMENT
Page 75
SECTION 4 - FLEXIBLE PAVEMENT

Page
4.1
UNBOUND PAVEMENT COURSES
S4-78
4.1.1
Lower Subbase
4.1.1.1 Description
4.1.1.2 Materials
4.1.1.3 Construction Methods
S4-78
S4-78
S4-78
S4-78
4.1.2
Subbase
4.1.2.1 Description
4.1.2.2 Materials
S4-79
S4-79
S4-79
S4-80
4.1.3
Gravel Surfacing
4.1.3.2 Materials
S4-81
S4-81
S4-82
4.1.4
Crushed Aggregate Roadbase
4.1.4.1 Description
4.1.4.2 Materials
S4-83
S4-83
S4-83
S4-84
4.2
BITUMINOUS PAVEMENT COURSES
S4-85
4.2.1
4.2.1.1
4.2.1.2
4.2.1.3
4.2.1.4
Bitumen Prime Coat

Description
Materials
Equipment
S4-85
S4-85
S4-85
S4-85
S4-87
4.2.2
4.2.2.1
4.2.2.2
4.2.2.3
4.2.2.4
Bituminous Tack Coat

Description
Materials
Equipment
S4-88
S4-88
S4-88
S4-88
S4-89
4.2.3
4.2.3.1
4.2.3.2
4.2.3.3
4.2.3.4
Bituminous Surface Dressing

Description
Materials
Equipment
S4-90
S4-90
S4-90
S4-91
S4-93
Page 76

Page
4.2.4
4.2.4.1
4.2.4.2
4.2.4.3
4.2.4.4
4.2.4.5
Asphaltic Concrete
Description
Materials
Asphaltic Concrete Mix Design
Equipment
S4-99
S4-99
S4-99
S4-102
S4-105
S4-110
4.2.5
4.2.5.1
4.2.5.2
4.2.5.3
4.2.5.4
Bituminous Macadam
Description
Materials
Equipment
S4-116
S4-116
S4-116
S4-116
S4-116
4.3
SHOULDERS
4.3.1
S4-119
Description
S4-119
4.3.2
Materials
4.3.2.1 Earth Shoulders
4.3.2.2 Gravel Shoulders
S4-119
S4-119
S4-119
4.3.3
S4-119
4.4
HORIZONTAL ALIGNMENT, SURFACE LEVELS AND

SURFACE REGULARITY OF PAVEMENT COURSES
S4-120
4.4.1
Horizontal Alignment
S4-120
4.4.2
Surface Levels of Pavement Courses
S4-120
4.4.3
Surface Regularity
S4-121
Page 77
SECTION 4 FLEXIBLE PAVEMENT

4.1
UNBOUND PAVEMENT
COURSES
4.1.1
Lower Subbase
4.1.1.1 Description
This work shall consist of
furnishing, placing, compacting
and shaping lower subbase
material on a prepared and
accepted subgrade in accordance
with this Specification and the
lines, levels, grades, dimensions
and cross-sections shown on the
Drawings and/or as required by
the S.O.

accordance with the provisions of
Sub-Section 2.2.7.
approval of finished subgrade,
any damage to or deterioration of
the subgrade shall be made good
to the satisfaction of the S.O.
before lower subbase is
constructed.
Lower subbase shall be placed
over the full width of the
formation to the required
thickness as shown on the
Drawings or directed by the S.O.
in one layer or more, each layer
not exceeding 200 mm
compacted thickness. Where two
or more layers are required they
shall be of approximately equal
thickness and none shall be less
than 100 mm compacted
thickness.
4.1.1.2 Materials
Lower subbase material shall be
inorganic soil, sand, gravel,
weathered or fragmented rock, or
a mixture of any of these
materials, essentially free from
vegetative and other organic
matter and expansive clay
minerals. It shall have a
maximum particle size of 75 mm
or less, and shall have a CBR
value not less than that shown on
the Drawings when compacted to
95% of the maximum dry density
determined in the B.S. 1377
method) and soaked for 4 days
under a surcharge of 4.5 kg.
Each layer of lower subbase shall

be processed as necessary to
bring its moisture content to a
uniform level throughout the
material suitable for compaction,
and shall then be compacted
using suitable compaction
equipment approved by the S.O.
to not less than 95% of the
Compaction shall be carried out
in a longitudinal direction along
the roadbed, and shall generally
begin at the outer edge and
progress uniformly towards the
crown on each side in such a
manner that each section receives
equal compactive effort, all to the
Prior to placing any lower

subbase material, the underlying
subgrade (particularly the top 300
mm of the subgrade) shall have
been shaped and compacted in
Page 78
The lower subbase shall be

finished in a neat and workman
like manner, and shall have an
average thickness over any 100
metre length not less than the
required thickness. The top
surface of the lower subbase shall
superelevation, levels and grades,
and shall be everywhere within
the tolerances specified in SubSection 4.4.
4.1.2 Subbase
4.1.2.1 Description
and shaping subbase material on
a prepared and accepted subgrade
or lower subbase in accordance
the S.O.
4.1.2.2 Materials

i) the liquid limit shall be not
more than 25%;
ii) the plasticity index shall be
not more than 6;
iii) the aggregate crushing value
when tested in accordance
with M.S. 30 shall be not
more than 35;
iv) unless otherwise specified on
the Drawings or directed by
the S.O., the material shall
have a CBR value of 30 or
more when compacted to
95% of the maximum dry
density determined in the B.S.
1377 Compaction Test (4.5 kg
rammer method) and soaked
for 4 days under a surcharge
of 4.5 kg;
v) the gradation shall conform
to one of the envelopes
shown in Table 4.1 with the
fraction passing the B.S. 75
um sieve not greater than 2/3
of the fraction passing the
B.S. 425 um sieve.
Subbase material shall be a

natural or prepared aggregate
comprising crushed rock,
weathered or fragmented rock,
gravel or crushed gravel, sand, or
a mixture of any of these
materials. It shall have a small
proportion of plastic or
non-plastic fines and shall be
and other organic matter,
expansive clay minerals and
lumps of clay. The material
shall conform to the following
physical and mechanical quality
requirements :-
Page 79
TABLE 4.1 - GRADATION LIMITS FOR SUBBASE MATERIAL
B.S.
Sieve
Size
50.0 mm
25.0 mm
9.5 mm
4.75 mm
2.00 mm
425 um
75 um
% Passing By Weight
A
100
30-65
25-55
15-40
8-20
2-8
B
100
79-95
40-75
30-60
20-45
15-30
5-20
C
100
50-85
35-65
25-50
15-30
5-20

Prior to placing any subbase
material, the underlying subgrade
(particularly the top 300 mm of the
subgrade) or lower subbase shall
have been shaped and compacted in
Sub-Section 2.2.7 or Sub-Section
4.1.1.3 as appropriate.
approval of finished subgrade or
lower subbase, any damage to or
deterioration of the subgrade or
lower subbase shall be made good
to the satisfaction of the S.O. before
subbase is constructed.
Subbase shall be placed with
over the full width of the formation
to the required thickness as shown
on the Drawings or directed by the
S.O. in one layer or more, each
layer not exceeding 200 mm
than 100 mm compacted thickness.
Each layer of subbase shall be
level throughout the material
D
100
60-100
50-85
40-70
25-45
5-20
E
100
55-100
40-100
20-50
6-20
F
100
70-100
55-100
30-70
8-25
suitable for compaction, and shall

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

neat and workmanlike manner;
its width shall be everywhere at
least that specified or shown on
the Drawings on both sides of the
centre-line; and its average
thickness over any 100 metre
length shall be not less than the
surface of the subbase shall have
the required shape,
and shall be everywhere within
the tolerances specified in SubSection 4.4.
4.1.3
4.1.3.2 Materials
Gravel surfacing material shall be
a natural or prepared soilaggregate mixture comprising
gravel and sand size particles
together with a small proportion
of plastic fines, and shall be
and other organic matter,
expansive clay minerals and
lumps of clay. The material shall
conform to the following physical
and mechanical quality
requirements :-
Gravel Surfacing
i) the liquid limit shall be not

more than 35%;
4.1.3.1 Description
ii) the plasticity index shall be in
the range 4 to 10;

and shaping gravel surfacing
material on a prepared and
accepted subgrade or lower
subbase in accordance with this
Specification and the lines, levels,
grades, dimensions and
cross-sections shown on the
the S.O.
iii) the aggregate crushing value

more than 35;
iv) the gradation shall conform
to one of the envelopes
shown in Table 4.2 with the
fraction passing the B.S. 75
um sieve not greater than 2/3
of the fraction passing the
B.S. 425 um sieve.
TABLE 4.2 - GRADATION LIMITS FOR GRAVEL SURFACING
% Passing By Weight
B.S. Sieve
Size
37.5 mm
12.5 mm
4.75 mm
2.00 mm
425 um
75 um
100
45 - 75
30 - 60
20 - 45
15 - 30
8 - 20
100
55 - 85
35 - 65
25 - 50
15 - 30
8 - 20
100
60 - 100
50 - 85
40 - 70
25 - 45
8 - 20
D
100
55 - 90
40 - 70
20 - 50
8 - 25
Page 81
Material with a maximum

particle size of 37.5 mm, while
otherwise not conforming to the
gradation specification but
satisfying the other requirements,
shall be acceptable provided that
it shall have a CBR value of 30
or more when compacted to 95%
method) and soaked for 4 days
under a surcharge of 4.5 kg.
Prior to placing any gravel
surfacing material, the underlying
subgrade (particularly the top 300
mm of the subgrade) or lower
subbase shall have been shaped
and compacted in accordance
with the provisions of SubSection 2.2.7 or Sub-Section
4.1.1.3 as appropriate.
approval of finished subgrade or
lower subbase, any damage to or
lower subbase shall be made
good to the satisfaction of the
S.O. before gravel surfacing is
constructed.
Gravel surfacing shall be placed
to the required width and
thickness as shown on the
thickness.
Each layer of gravel surfacing
shall be processed as necessary to
bring its moisture content to a

uniform level throughout the
material suitable for compaction,
and shall then be compacted
using suitable compaction
to not less than 95% of the
the carriageway, and shall
generally begin at the outer edge
and progress uniformly towards
the centre on each side, except on
S.O.
and compaction of gravel
surfacing material, care shall be
taken to maintain a uniform
gradation of the material and
prevent its separation into coarse
and fine parts, all to the
The gravel surfacing shall be
finished in a neat and
workmanlike manner; its width
shall be everywhere at least that
specified or shown on the
Drawings on both sides of the
required thickness and its
minimum thickness at any point
shall be not less than the required
thickness minus 20 mm.
Page 82
The top surface of the gravel

surfacing shall have the required
shape, superelevation, levels and
grades, and shall be everywhere
within 10 mm of the required
plane or such higher,
approximately parallel plane, as
the S.O. shall approve.
4.1.4
iv) not less than 80% of particles

retained on the B.S. 4.75 mm
sieve shall have at least one
fractured face;
v) the weighted average loss of
weight in the sodium sulphate
soundness test (5 cycles)
with AASHTO Test Method
T 104 shall be not more than
12%;
Crushed Aggregate Roadbase
4.1.4.1 Description
and shaping crushed aggregate
roadbase material on a prepared
and accepted subgrade or lower
subbase or subbase in accordance
the S.O.
vi) the material shall have a CBR

value of not less than 80 when
compacted to 95% of the
maximum dry density
Compaction Test (4.5 kg
rammer method) and soaked
for 4 days under a surcharge
of 4.5 kg;
vii)the gradation shall comply
with the envelope shown in
Table 4.3 for the type
specified.
4.1.4.2 Materials
Crushed aggregate roadbase
material shall be crushed rock, or
crushed gravel, or a mixture of
crushed and natural aggregates,
which is hard, durable, clean and
essentially free from clay and
other deleterious materials.
The material shall conform to the
mechanical quality requirements:i) the plasticity index shall be not
more than 6;
ii) the aggregate crushing value
when tested in accordance with
M.S. 30 shall be not more than
30;
iii) the flakiness index when tested in
accordance with M.S. 30 shall be
not more than 30;
TABLE 4.3 - GRADATION LIMITS FOR

CRUSHED AGGREGATE ROADBASE
B.S. Sieve
Size
50.0 mm
37.5 mm
28.0 mm
20.0 mm
10.0 mm
5.0 mm
2.36 mm
2.00 mm
600 um
425 um
75 um
% Passing By Weight
Type I
Type II
100
95 - 100
60 - 80
40 - 60
25 - 40
15 - 30
8 22
08
100
85 - 100
70 - 100
60 - 90
40 - 65
30 - 55
20 - 40
10 - 25
2 - 10
Page 83

Prior to placing any crushed
aggregate roadbase material, the
underlying subgrade or lower
subbase or subbase shall have
the appropriate Section of this
Specification. Notwithstanding
any earlier approval of finished
subgrade or lower subbase or
subbase, any damage to or
lower subbase or subbase shall be
made good to the satisfaction of
the S.O. before crushed aggregate
roadbase is constructed.
Crushed aggregate roadbase shall
be placed to the required width
and thickness as shown on the
thickness. Spreading shall be
done by a mechanical spreader
approved by the S.O. or, if
approved by the S.O., by motor
grader.
Prior to spreading, crushed
aggregate roadbase shall be
level throughout the material
suitable for compaction. Spread
material shall be maintained at
the correct moisture content for
proper compaction by sprinkling
with water or drying as may be
necessary, and shall be
compacted using suitable
compaction equipment approved
by the S.O. to not less than 95%

method).
the carriageway, and shall
generally begin at the outer edge
and progress uniformly towards
the centre on each side, except on
S.O.
and compaction of crushed
aggregate roadbase material, care
shall be taken to maintain a uni
form gradation of the material
and prevent its separation into
coarse and fine parts, all to the
The crushed aggregate roadbase
shall be finished in a neat and
workmanlike manner; its width
specified or shown on the
surface of the crushed aggregate
roadbase shall have the required
within the tolerances specified in
Sub-Section 4.4.2.
Page 84
4.2
BITUMINOUS PAVEMENT
COURSES
4.2.1
Bitumen Prime Coat
4.2.1.1 Description
careful and thorough cleaning of
the surface of a prepared and
accepted crushed aggregate
roadbase, and the furnishing and
application to the cleaned
roadbase surface of a bituminous
priming material, all in
accordance with this
Specification and the lines,
dimensions and cross-sections
shown on the Drawings and/or as
4.2.1.2 Materials
The bituminous priming material
shall be either cut-back bitumen
or bitumen emulsion as stated in
the Bill of Quantities.
Cut-back bitumen shall be grade
RC-70 or MC-70 conforming to
the requirements of M.S. 159.
Bitumen emulsion shall be slow
setting, grade SS-1 or SS-1K,
conforming to the requirements
of M.S. 161, as appropriate to the
type of roadbase material to be
primed and approved by the S.O.
4.2.1.3 Equipment
The equipment used by the
Contractor shall include a power
broom, a compressed air blower,
a self-propelled pressure
distributor for bituminous
material, and as necessary,
equipment for storing and heating
bituminous material.

(a) Power Broom
The power broom shall be a
rotary type specifically
designed for sweeping road
surfaces, and shall be
(b) Compressed Air Blower
The compressed air blower
shall comprise a portable air
compressor of 3 cu.m/min. in
capacity at 0.7 N/sq.mm
delivery pressure with a
suitable hose and nozzle for
blowing clean a road surface
after power brooming, and
shall be approved by the S.O.
(c) Pressure Distributor for
Bituminous Material
The distributor shall be a
purpose built model of
recognised manufacture and
It shall conform to the
requirements described
hereunder.
The distributor shall have a
suitable capacity and shall be
equipped with a gas or oil
fired heating system capable
of heating a full charge of
bituminous material to
l80C. The heating system
shall be such that overheating
of the bituminous material
will not occur and shall be of
a type in which flames from
the burner do not come into
direct contact with the casing
of the tank containing the
bituminous material. The
tank shall be insulated in such
a manner that when filled
with bituminous material at
l80C and not heated,
Page 85
the drop in temperature shall be

less than 3C per hour. A
thermometer shall be provided to
measure continuously the
temperature of the bituminous
material in the tank and shall be
so arranged that the highest
temperature in the tank is
measured. The tank shall be
fitted with an accurately
calibrated dipstick or contents
gauge, and the pipe for filling the
tank shall be fitted with an easily
replaceable filter.
The distributor shall run on
pneumatic tyred wheels of such
width and number that the load
produced on the road surface
when the vehicle is fully charged
shall not exceed l2 kg/mm of tyre
width. The vehicle shall be
equipped with a `fifth wheel'
tacheometer system to accurately
measure its forward speed during
spraying operations.
The distributor shall be equipped
with a full circulation type spray
bar with nozzles from which the
bituminous material is sprayed on
to the road surface uniformly
over the full spraying width. The
spraying width shall be variable
in increments of not more than
100 mm up to a maximum of 5.0
metres. The spraying pump shall
be driven by a separate power
unit and shall be equipped with
an accurate pressure gauge and
an accurate flow rate gauge or
meter. On the suction side the
pump shall be fitted with an
easily replaceable filter. The
spray bar and pump shall be so
designed that bituminous material
at even temperature and uniform
pressure may be sprayed uni
formly over the spraying width at
controlled rates in the range

0.25 to 8.0 litres/sq.m at normal
distributor operating speeds, such
that deviation from the prescribed
rate of application shall not
exceed 10%.
The distributor shall be equipped
with a hand spraying system.
The meters for the `fifth wheel'
tachometer system and the
bituminous material pumping
flow rate, pumping pressure and
temperature shall be located in
such a manner that the vehicle
driver can easily read them while
operating the distributor. The
spray bar shall be controlled by a
second operator riding at the rear
of the vehicle in such a position
that all the discharge sprays are in
his good view.
All measuring equipment on the
distributor shall have been
recently calibrated, and accurate
and satisfactory records of the
calibrations shall be submitted to
the S.O. If in the course of the
work the rates of application of
bituminous material are found to
be inaccurate, the distributor shall
be withdrawn from the Works
and recalibrated to the
being returned to service.
The S.O. may require such
performance tests as he considers
necessary to check that the
distributor is operating
satisfactorily. As directed by the
S.O., the Contractor shall make
the distributor and its equipment
available for such tests and shall
supply all necessary assistance,
materials, tools, testing apparatus,
etc., all at the Contractor's own
expense.
Page 86
(d) Storage and Heating Facilities

for Bituminous Material
Tanks for storage of
bituminous material shall
have a capacity suited to the
proposed rate of utilisation of
the material and the method
and frequency of its delivery
to the Works, all to the satis
faction of the S.O. The tanks
and, where necessary, barrel
decanters shall be equipped
with heating systems which
provide for effective and
positive control of the
temperature of the bituminous
material at all times up to the
temperature required for
utilisation. The method of
heating shall be such that
neither flames nor the
products of combustion shall
come into direct contact with
the bituminous material or the
casing of its immediate
container, and such that no
portion of the bituminous
material shall be subject to
overheating.
(a) General Conditions
Bitumen prime coat work
shall only be carried out in
dry, warm weather when the
surface to be treated is
essentially dry.
(b) Surface Preparation and
Cleaning
Prior to applying the prime
coat, the crushed aggregate
roadbase shall have been
shaped and compacted in
accordance with the
provisions of Sub-Section
4.1.4.3.

approval of finished crushed
aggregate roadbase, any
damage to or deterioration of
the roadbase shall be made
good to the satisfaction of the
S.O. before prime coat is
applied.
Immediately prior to applying
the bituminous material, the
full width of the surface to be
treated shall be swept using a
power broom followed by a
compressed air blower and, if
necessary, scraped using hand
tools to remove all dirt, dust
and other objectionable
material, all to the satisfaction
of the S.O.
(c) Application of Bituminous
Material
The bituminous priming
material shall be sprayed on
to the cleaned roadbase
surface by means of a
pressure distributor. Any
areas inaccessible to the
distributor spray bar shall be
treated using the distributor's
hand spraying system. The
rate or rates of application
shall be as directed by the
S.O. based on the results of
test applications, but shall
usually be in the range 0.5 to
1.0 litre/sq.m. The
temperature of cut-back
bitumen shall be maintained
in the range 50C to 70C
during spraying operations.
For bitumen emulsions, the
spraying temperature shall be
in the range 25C to 45C.
Page 87
If necessary, in order to
prevent the bituminous
material from flowing on the
sprayed surface, the pre
scribed prime coat shall be
applied in two separate
spraying operations. Where
the condition of the treated
surface indicates that it is
necessary, bituminous
material additional to that
prescribed shall be applied as
the S.O. shall direct.
Prime coat shall be distributed
uniformly over the surface to
be treated without streaking;
the quantities applied shall not
deviate by more than 10%
from those prescribed. Areas
with insufficient bituminous
material shall be resprayed as
necessary to make up the
deficiency, all to the
The surfaces of structures,
road furniture and trees
adjacent to the areas being
sprayed shall be protected in
such a manner as to prevent
their being spattered or
marred by bituminous
material. Bituminous material
shall not be discharged into
road drains, gutters, etc.
(d) Curing and Opening to Traffic
Prime coat shall normally be
left undisturbed for at least 24
hours after application and
shall not be opened to traffic
until, in the opinion of the
S.O., it has penetrated the
roadbase and cured
sufficiently so that it will not
be picked up by the wheels of
vehicles.
The Contractor shall maintain

the prime coat, all to the
satisfaction of the S.O., until
the overlying pavement
course is constructed, which
shall not be within 24 hours
after the application of the
bituminous priming material
nor within such longer period
as is required, in the opinion
of the S.O., for the prime coat
to achieve maximum
penetration of the roadbase
and become fully cured.
4.2.2
Bituminous Tack Coat
4.2.2.1 Description
accepted bituminous or bitumen
primed pavement course, and the
furnishing and application to the
cleaned surface of a bituminous
tack coat prior to the construction
of an overlying bituminous
pavement course, all in
4.2.2.2 Materials
Bituminous tack coat material
shall be rapid setting bitumen
emulsion of grade RS-1 or RS1K conforming to the
requirements of M.S. 161.
4.2.2.3 Equipment
The equipment shall be as
Page 88

Material

Bituminous tack coat shall
only be applied to a clean,
dry, bituminous or bitumen
primed surface.
Bituminous tack coat shall
only be applied as far in
advance of the construction of
the overlying bituminous
pavement course as is
necessary to achieve a satis
factory degree of tackiness
before the overlying material
is placed, all to the
Cleaning
Prior to applying bituminous
tack coat, the surface to be
treated shall have been
prepared in accordance with
the appropriate Sections of
this Specification.
approval of this surface, any
damage to it or deterioration
of it shall be made good
before tack coat is applied.
Immediately prior to applying
bituminous tack coat, the full
width of the surface to be
treated shall be swept using a
compressed air blower, and if
necessary, scraped using hand
tools, to remove all dirt, dust
and other objectionable
material, all to the satisfaction
of the S.O.
The bituminous tack coat

shall be sprayed on to the
cleaned bituminous or
bitumen primed surface by
means of a pressure
distributor. Any areas
inaccessible to the distributor
spray bar shall be treated
using the distributor's hand
spraying system. The rate or
rates of application shall be as
directed by the S.O. based on
the results of test applications,
but shall usually be in the
range 0.25 to 0.55 litres/sq.m.
The temperature of the
bituminous material shall be
maintained in the range 25C
to 45C during spraying
operations.
Tack coat shall be distributed
uniformly over the surface to
be treated without streaking;
the quantities applied shall not
deviate by more than 10%
from those prescribed. Areas
with bituminous material in
excess of these limits shall
have the excess removed at
the Contractor's expense, and
areas with insufficient
bituminous material shall be
resprayed as necessary to
make up the deficiency, all to
sprayed shall be protected in
such a manner as to prevent
Page 89
Traffic shall be kept off the

tack coat at all times, and the
Contractor shall maintain the
tack coat, all to the
satisfaction of the S.O., until
the overlying pavement
course is constructed.
4.2.3
Bituminous Surface Dressing
4.2.3.1 Description
primed pavement course, and the
furnishing and placing on the
cleaned surface of one or two
applications of bituminous
material and cover aggregate, all
required by the S.O. When one
application of bituminous
material and cover aggregate is
placed the term `single
bituminous surface dressing'
(SBSD) shall apply, and when
two applications of bituminous
material and cover aggregate are
placed, the term `double
bituminous surface dressing'
(DBSD) shall apply.
4.2.3.2 Materials

Penetration graded bitumen
shall be 80-100 grade con
forming to M.S. 124.
Cut-back bitumen shall be
grade RC-70 or MC-70
conforming to M.S. 159.
Bitumen emulsion shall be
rapid setting of grade RS1, RS-1K, RS-2, RS-2K or
RS-3K conforming to M.S.
161. The grade of emulsion
selected shall be anionic or
cationic as appropriate to the
type of rock from which the
cover aggregate is derived,
and shall be approved by the
S.O.
(b) Additives for Bituminous
Material
An adhesion and antistripping agent shall be added
to the bituminous material if
the S.O. shall so direct or
approve. The additive shall be
of a type approved by the
S.O. and the required quantity
of additive shall be
thoroughly mixed with the
bituminous material in
accordance with the
manufacturer's instructions or
as directed by the S.O. for
such time as is necessary to
produce a homogenous
mixture.
(a) Bituminous Material

Bituminous binder for
bituminous surface dressing
shall be penetration graded
bitumen, or cut-back bitumen,
or bitumen emulsion as
shown on the Drawings or
otherwise specified.
(c) Aggregates for Bituminous

Surface Dressing
For single bituminous surface
dressing the cover aggregate
shall be nominal 20 mm, 14
mm, 10 mm or 6 mm size
chippings as shown on the
Drawings and/or directed by
the S.O.
Page 90
For double bituminous

surface dressing the cover
aggregate for the first
material and cover aggregate
shall be nominal 20 mm size
chippings, and the cover
aggregate for the second
shall be nominal 10 mm size
chippings.
iii) the weighted average loss

of weight in the sodium
sulphate soundness test (5
cycles) when tested in
accordance with AASHTO
Test Method T 104 shall
be not more than 12%;
Cover aggregates shall be

screened, crushed stone and
shall comprise clean, dry,
hard, tough, sound, angular
and cubical chippings free
from vegetative and other
organic matter, clay and other
deleterious substances, and
containing few, if any, flaky
or elongated particles. Dusty
chippings shall be washed
clean, all to the satisfaction of
the S.O. Cover agregates
physical and mechanical
requirements :-
v) the polished stone value

less than 40;
i) using the type of

bituminous material to be
used in the Works, treated
with additive if so
required, the coated area in
the coating and stripping
test for bitumen aggregate
mixtures, AASHTO Test
Method T 182, shall not
be less than 95%;
ii) the aggregate crushing
value when tested in
accordance with M.S. 30
shall be not more than 30;
iv) the flakiness index when

tested in accordance with
M.S. 30 shall be not more
than 25;
vi) the gradation shall con

form to the appropriate
envelope shown in Table
4.4.
4.2.3.3 Equipment
The Contractor shall provide all
the plant and equipment
necessary for executing the work
Specification, and shall furnish
the S.O. with such details of
particular items of equipment,
e.g. manufacturer, model type,
capacity, weight, etc., as the S.O.
shall require.
The equipment shall include a
power broom, a compressed air
blower, a self-propelled pressure
distributor for bituminous
material, all necessary equipment
for storing and heating
bituminous material, aggregate
spreading equipment, a suitable
number of tip-trucks and a selfpropelled pneumatic tyred roller.
Page 91
TABLE 4.4 - GRADATION LIMITS FOR BITUMINOUS SURFACE DRESSING
% Passing By Weight
B.S.
Sieve
Size
25.0 mm
20.0 mm
14.0 mm
10.0 mm
6.3 mm
4.75 mm
2.36 mm
Nominal
20 mm
Chippings
Nominal
14 mm
Chippings
Nominal
10 mm
Chippings
Nominal
6 mm
Chippings
100
85 - 100
0 - 20
0-5
0-2
100
85 - 100
0 - 20
0-5
0-2
100
85 - 100
0 - 20
0 - 10
0-2
100
85 - 100
0 - 25
0 - 10
(a) Power Broom

The power broom shall be
as specified in Sub-Section
4.2.1.3(a).
(b) Compressed Air Blower
The compressed air
blower shall be as
specified in Sub-Section
4.2.1.3 (b).
(c) Pressure Distributor for
Bituminous Material
The distributor shall be as
4.2.1.3(c).
(d) Storage and Heating
Facilities for Bituminous
Material
Storage and heating
facilities for bituminous
material shall be as
4.2.1.3 (d).
(e) Aggregate Spreading

Equipment
Aggregates shall be placed
using mechanical
spreaders of a type
spreaders shall be capable
of applying aggregate
uniformly over the full
width of the area being
treated and shall have
controls to regulate the
rate of spread as required
by this Specification, all to
(f) Tip-Trucks
The Contractor shall
provide a suitable number
of tip-trucks of a type
approved by the S.O.,
capable of spreading
aggregate in accordance
with this Specification.
Page 92
(g) Pneumatic Tyred Roller

The pneumatic tyred roller
shall be of recognised
manufcature and shall be
approved by the S.O. It
shall conform to the
requirements described
hereunder.
shall be self-propelled and
capable of being reversed
without backlash; it shall
be equipped with power
steering and dual controls
allowing operation from
either the left or right side.
The roller shall have nine
wheels equipped with
smooth treaded tyres all of
the same size and
construction, and capable
of operating at inflation
pressures of up to 0.9
N/sq.mm. Five wheels
shall be on the driven axle
and four on the steering
axle, all equally spaced on
both axles and arranged so
that the tyres on the
steering axle track midway
between those on the
driven axle with a small
overlap. The roller shall be
equipped with water tanks,
sprinkler systems and pads
of coconut matting to keep
all tyres evenly wetted
during operation.
The roller shall be
equipped with means of
adjusting its total weight
by ballasting so that the
load per wheel can be
varied in the range 1.0 to
2.0 tonnes.

In operation, the ballasted
weight and the tyre
inflation pressure shall be
adjusted to meet the
requirements of each
particular operation. Each
tyre shall be kept inflated
at the specified pressure
such that the pressure
difference between any
two tyres shall not exceed
0.04 N/sq.mm. Means
shall be provided for
checking and adjusting
tyre pressures at all times
at the place of the works.
The Contractor shall
provide the S.O. with a
calibration chart for the
roller showing the
relationship between the
quantity or depth of ballast
and total weight, and also
a chart showing the
relationship between
wheel load, tyre inflation
pressure and contact
pressure.
Bituminous surface dressing
shall only be carried out in
dry, warm weather when the
surface to be treated is dry.
Work shall be discontinued
when rain appears imminent
and during periods of strong
wind.
The S.O. may order the
discontinuation of work on
account of adverse weather,
unsatisfactory condition of
materials, equipment or
Page 93
surface to be treated, or such

other conditions as he shall
consider detrimental to the
work.

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

Cleaning
Prior to constructing a
bituminous surface dressing,
the surface to be treated shall
have been prepared in
accordance with the
appropriate Sections of this
Specification.Notwithstanding
any earlier approval of this
surface, any damage to or
deterioration of it shall be
made good before surface
dressing is commenced.
Immediately prior to
commencing surface dressing,
the full width of the surface to
be treated, together with an
additional 300 mm width on
each side, shall be swept
using a power broom
followed by a compressed air
blower and, if necessary,
scraped using hand tools to
remove all loose particles,
dirt, dust and other
objectionable material, all to
In double bituminous surface
dressing construction, the
surface of the first application
of bituminous material and
cover aggregate shall be
similarly made good and
cleaned, immediately prior to
commencing the second
application.
The rate or rates of

application shall be as
the results of laboratory tests
and/or test applications but for
penetration graded bitumen
shall usually be in the
appropriate range given in
Table 4.5.
TABLE 4.5 RATES OF APPLICATION

OF PENETRATION GRADED BITUMEN
Nominal Size
of Aggregate
Rate of Application of
Penetration Graded
Bitumen
20 mm
2.0 - 3.0 litre/sq.m
14 mm
10 mm
6 mm
Page 94
The rates of application

for cut-back bitumens and
bitumen emulsions shall
be commensurately higher
depending on their residual
bitumen contents.
The temperature of the
be maintained during
spraying operations within
the appropriate range
given in Table 4.6.
The bituminous material
shall be distributed
uniformly over the surface
to be treated without
streaking; the quantities
applied shall not deviate
by more than 10% from
those prescribed. The rate
of application shall be
checked for each spraying
run by measuring the
volume of bituminous
material in the distributor
before and after spraying
and the area treated.
Adjustments shall be made
as necessary to ensure that
the prescribed rate of
application is maintained
in subsequent runs.
Spraying shall be
discontinued immediately
if any defect develops in
the distributor, and it shall
not be resumed until the
fault has been rectified to

The spraying of bituminous
material over any portion of
the surface to be treated shall
not be carried out more than
two minutes in advance of
placing the cover aggregate
on that portion at the specified
rate; an the progress of
spraying the bituminous
material shall be restricted as
necessary to comply with
this requirement.
TABLE 4.6 - SPRAYING TEMPERATURE
FOR BITUMINOUS
Bituminous Material Spraying Temperature
80-100 penetration
grade bitumen
150 oC to 165 oC
Cut-back bitumen
grade
RC-70 or MC-70
50 oC to 65 oC
25oC to 45 oC
Bitumen emulsions
Bituminous materials
Bituminous materials shall
not be heated to spraying
temperatures too soon in
advance of requirements.
Any bituminous material
which has been heated to
spraying temperature for
more than ten hours or
which has been overheated
shall be rejected.
Page 95
In cases where the

bituminous material is
applied in lanes there shall
be a small overlap of
bituminous material at the
joints between lanes equal
in width to the edge strip
of the sprayed area which
does not receive the full
rate of application of
bituminous material. For
double bituminous surface
dressing, joints in the
second application of
be offset from those in the
first application by 150 300 mm for longitudinal
joints and by at least 1.0
metre, where possible, for
transverse joints.
Each spraying run shall
commence and terminate
on lengths of building
paper placed across the
full spraying width
immediately before and
after the section to be
sprayed. Sufficient building
paper shall be
placed so that the distributor
may be started and stopped
with the spray bar over paper,
and so that the correct
distributor road speed and rate
of spraying can be maintained
over the entire length of the
section to be sprayed, all to
Immediately after use and
before application of cover
aggregate, the building
paper shall be removed
and disposed of in a manner

Provision shall be made
for a volume of
bituminous material of at
least 10% of the capacity
of the distributor, or such
other quantity as the S.O.
shall direct, to remain in
the distributor tank at the
completion of each spraying
run, in order to avoid air
entrapment within the
bitumen spraying system.
sprayed shall be protected
in such a manner as to prevent
(d) Application of Cover
Aggregate
Before each spraying run
of bituminous material
commences, sufficient
aggregate to provide full
cover at the prescribed rate
of application over the
entire area to be sprayed
shall have been loaded in
trucks at the Site of the
Works in readiness for
spreading.
Immediately following
the application of the
bituminous material, the
clean, dry cover aggregate
shall be uniformly spread over
the bituminous material using
mechanical spreaders
Page 96
The aggregate shall be placed

as quickly as practicable after
the application of bituminous
material on all parts of the
area to be covered, and for no
portion of the surface to be
treated shall there be a delay
of more than two minutes
between the application of the
bituminous material
and the spreading of
the aggregate.
The trucks feeding the
aggregate to the mechanical
spreaders shall operate
backward during aggregate
spreading in order that the
wheels of the spreaders and
trucks shall not run on
uncovered bituminous
material.
The rate of application of
cover aggregate shall be as
the results of laboratory tests
and/or tests applications, but
shall usually be in the
appropriate range given in
Table 4.7
TABLE 4.7 - RATES OF APPLICATION OF
COVER AGGREGATE
Nominal
Size
Rate of Application
of Aggregate
20 mm
17 27 kg/sq.m
14 mm
12 18 kg/sq.m
10 mm
8 12 kg/sq.m
6 mm
5 8 kg/sq.m
The rate of application shall

be checked for each spraying
run from measurements of the
quantities of aggregate in the
trucks and the area treated, or
by sampling and measuring
the aggregate spread on the
road. Any bare or
insufficiently covered areas
shall be made good by hand
spreading as quickly as
possible. Aggregate in excess
of the rate prescribed shall be
evenly distributed over the
surface or removed as quickly
as possible, all to the
In cases where the surface
dressing is constructed in
lanes, the edge of the
aggregate spread adjacent to
an untreated lane shall
coincide with the edge of the
sprayed area which receives
the full rate of application of
the bituminous material. This
will leave a narrow strip of
bituminous material of partial
thickness which shall be
overlapped by the bituminous
material spray and aggregate
spread of the adjacent lane.
Immediately following the
spreading of the aggregate to
the satisfaction of the S.O.,
the aggregate shall be rolled
with a pneumatic tyred roller
approved by the S.O. to
embed the aggregate in the
bituminous material. Rolling
shall commence as quickly as
practicable after the
application of the bituminous
material and aggregate on all
parts of the area to be
covered, and for no portion
of the surface to be treated
shall there be a delay of more
Page 97
than 3 minutes between the

application of the bituminous
material and the
commencement of rolling.
shall be ballasted to an
operating weight of 9 - 10
tonnes and its tyre inflation
pressure shall be 0.53
N/sq.mm for surface dressing
work. Rolling shall be
continued for as long as is
necessary to thoroughly
embed the aggregate in the
bituminous material, all to the
Rolling shall generally begin
at the outer edge of surface
dressing and progress
uniformly towards the centre
on each side, except on super
elevated curves where rolling
shall begin at the lower edge
and progress uniformly
towards the higher edge.
Consecutive roller passes
shall generally overlap by
about one half of the roller's
width.
When, in the opinion of the
S.O., the bituminous material
has hardened sufficiently to
prevent the dislodgement of
embedded aggregate by the
action of the power broom, all
loose aggregate shall be swept
from the treated surface using
the power broom and
compressed air blower and
disposed of to the satisfaction
of the S.O. Where the
dressing so prepared is the
first application of a double
bituminous surface dressing,
construction of the second

shall then proceed as soon as
is practicable.
(e) Opening to Traffic
Bituminous surface dressing
shall normally not be opened
to traffic until such time as,
in the opinion of the S.O., the
surfacing shall have
developed sufficient strength
to withstand normal traffic
forces without dislodgement
of the aggregate. This will
usually be not less than 24
hours after the completion of
rolling. Where it is necessary
to allow earlier use of the
finished surface to facilitate
the movement of traffic,
vehicles may be allowed to
run on the work after rolling
has been completed, provided
that speeds are restricted to 30
km per hour or less and sharp
turning movements are
prohibited. The finished
surface shall subsequently
have to be closed
temporarily to enable the
loose aggregate to be swept
off and disposed of as
described in Sub-Section
4.2.3.4 (d).
Ideally, the first application of
bituminous material and cover
aggregate of a double
bituminous surface dressing
should not be opened to
traffic before construction of
the second application.
However, where it is
necessary to facilitate the
movement of traffic, the first
application may be opened to
traffic prior to construction of
the second application.
Nevertheless, traffic
movement on the completed
Page 98
first application shall be kept

to a practicable minimum and
the second application shall
be constructed as soon as is
practicable after the
completion of the first.
4.2.4 Asphaltic Concrete

4.2.4.1
organic matter, and other

deleterious substances. They
physical and mechanical quality
requirements :i) the aggregate crushing value
more than 30;
Description
furnishing, placing, shaping and
compacting asphaltic concrete
binder course and/or wearing
course on a prepared and
primed pavement course, and
shall include the careful and
thorough cleaning of surfaces
which are to be covered without
receiving a bituminous tack coat.
The work shall be carried out all
levels, grades, dimensions and
cross-sections shown on the
the S.O.
4.2.4.2
Materials
(a) Aggregates
Aggregate for asphaltic
concrete shall be a mixture of
coarse and fine aggregates
and, if necessary, mineral
filler. The individual aggregates
shall be of sizes suitable for
blending to produce the required
gradation of the combined
aggregate, all to the satisfaction
of the S.O.
Coarse aggregates shall be
screened crushed hard rock,
angular in shape and free from
dust, clay, vegetative and other
ii) the weighted average loss of

with AASHTO Test Method T
104 shall be not more than
12%;
iii) the flakiness index when
than 30;
iv) the water absorption when
than 2%;
v) the polished stone value when
M.S. 30 shall be not less than
40 (only applicable to
aggregates for wearing
course).
Fine aggregates shall be clean
natural sands, screened quarry
fines, or mining sand. Mining
sand shall be thoroughly washed
before use. Other types of fine
aggregate may be used subject to
the approval of the S.O.
Fine aggregates shall be nonplastic and free from clay, loam,
aggregations of material,
vegetative and other organic
matter, and other deleterious
substances.
Page 99
They shall conform to the

mechanical quality requirements:i) the weighted average loss of
with AASHTO Test Method T
104 shall be not more than
12%;
ii) the water absorption when
than 2%.
Notwithstanding compliance with

the requirements of this
Specification, limestone
aggregates shall not be permitted
for use in wearing course.
The gradation of the combined
coarse and fine aggregates,
together with ordinary Portland
cement added as an adhesion and
anti-stripping agent and, if
necessary, any other mineral
filler, shall conform to the
appropriate envelope shown in
Table 4.8
TABLE 4.8 - GRADATION LIMITS FOR ASPHALTIC CONCRETE
Mix Type
Wearing Course
Binder Course
Mix
Designation
ACW 20
ACB 28
B.S. Sieve
% Passing by weight
37.5 mm
100
28.0 mm
100
80 - 100
20.0 mm
76 - 100
72 - 93
14.0 mm
64 - 89
58 - 82
10.0 mm
56 - 81
50 - 75
5.0 mm
46 - 71
36 - 58
3.35 mm
32 - 58
30 - 52
1.18 mm
20 - 42
18 - 38
425 um
12 - 28
11 - 25
150 um
6 - 16
5 - 14
75 um
4-8
3-8
Page 100
The gradation envelopes in the

above Table are purposely wider
than the tolerances for good
works control of asphaltic
concrete mixes. For each type of
mix required in the Works, the
Contractor shall establish a job
mix formula gradation which
shall consist of a single definite
percentage passing for each sieve
size in the above Table and shall
produce a smooth curve within
and essentially parallel to the
appropriate gradation envelope.
This job mix formula gradation,
with the allowable tolerances for
a single test as specified in SubSection 4.2.4.3 (c), then becomes
the job control envelope and this
job control envelope must be
totally within the limits of the
appropriate gradation envelope in
the above Table.
(b) Mineral Filler
Mineral filler shall be finely
divided mineral matter such as
rock dust, limestone dust, hydrated
lime, hydraulic cement, or such other
suitable material as the S.O. shall
approve. At the time of mixing with
bitumen it shall be sufficiently dry to
flow freely and shall be essentially
free from agglomerations. Not less
than 70% by weight shall pass the
B.S. 75 um sieve.
(c) Bituminous Material
Bituminous binder for asphaltic
concrete shall be penetration graded
bitumen of 80-100 grade conforming
to M.S. 124.
(d) Anti-Stripping Agent
Ordinary Portland cement shall be
added to the combined aggregate for
asphaltic concrete to serve as an

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

manufacturer's instructions. In such a
case, the agent shall be added to the
bitumen binder used in the bitumen
stripping tests in the appropriate amount
and manner.
Aggregate which does not perform
satisfactorily in the bitumen stripping
tests, using the approved adhesion and
anti-stripping agent when appropriate,
shall not be used in asphaltic concrete.
4.2.4.3 Asphaltic Concrete Mix Design
(a) Job Mix Formulae
After obtaining supplies or
production (as applicable) of all
aggregates consistent as to gradation
and other qualities, the Contractor
shall propose a job mix formula for
each class of mix required in the
Works. In order to attain optimum
quality of the mixtures, the job mix
formula for each class shall be
prepared on the basis of testing
several trial gradations within the
limits set in Table 4.8 at an
appropriate range of bitumen
contents. As a guide to the testing
range of bitumen contents, the design
bitumen content will usually be in
the appropriate range given in Table
4.9.
A sample of each trial mix (i.e. each

combination of trial gradation and
bitumen content) shall be subject to a
comprehensive Marshall method test
and analysis as follows :i) preparation of specimens for the
standard stability and flow test in
accordance with AASHTO Test
Method T 245 using the 75
blows/face compaction standard;
ii) determination of the bulk
specific gravity of the specimens
in accordance with AASHTO
Test Method T 166;
iii) determination of the stability and
flow values in accordance with
AASHTO Test Method T 245;
iv) analysis of the density and
voids parameters to determine
the percentage of voids in the
compacted aggregate, the
percentage of voids in the
compacted aggregate filled with
bitumen, and hence the
percentage of air voids in the
compacted mix.
For each trial mix conforming to a
proposed job mix formula, the
parameters of the above tests and
analyses shall conform to the
requirements of the appropriate type
of mix as given in Table 4.10.
TABLE 4.9 - DESIGN BITUMEN

CONTENTS
ACW14 - Wearing Course
5.0 7.0 %
ACW14 - Binder Course
4.5 - 6.5 %
ACB 28 - Binder Course
4.0 - 6.0%
Page 102
TABLE 4.10 - TEST AND ANALYSIS PARAMETERS

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

small pockets of air between the
coated aggregate particles in a
compacted asphaltic concrete mix.
The portion of the bitumen absorbed
into the aggregate particles must
therefore be allowed for when
calculating the air voids. For
combined aggregate with a water
absorption of not more than 2.0%,
the absorbed bitumen may be
estimated on the basis that the
absorption of bitumen will be
approximately 20% of the water
absorption.
Voids in the aggregate of a mix shall
be calculated on the basis of the
weighted average bulk specific
gravity on an oven dried basis of the
coarse and fine aggregate fractions
(separated by the ASTM # 10 sieve
or B.S. 2.0 mm sieve) as determined
in accordance with AASHTO Test
Method T 84 and T 85 as applicable.
The Marshall density of an asphaltic

concrete mix is defined as the
average density of a set of three (3)
test specimens moulded for the
Method T 245 using the 75 blows
per face compaction standard.
The Contractor shall submit to the
S.O. full details of his proposed job
mix formula for each class of mix
required in the Works including :i) the gradation analysis of each
aggregate to be used in the mix;
ii) the proportions for cold batching
the aggregates;
iii) the mixing plant screen sizes, the
smallest of which shall generally
be not more than 3.2 mm;
iv) the gradation analysis of the
aggregate in each of the mixing
plants' hot bins and of the mineral
filler (including any ordinary
Portland cement added as
anti-stripping agent);
Page 103
v) the job mix formula gradation of

the combined aggregate and
filler;
vi) the proportions for combining the
hot bin aggregates and filler;
vii)the bitumen content (by weight of
total mix);
viii)the dry and wet mixing times if a
batch plant is to be used, or the
mixing time if a continuous mix
plant is to be used;
ix) the full results of the
comprehensive Marshall method
tests and analyses as described
above for each trial mix used in
determining the job mix formula.
The S.O. may require changes of any
of the factors in each proposed job
mix formula and further tests and
analyses in order to attain optimum
quality of the asphaltic concrete
mixes.
(b) Plant Trials
After having received the S.O.'s
preliminary approval of his proposed
job mix formulae, the Contractor
shall arrange to mix, lay and compact
asphaltic concrete conforming to the
proposed formula for each class of mix
required in the Works. A minimum of
10 tonnes of each mix shall be placed
in trial areas to demonstrate to the
satisfaction of the S.O. that the mixing,
laying and compacting equipment
conforms to the requirements of this
Specification, and that the proposed
mixes are satisfactory. The trial areas
shall not be part of the Contract Works
but shall be provided by the Contractor
at his own expense. They shall be

As directed by the S.O., comprehensive
sampling and testing of each class of
mix shall be carried out to check for
satisfactory compliance with its job mix
formula, and for a satisfactory degree of
compaction.
As a result of the plant trials, the S.O.
may require amendments to the job mix
formulae, further tests and analyses,
and possibly additional plant trials
before finally approving the mixes for
full scale production and use in the
Works.
(c) Compliance with the Job Mix Formulae
The S.O.'s final approval of the job mix
formulae shall bind the Contractor to
furnish asphaltic concrete mixes
meeting the precise gradations and
bitumen contents specified in these
formulae within the tolerances set
forth in Table 4.11.
Modifications to a job mix formula may
only be made with the approval of the
S.O. Should the S.O. at any time have
reason to believe that the materials and
methods of mixing and laying are
different from those approved, he shall
so advise the Contractor, and may order
that asphaltic concrete works be
discontinued pending further trials and
testing.
Page 104
TABLE 4.11 - TOLERANCES FOR ASPHALTIC CONCRETE MIXES
ParameterPermissible Variation
% By Weight of Total
Mix
Bitumen.
+ 0.2%
Fractions of combined
aggregate passing 5.0 mm
and larger sieves.
+ 5.0%
aggregate passing 3.35 mm
and 1.18 mm sieves.
+ 4.0%
aggregate passing 425 um
and 150 um sieves.
+ 3.0%
Fraction of combined
aggregate passing 75 um
sieve.
+ 2.0%
4.2.4.4 Equipment
The Contractor shall provide all the
plant and equipment necessary for
executing the work in accordance
with this Specification and shall
furnish the S.O. with such details of
particular items of equipment, e.g.
manufacturer, model type, capacity,
weight, operating features, etc., as
the S.O. shall require.
(a) Road Cleaning Equipment
Road cleaning equipment will be
required where asphaltic concrete is
to be laid on a surface which is not
to receive a tack coat. The
equipment shall be the same as that
required for preparing a surface for
a tack coat, and shall include a
power broom and compressed air
blower as specified in Sub-Sections

4.2.1.3 (a) and 4.2.1.3 (b) respectively.
(b) Asphalt Mixing Plant
The asphalt plant shall be either a
batch plant or a drum mix plant or a
continuous mix plant of recognized
manufacture and shall be approved by
the S.O. It shall conform to the
requirements described hereunder.
The mixing plant shall have a capacity
suited to the Works and sufficient to
enable the paver to operate more or less
continuously when paving at normal
speeds at the required thicknesses. The
plant shall be so designed as to enable
consistent production of asphaltic
Page 105
concrete mixes within the tolerances

prescribed in this Specification, all to
Scales for all weigh boxes or hoppers
shall be of the springless dial type,
accurate to within 0.5% of the
maximum load that may be required.
Scale dials and pointers shall be easily
read from their operator's normal
position without significant parallax
errors. Scales shall be substantially
constructed so that they shall maintain
their accuracy after initial adjustment.
The Contractor shall furnish not less
than ten 25 kg test weights at the plant
for checking, adjusting and calibrating
scales.
Tanks for storage of bitumen shall have
a capacity suited to the proposed rate of
utilization of the material and the
method and frequency of its delivery to
the Works, all to the satisfaction of the
S.O. The tanks shall be provided with
means of measuring the volume of their
contents at all times and of drawing off
samples of the contents. The bitumen
feeding system shall provide for
continuous circulation of hot binder
through the system and back into the
feed tank. The end of the return line
discharging into the feed tank shall
always be kept submerged in the
bitumen in the tank in order to prevent
oxidation of the returning hot binder.
The storage tanks, and where necessary
barrel decanters, and all elements of the
bitumen feeding system shall be
equipped with heating systems or
insulating jackets as necessary to
provide for effective and positive control
of the temperature of the bitumen at all
times up to the temperature required for
utilisation. . The method of heating
shall be such that neither flames nor the
products of combustion shall come into
direct contact contact with the bitumen
or the casing of its immediate container,
and such that no portion of the bitumen
shall be subject to overheating.

The plant shall be provided with
accurate mechanical means for
uniformly feeding the aggregates into
the dryer so that uniform production and
temperature of the heated aggregates
will be obtained. A separate feed bin
with an adjustable gate opening shall be
provided for each aggregate to be
included in the combined aggregate for
the mix; normally four bins will be
required. The feed bins and gates shall
be so constructed and equipped that they
shall be readily accessible for calibrating
at all times, and shall provide for a
continuous and uniform flow of each
aggregate required in the mix.
The plant shall have a rotary drum dryer
of satisfactory design for drying and
heating the combined aggregate so that
its temperature will be at the required
level at the time it is mixed with the
bitumen. The burner shall be so
designed that complete combustion of
the fuel will be obtained, and the
aggregate will remain clean and not
become coated with soot or oil.
The plant shall be equipped with four
(or more) screens, the smallest of which
shall generally be not more than 3.2
mm. The screens shall have a normal
capacity slightly in excess of the
maximum output of the mixing plant.
The screens shall be readily accessible
for inspection.
The plant shall include four (or more)
storage bins for screened aggregates,
each with a capacity of not less than
twice the pugmill dead load capacity.
The bins shall be arranged so as to
provide separate dry storage for each
screened fraction of the aggregate. Each
bin shall be provided with an overflow
pipe of such size and location as to
prevent any backing up of material into
other bins. Each bin shall be so
constructed that representative aggregate
samples can be readily obtained, and
Page 106
shall have means for observing the

aggregate level. Separate dry storage
shall be provided for mineral filler, and
the plant shall be satisfactorily equipped
to feed filler into the mixer.
Satisfactory means by either weighing
or metering shall be provided to obtain
the prescribed amount of bitumen in the
mix within the specified tolerance.
Means shall be provided for checking
the quantity or flow rate of binder
entering the mixer. Suitable means shall
be provided for maintaining the
prescribed temperature of the bitumen in
the pipelines, weigh bucket or flow
meter, and spray bars.
An armoured thermometer with a
range of 30 oC to 200 oC shall be fitted
in the bitumen feed line at a suitable
location near the discharge valve at the
mixer unit. Suitable dial-scale mercury
actuated thermometers, electric
pyrometers or other thermometric
instruments shall be fitted at the
discharge chute of the dryer and in each
hot aggregate storage bin to indicate the
temperatures of the heated aggregates.
The plant shall be equipped with a dust
collector so constructed as to waste the
material collected or feed it uniformly to
the heated aggregate.
The plant shall be equipped with
adequate and safe stairways to the
mixing platform and sampling locations,
and guarded ladders and cat-walks shall
provide access to all other positions as
necessary for proper operation,
inspection and maintenance of the plant,
all to the satisfaction of the S.O. All
gears, pulleys, chains, sprockets and
other dangerous moving parts shall be
properly guarded and protected. Ample
and unobstructed space shall be
provided on the mixing platform, and
clear and unobstructed passage shall be
maintained at all times in and around

the truck loading area, which shall be
kept free from drippings from the mixer.
Special Requirements for Batch Plants
Each storage bin for screened aggregate
shall be provided with a bottom outlet
gate so constructed as to prevent leakage
when closed. These gates shall have a
quick and complete closing action.
The plant shall be equipped with a
weigh box or hopper for accurately
weighing out aggregate from each of the
screened aggregate storage bins. The
weigh box or hopper shall be
suspended from its scale's lever
mechanism and shall be sufficiently
large to hold a full batch equal to the
pugmill capacity without hand raking or
spilling of the aggregate. The discharge
gate shall be so constructed as to allow
rapid and complete emptying of the
weigh box or hopper into the mixer, and
prevent leakage when closed.
The plant shall be equipped with a
binder weigh bucket which shall be
charged through a fast acting non-drip
valve in the binder feed pipe located
directly over the bucket. The bucket
shall be suspended from its scale's lever
mechanism and shall have a capacity
sufficient to weigh out binder up to 20%
of the weight of the pugmill dead load
capacity. The bucket shall have a
discharge mechanism which shall
provide for rapid and complete
emptying of the bucket in a thin uniform
sheet or multiple sprays over the full
length and width of the mixer. The
dicharge mechanism shall not leak or
drip when closed.
The batch mixer shall be a suitable
twinshaft pugmill, with a capacity of at
least 500 kg of asphaltic concrete,
capable of producing a thoroughly
homogeneous mixture. The clearance of
the paddle blades from all fixed and
Page 107
moving parts of the mixer shall be not

more than 20 mm. If the pugmill is not
enclosed it shall be equipped with a dust
hood to prevent loss of fines from the
mixture. The discharge gate shall be so
constructed as to allow rapid and
complete emptying of the mixer, and
prevent leakage of any mix constituent
when closed.
The mixer shall be equipped with an
accurate time lock system for
controlling the operations of a complete
mixing cycle. It shall lock the aggregate
weigh box or hopper gate after charging
the mixer with aggregate, until the
closing of the mixer gate at the
completion of the mixing cycle; it shall
lock the binder weigh bucket discharge
mechanism during the dry mixing and
wet mixing periods. (The dry mixing
period is defined as the interval of time
between the opening of the aggregate
weigh box or hopper gate and the start
of discharging the binder weigh bucket.
The wet mixing period is defined as the
interval of time between the start of
discharging the binder weigh bucket and
the opening of the mixer gate.) The dry
and wet mixing periods shall both be
adjustable in increments of not more
than 5 seconds from zero to not less than
120 seconds total for dry and wet
mixing.
Special Requirements for Drum Mix
Plants
The cold material feeder unit shall
consist of not less than 5 compartments
with suitable heaped capacity
appropriate for the plant. Each bin shall
be provided with a control gate and
measuring feeder suitable for accurate
blending of the aggregates on to the cold
feed collecting conveyor. The cold feed
system shall incorporate a device for
moisture compensation capable of

producing an accurate and continuous
blend of the individual aggregate sizes
from the cold feed compartment.
The drum mixer shall be of an inclined,
oil-fired and parallel flow type in which
the aggregates and exhaust gases flow in
the same direction. The drum mixer
length to diameter ratio shall be such as
to ensure efficient drying and intimate
mixing of aggregate, filler and binder
over the full range of rated operating
efficiencies. A bypass chute shall be
incorporated for sampling of cold
aggregate.
Freshly mixed material shall be
delivered and stored in a surge silo
through a proper conveyor system.
Special Requirements for Continuous
Mix Plants
Each storage bin for screened aggregate
shall be provided with an accurately
controlled variable orifice gate
discharging on to an aggregate feed
mechanism. The discharge orifice shall
be rectangular with one dimension
variable by means of an adjustable and
lockable gate, which shall have an
indicator showing the distance it is open.
These gates shall be used for accurately
proportioning the screened aggregates
for the mix.
The plant shall have means of
calibrating the aggregate bin discharge
gate openings by weighing test samples
obtained by diverting the aggregate fed
out of each bin into a suitable test box.
Test boxes shall have a capacity of not
less than 100 kg each.
The plant shall have satisfactory means
of effecting positive interlocking control
between the flow of screened aggregates
from the storage bins and the flow of
binder from the meter or other
proportioning device. This control shall
Page 108
be accomplished by interlocking
mechanical means or another positive
method satisfactory to the S.O.
The continuous mixer shall be a suitable
twin-shaft pugmill with an adjustable
dam and paddles with reversible blade
pitch for adjusting the volume of
mixture held in the pugmill. The
clearance of the paddle blades from all
fixed parts of the mixer shall be not
more than 20 mm. The binder shall be
fed into the mixer through a spray bar
directed on to the aggregate across the
full width of the pugmill at the feed end.
The discharging mixture shall pass over
the dam into a hopper with a discharge
gate so constructed as to allow rapid and
complete emptying of the hopper, and
prevent leakage of the mix when closed.
The mixer shall be equipped with a
permanent gauge for measuring the
depth of mixture in the pugmill and a
manufacturer's calibration plate showing
the volume of mixture in the pugmill at
each increment of depth.
The mixing time shall be determined
using the formula :Mixing time (seconds) =
Dead weight of mix in pugmill (kg)
Pugmill output (kg per second)
and for a given output it may be varied
slightly by adjusting the depth (and
hence weight) of the mixture held in the
pugmill by varying the dam height, the
configuration of the paddle blades, or
both. However for substantial
adjustments of the mixing time, in order
to maintain the depth at a level
compatible with efficient mixing, i.e. so
that the paddle tips just break out of the
mixture at the height of their action, the
rate of feed of materials to the mixer
(and hence output) should be changed.

(c) Tip-Trucks
The Contractor shall provide a suitable
number of tip-trucks of a type approved
by the S.O. for transporting asphaltic
concrete from the mixing plant to the
paving works. The trucks shall have
trays with smooth, flat beds and sides,
and shall have load capacities of not less
than 5 tonnes. Prior to loading, the
inside of each truck tray shall be lightly
and evenly coated with a soap or
detergent solution, or such other liquid
as the S.O. shall approve, to prevent
adhesion of the asphaltic concrete. The
trucks shall be equipped with covers of
canvas or other suitable material to
protect the asphaltic concrete.
(d) Asphalt Paver
The asphalt paver shall be of recognized
manufacture and shall be approved by
the S.O. It shall conform to the
requirements described hereunder.
The paver shall be self-propelled and
capable of reverse as well as forward
travel. It shall be equipped with a
hopper at the front designed to receive
the paving mixture from tip-trucks, and
shall have a mechanical distribution
system for spreading the mixture evenly
and without segregation over the surface
to be paved in front of a screeding and
compacting unit which shall be
equipped with a suitable heating device.
The screeding and compacting
mechanism shall be capable of
confining the edges of the material
being laid without the use of stationary
side forms, shall be adjustable to strike
off the mixture to the thickness and
cross-section shape required, and shall
be controlled by an automatic levelling
device to produce an even carpet of
bituminous mixture with a uniform sur
face texture free from indentations,
ridges, tear marks or other irregularities.
Page 109
The paver shall be capable of laying the

bituminous mixture in paving widths in
the range 2.5 to 3.75 m and of finishing
the pavement layer true to the required
lines, grades, levels, dimensions and
cross-sections, subject to compaction by
rolling, all to the satisfaction of the S.O.
(e) Rollers
A pneumatic tyred roller and two steel
wheeled tandem rollers shall be
provided. However, a three wheeled
steel roller may be substituted for one of
the tandem rollers if the S.O. shall so
approve. All rollers shall be of
recognized manufacture and shall be
The pneumatic tyred roller shall be as
specified in Sub-Section 4.2.3.3 (g).
Steel wheeled rollers shall conform to
the requirements described hereunder.
Steel wheeled rollers shall be selfpropelled and capable of being reversed
without backlash; they shall be equipped
with power steering and dual controls
allowing operation from either the left or
right side. They shall be equipped with
water tanks, sprinkler systems and
scraper blades to keep all wheels evenly
wetted and clean during operation.
Each steel wheeled roller shall be
ballasted so that its total operating
weight is in the range 8 to 10 tonnes and
its driven roll (or rolls) shall exert a
rolling force of not less than 3.5
tonnes/metre of roll width. The
Contractor shall provide the S.O. with a
calibration chart for each roller showing
the relationships between the quantity or
depth of ballast and total weight and
rolling force.

Asphaltic concrete paving work
shall only be carried out in dry
weather when the surface to be
covered is dry, or if so specified,
has received a bituminous tack
coat which shall have achieved a
satisfactory degree of tackiness,
All laying, rolling and finishing
work shall be carried out during
daylight hours, unless the Contractor
shall have provided suitable floodlighting for the job site, to the
The S.O. may order the
discontinuation of work on account
of adverse weather, unsatisfactory
condition of materials, equipment or
surface to be paved, or such other
conditions as he shall consider detri
mental to the work.
(b) Surface Preparation and Cleaning
Prior to constructing an asphaltic
concrete pavement layer, the surface
to be covered shall have been
prepared in accordance with the
appropriate Sections of this
Specification. Notwithstanding any
earlier approval of this surface, any
damage to or deterioration of it shall
be made good before asphaltic
concrete paving work is commenced.
If the surface to be covered is not to
be provided with a bituminous tack
coat, then immediately prior to
commencing asphaltic concrete
paving, it shall be swept using a
compressed air blower and, if
necessary, scraped using hand tools
to remove all loose particles, dirt,
dust and other objectionable
Page 110
material, all to the satisfaction of the

S.O.
If the surface to be covered is to be

provided with a bituminous tack coat,
then this shall be applied all in
accordance with the provisions of SubSection 4.2.2.
Ordinary Portland cement and/or

other mineral filler to be used in the
mix shall be stored separately and
kept completely dry. Its rate of feed
into the plant shall be accurately
controlled by weight or volumetric
measurement, all to the satisfaction
of the S.O.
(c) Aggregate Handling and Heating
(d) Heating of Bitumen
Each aggregate to be used in the

asphaltic concrete mixes shall be stored
in a separate stockpile near the mixing
plant. Stockpiles of sand and other fine
aggregates shall be kept dry using
waterproof covers and other means as
necessary. In placing the aggregates in
the stockpiles and loading them into the
mixing plant's cold aggregate feed bins,
care shall be taken to prevent
segregation or uncontrolled combination
of materials of different gradation.
Segregated or contaminated materials
shall be rescreened or rejected for use in
the Works and removed from the mixing
plant site.
The binder shall be heated so that

when delivered to the mixer it shall
be at a temperature in the range
140C to 160C.
The aggregates shall be fed into the

dryer at a uniform rate proportioned in
accordance with the appropriate job mix
formula. The rate of feed for each
aggregate shall be maintained within
10% of the rate prescribed, and the
total rate of feed shall be such that
the plant's screens shall never be
overloaded.
For each batch the screened hot

aggregates shall be weighed out into
the aggregate weigh hopper in
accordance with the proportions
prescribed in the appropriate job mix
formula; the sequence of weighing
out shall commence with the largest
sized aggregate and progress down
to the fines, unless the S.O. shall
otherwise approve. Mineral filler
shall be weighed out into the filler
weigh hopper, where this is
provided, or added last to the
aggregate weigh hopper, in
accordance with the job mix formula
proportions.
The aggregates shall be dried and heated

so that when delivered to the mixer they
shall be at a temperature in the range
150C to 170C.
Immediately after heating, the
aggregates shall be screened into four
(or more) fractions which shall be
separately stored in the hot aggregate
storage bins in readiness for mixing.
(e) Mixing Asphaltic Concrete

The mixing plant shall be so
coordinated and operated as to
consistently produce asphaltic
concrete mixes within the tolerances
prescribed in this Specification, all
Mixing in Batch Plants
The hot binder shall be weighed out

into the binder weigh bucket in
ccordance with the proportions
prescribed in the job mix formula.
Page 111
The hot aggregates and filler shall be

discharged into the pugmill and
mixed dry for the dry mixing time
prescribed in the job mix formula,
which shall usually be in the range 5
to 10 seconds. The hot binder shall
then be added and wet mixing per
formed for the wet mixing time
prescribed in the job mix formula;
this shall be sufficient so that all
particles of aggregate are uniformly
coated with bitumen, and shall
usually be 45 seconds or more for
dense graded mixtures.
The volume of each batch shall be
such that the tips of the pugmill
paddle blades just break out of the
mixture at the height of their action.
After the completion of wet mixing,
each batch of asphaltic concrete shall
be discharged from the pugmill
either into a storage hopper or
directly into a truck for hauling to
the paving site. Care shall be taken
that no segregation of the mix
occurs.
Mixing in Continuous Mix Plants
The screened hot aggregates and
filler shall be fed continuously from
their storage bins in accordance with
the proportions prescribed in the
appropriate job mix formula,
combined in the plant, and fed
continuously into the mixer. The hot
binder shall be sprayed on to the
combined aggregate as it enters the
pugmill at the rate required to
achieve the bitumen content pre
scribed in the job mix formula. The
materials shall then be carried
through the pugmill and in the
process be thoroughly mixed by
the action of the paddles and dis
charged over the dam into the stor
age hopper. The mixing time (as
defined in Sub-Section 4.2.4.4 (b)

shall be as prescribed in the job mix
formula; this shall be sufficient so
that all particles of aggregate are
uniformly coated with bitumen, and
shall usually be 45 seconds or more
for dense graded mixtures.
The plant shall be so adjusted as to
maintain the level of mixture in the
pugmill such that the tips of the
paddle blades just break out of the
mixture at the height of their action.
(f) Transportation of Asphaltic
Concrete
Asphaltic concrete shall be
transported from the mixing plant to
the site of the paving works in loads
of not less than 5 tonnes using
tip-trucks as specified in
Sub-Section 4.2.4.4 (c). Except
where asphaltic concrete is to be
hand laid, it shall be discharged
directly into the paver hopper, as
required, from the tip-trucks. Care
shall be taken in the truck loading,
hauling and unloading operations to
prevent segregation of the mix.
During transportation, the asphaltic
concrete shall be protected from
contamination by water, dust, dirt
and other deleterious materials.
The temperature of asphaltic
concrete immediately before
unloading from the truck either into
the paver hopper or on to the road
for hand spreading shall be not less
than 125C. Any load which has
cooled below the specified
temperature in the truck shall be
rejected for use in the Works and
removed from the Site of the Works.
(g) Laying Asphaltic Concrete
The sequence of laying operations
shall be planned in advance by the
Contractor and approved by the S.O.
Page 112
Generally each paving layer shall

have a compacted thickness of not
less than twice the nominal
maximum aggregate size of the
mixture, and not more than 100 mm.
Where applicable, e.g. on
superelevated sections and on
carriageways with cross-slope in one
direction only, laying shall
commence along the lower side of
the carriageway and progress to the
higher side. Laying shall not be
carried out in a downhill direction
along any section of road.
As far as is practicable, laying shall
be carried out using a paver
approved by the S.O. Hand-casting
of bituminous mix on to the machine
finished surface shall be kept to the
practicable minimum necessary for
correcting blemishes and
irregularities. In any areas
inaccessible to the paver, laying shall
be carried out by hand methods
using rakes, lutes and other hand
tools, all to the satisfaction of the
S.O. All laying of bituminous mix
shall be such that after compaction
by rolling the specified course or
layer thickness and surface profile
shall be achieved. Care shall be
taken to achieve a uniform surface
texture free from indentations,
ridges, tear marks or other
irregularities, and to prevent
segregation of the mix.

and before laying restarts after each
interruption of the paving operation.
As far as is practicable, the paver
shall be operated continuously and
the supply of bituminous mix shall
be regulated so as to enable
continuous paving. Transverse joints
in a paving lane shall be kept to a
practicable minimum, and
intermittent stopping and restarting
of the paver shall be avoided as far
as is practicable.
Care shall be taken that no
bituminous mix is placed on
expansion joints at bridges,
inspection covers for utilities ducts,
drainage and sewerage manholes and
the like, and that catchpits, drainage
openings through kerbs, etc., remain
properly open and serviceable.
During laying operations, such areas
and openings shall be protected by
suitably shaped and secured boards
or other materials approved by the
S.O., and compaction of mix in the
immediately surrounding or adjacent
areas shall be completed by hand
methods, all to the satisfaction of
the S.O. Alternatively, bituminous
mix shall be laid and compacted by
hand methods as necessary around
surfacing discontinuities of these
types, all to the satisfaction of the
S.O.
(h) Construction Joints
At the commencement of initial

rolling the temperature of asphaltic
concrete shall be not less than
110C. Material which has cooled
below the specified temperature
before laying shall not be used and
shall be removed from the Site of the
Works. The Contractor shall provide
accurate thermometers at the paving
site at all times, and shall check the
temperature of asphaltic concrete in
the paver hopper at regular intervals
Existing bituminous surfacing which

new bituminous mix is to adjoin
shall be cut back to present a
straight, vertical edge not less than
25 mm deep and a smooth transition
section not less than 0.5 metre long
against which to lay the new
material. The specified thickness of
the new surfacing shall be built up
gradually from the vertical joint to
avoid any bumps or ridges across the
carriageway.
Page 113
Where longitudinal or transverse

joints are required in a layer of
bituminous mix under construction,
the material first laid and compacted
shall be cut back to a vertical face for
the full thickness of the layer on a
line satisfactory to the S.O. before
the adjacent area is paved.
At all construction joints, a thin
uniform coating of bitumen emulsion
of grade RS-1 or RS-1K shall be
brushed on to the vertically cut joint
faces some 10 to 15 minutes before
laying the next section of bituminous
mix commences to ensure good
bonding. Also, all contact surfaces
of kerbs, gutters, manholes,
catchpits, etc., shall be similarly
treated with a coating of bitumen
emulsion before bituminous mix is
placed against them.
Construction joints in a layer of
bituminous mix shall be offset from
those in any immediately underlying
bituminous layer by at least 100 mm
for longitudinal joints and at least 0.5
metre, where possible, for transverse
joints.
(i) Compaction of Asphaltic
Concrete
For each layer of asphaltic concrete,
compaction by rolling shall
commence as soon after laying as the
material will support the rollers
without undue displacement;
nevertheless the temperature of
asphaltic concrete at the
commencement of rolling shall be
not less than 110C.
In any areas inaccessible to the
rollers, proper compaction shall be
carried out using vibrating plate
compactors, hand tampers or other
suitable means, all to the satisfaction
of the S.O.

Initial (or breakdown) rolling shall
be carried out with an approved steel
wheeled tandem roller or three
wheeled steel roller. The principal
heavy rolling shall be carried out
with an approved pneumatic tyred
roller immediately following the
initial rolling; the pneumatic tyred
roller shall be ballasted to an
operating weight of not less than 15
tonnes and its tyre inflation pressure
shall be not less than 0.7 N/sq.mm.
The final rolling shall be carried out
with an approved steel wheeled
tandem roller and shall serve to
eliminate minor surface irregularities
left by the pneumatic tyred roller.
All rollers shall operate in a
longitudinal direction along the
carriageway with their driven wheels
towards the paver. Rolling shall
generally commence at the lower
edge of the paved width and progress
uniformly to the higher edge, except
that where there is a longitudinal
construction joint at the higher edge,
this shall be rolled first ahead of the
normal pattern of rolling. Generally,
successive roller passes shall overlap
by half the width of the roller, and
the points at which the roller is
reversed shall be staggered.
However, when operating on
gradients in excess of 4%, the
breakdown roller shall not pass over
any previously unrolled mix when
operating in the downhill direction.
In all cases, compaction shall be
carried out in such a manner that
each section receives equal
compactive effort, all to the
The steel wheeled rollers shall
operate at speeds of not more than 5
km/hr and the pneumatic tyred
rollers shall operate at speeds of
not more than 8 km/hr. No roller or
Page 114
heavy vehicle shall be allowed to

stand on newly laid bituminous mix
before compaction has been
completed and the material has
thoroughly cooled and set. Rolling
shall continue as long as is necessary
to achieve the appropriate
requirement as follows :-
the average thickness over any 100

metre length shall be not less than
the required thickness, and the
minimum thickness at any point
shall be not less than the required
thickness minus 5 mm.
Wearing course
98 - 100% Marshall
density
The top surface of a wearing or

binder course shall have the required
Sub-Section 4.4.
Binder course
95 - 100% Marshall
density
(k) Opening to Traffic
Type of Pavement
Layer
Required Compacted
Density
Care shall be taken to prevent overcompaction of asphaltic concrete.

Within 24 hours of laying and
compacting the bituminous mix, the
Contractor shall cut core samples of
not less than 100 mm nominal
diameter at locations selected by the
S.O. The rate of sampling shall be 1
sample per 500 sq.m of mix laid, but
not less than 2 samples for the work
completed in each paving session.
These core samples shall be used by
the S.O. to determine the thickness
of the compacted layer of mix and
the compacted density of the
material in accordance with either
ASTM Test Method D 1188 or
ASTM Test Method D 2726,
whichever is applicable.
Asphaltic concrete shall not be

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

Asphaltic concrete binder and
wearing courses shall be finished in a
neat and workmanlike manner; their
widths shall be everywhere at least
those specified or shown on the
centre-line; ;
Page 115
4.2.5 Bituminous Macadam

4.2.5.1 Description
This work shall consist of furnishing,
placing, shaping and compacting
bituminous macadam roadbase
and/or levelling course and/or binder
course and/or wearing course on a
prepared and accepted bituminous or
bitumen primed pavement course,
and shall include the careful and
thorough cleaning of surfaces which
are to be covered without receiving a
bituminous tack coat. The work shall
be carried out all in accordance with
this Specification and the lines,
levels, grades, dimensions and crosssections shown on the Drawings
and/or as required by the S.O.

4.2.5.3 Equipment
The equipment shall be all as
All the provisions of Sub-Section
4.2.4.5 for the construction of
asphaltic concrete pavement courses
shall apply as appropriate to the
construction of bituminous macadam
pavement courses with the
following variations and additions.
(a) Aggregate Heating
The aggregates shall be dried and
heated so that when delivered to the
mixer they shall be at a temperature
in the range 140 oC to 160 oC.
4.2.5.2 Materials
(b) Rolling Temperature
The materials for bituminous
macadam (aggregates, mineral filler,
bituminous binder and anti-stripping
agent) shall comply with all the
requirements of Sub-Section 4.2.4.2,
except for the combined gradation
requirements.
For each bituminous macadam mix,
the gradation of the combined coarse
and fine aggregates, together with
ordinary Portland cement added as
an adhesion and anti-stripping agent
and, if necessary, any other mineral
filler, shall conform to the
appropriate envelope given in Table
4.12. The binder content shall also be
in accordance with Table 4.12.
Where the characteristics of the
aggregates require a binder content
other than that given in the above
Table, the revised target binder
content shall be agreed between the
Contractor and the S.O. and the same
tolerances shall apply.
The temperature of bituminous

macadam at the commencement of
rolling shall be not less than 100 oC.
(c) Compacted Density
The compacted density of
bituminous macadam shall be as
follows :Type of Pavement
Layer
Required Compacted
Density
Bound roadbase
90 - 100% Marshall
density
Levelling course
90 - 100% Marshall
density
Binder course
95 - 100% Marshall
density
Wearing course
98 - 100% Marshall
density
Page 116
The Marshall density of a

bituminous macadam mix is defined
as the average density of a set of
three test specimens moulded in the
same way as asphaltic concrete
specimens are prepared for the
Method T 245 using the 75 blows
per face compaction standard. The
bulk specific gravity of the
specimens shall be determined in
Method T 166.
Bituminous macadam levelling

course shall be finished in a neat and
workmanlike manner; its dimensions
shall be as specified or shown on the
Drawings or as directed by the S.O.,
all to the satisfaction of the S.O. The
top surface of bituminous macadam
levelling course shall have the
The Marshall density of each mix

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

wearing courses shall be finished in a
neat and workmanlike manner; their
widths shall be everywhere at least
those specified or shown on the
centre-line; the average thickness
over any 100 metre length shall be
not less than the required thickness,
and the minimum thickness at any
point shall be not less than the
required thickness minus 5 mm. The
top surface of a wearing or binder
course shall have the required shape,
and shall be everywhere within the
tolerances specified in Sub-Section
4.4.
(d) Finished Bituminous Macadam

Bituminous macadam roadbase shall
be finished in a neat and
workmanlike manner; its width shall
be everywhere at least that specified
or shown on the Drawings on both
sides of the centre-line; and its
average thickness over any 100
metre length shall be not less than
the required thickness. The top
surface of bituminous macadam
roadbase shall have the required
Sub-Section 4.4.2.
required shape,, superelevation,

levels and grades, and shall be every
where within the tolerances for
binder course specified in SubSection 4.4.
Page 117
TABLE 4.12 - GRADATION LIMITS AND BINDER CONTENTS

FOR BITUMINOUS MACADAM
Mix Type
Bound
Bound
Roadbas Roadbase
e
Mix
Designatio
n
BMR40
BMR28
Levelling
Course
Binder
Course
Binder
Course
Wearing
Course
Wearing
Coursex
BML10
BMB28
BMB20
BMW14
BMW20
%
Passing
by Weight
B.S. Test
Sieve
50.0 mm
37.5 mm
28.0 mm
20.0 mm
14.0 mm
10.0 mm
6.3 mm
3.35 mm
1.18 mm
300 mm
75 mm
100
95 - 100
70 - 94
56 - 76
44 - 60
32 - 46
7 - 21
2-9
100
90 - 100
71 - 95
56 - 80
44 - 60
31 - 45
7 - 21
2-8
100
85 - 100
30 - 60
15 - 25
2-6
100
90 - 100
71 - 95
58 - 82
44 - 60
32 - 46
7 - 21
2-8
100
95 - 100
65 - 85
52 - 72
39 - 55
32 - 46
7 - 21
2-8
100
95 - 100
70 - 90
45 - 65
30 - 45
15 - 30
3-7
100
95 - 100
65 - 85
52 - 72
39 - 55
32 - 46
7 - 21
2-8
Binder
Content
3.5 "
4.0 "
5.1 "
4.7 "
4.7 "
5.0 "
4.9 "
0.5%
0.5%
0.5%
0.6%
0.6%
0.5%
0.5%
Page 118
4.3
SHOULDERS
4.3.1
Description
This work shall consist of furnishing,
compacting and shaping earth or
gravel shoulder material on a
prepared and accepted subbase or
lower subbase or subgrade, all in
and the lines, levels, grades,
dimensions and cross-sections shown
on the Drawings and/or as required
by the S.O.
For paved shoulders, the bituminous
surfacing and underlying pavement
courses shall be constructed as
described in the appropriate Sections
of this Specification.
4.3.2
Materials
4.3.2.1 Earth Shoulders

Earth shoulder material shall
be suitable material as
described in Sub-Section 2.2.1.
4.3.2.2 Gravel Shoulders
Gravel shoulder material shall
conform to the requirements for
gravel surfacing material set forth
in Sub-Section 4.1.3.2.
4.3.3
Shoulders shall be constructed in
stages or in one operation as directed
or approved by the S.O., but in no
instance shall a shoulder be built up
to a level higher than that part of the
abutting carriageway structure which
has been completed and accepted.
Prior to placing any shoulder
material, the underlying subbase or
lower subbase or subgrade shall have

Sub-Section 4.1.2.3, and the abutting
carriageway structure course or
courses shall likewise have been
shaped and compacted in accordance
with the provisions of the
appropriate Sub-Section or SubSections of this Specification.
of the underlying and abutting
pavement courses, any damage to or
deterioration of these underlying
and abutting pavement courses shall
be made good to the satisfaction of
the S.O. before shoulder construction
proceeds.
Shoulders shall be placed to the
required width and thickness as
shown on the Drawings or directed
by the S.O. in one layer or more,
each layer not exceeding 200 mm
compacted thickness at the point of
maximum thickness. Where two or
more layers are required they shall
be of approximately equal shape and
thickness, and none shall be less than
100 mm compacted thickness at the
point of maximum thickness.
Each layer of shoulder material shall
be processed as necessary to bring its
moisture content to a uniform level
throughout the material suitable for
compaction, and shall then be
compacted using suitable
compaction equipment approved by
the S.O. to not less than 95% of the
maximum dry density determined in
the B.S. 1377 Compaction Test (4.5
kg rammer method). Compaction
shall be carried out in a longitudinal
direction along the shoulder and
shall generally begin at the outer
edge and progress uniformly towards
the carriageway, except on
superelevated curves where rolling
shall begin at lower edge and
progress uniformly towards the
higher edge.
Page 119
In all cases, compaction shall be

each section receives compactive
effort appropriate to its thickness, all
Throughout the placing, adjustment
of moisture content and compaction
of shoulder material, care shall be
taken to maintain a uniform
gradation of the material and prevent
its seperation into coarse and
seperate parts, all to the satisfaction
of the S.O.
Where shown on the Drawings or
directed by the S.O., earth shoulders
shall be turfed in accordance with
Shoulders shall be finished in a neat
and workmanlike manner. The total
width of carriageway and shoulder
on both sides of the centre-line. The
top surface of each shoulder shall
shall be everywhere within 10 mm
of the required plane, and shall
provide a flush joint with the
carriageway surface and shall be
uniformly free draining away from
the carriageway, all to the
4.4
HORIZONTAL ALIGNMENT,
SURFACE LEVELS AND
SURFACE REGULARITY OF
PAVEMENT COURSES
4.4.1
Horizontal Alignment
The horizontal alignment shall be
determined from the centre-line of
the pavement surface shown on the
Drawings. The edges of the
pavement as constructed and all
other parallel construction lines shall
be correct within a tolerance of + 50

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

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

LEVELS OF PAVEMENT COURSES
Pavement Course
Tolerance
Wearing Course
+ 5 mm
Binder Course
+ 5 mm
Roadbase
+ 0 mm
- 20 mm
Subbase and Lower

Subbase
+ 10 mm
- 20 mm
The combination of permitted

tolerances in the levels of different
pavement courses shall not result in a
pavement thickness less than that
shown on the Drawings. Each
pavement course shall have an
average thickness not less than that
Page 120
4.4.3
Surface Regularity
The traverse length of 300 m and its

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

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

is less than 300 m the measurements
shall be taken on 75 m lengths.
The transverse regularity of a newly
laid surface shall be measured with a
3 m straight-edge and shall have no
greater depression under the
straight-edge than that shown in
Table 4.14
TABLE 4.14 - TOLERANCES FOR SURFACE IRREGULARITIES
Class of
Surface
Regularity
Longitudinal Direction
Transverse
Direction
Maximum Permissible Number

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

Surface Regularity and no longitudinal irregularity exceeding 15 mm shall be
permitted for Class SR2 and Class SR3 Surface Regularities.
The class of Surface Regularity for each portion of the Works shall be as stated on
the Drawings or in the Bills of Quantities.
Page 121
SECTION 5
PORTLAND CEMENT
CONCRETE PAVEMENT
Page 122
SECTION 5 - PORTLAND CEMENT CONCRETE PAVEMENT

Page
5.1
DESCRIPTION
S5-125
5.2
MATERIALS
S5-125
5.2.1
Cement
S5-125
5.2 2
Aggregate
S5-125
5.2.3
Joint Filler
S5-125
5.2.4
Joint Sealants and Seals
S5-125
5.2.5
Waterproof Membrane
S5-126
5.2.6
Curing Materials
S5-126
5.3
PRODUCTION OF CONCRETE
S5-128
5.3.1
Concrete
S5-128
5.3.2
Equipment
S5-128
5.4
CONSTRUCTION
5.4.1
Preparation of Subgrade or Subbase
S5-128
S5-128
5.4.2
Construction by Machine
5.4.2.1 Fixed Forms, Rails and Guide Wires For Machine Construction
5.4.2.2 Construction by Fixed Form Paving Machine
5.4.2.3 Construction by Slip Form Paving Machine
5.4.3
Construction by Hand-Guided Method
S5-128
S5-128
S5-129
S5-131
S5-132
5.4.4
Manual Construction
5.4.4.1 Side Forms for Manual Construction
S5-132
S5-133
Page 123

Page
5.5
JOINTS
5.5.1
Transverse Expansion Joints
S5-133
S5-133
5.5.2
Transverse Contraction Joints
5.5.2.1 Planes of Weakness
5.5.2.2 Load Transfer Assemblies
S5-134
S5-134
S5-135
5.5.3
Longitudinal Joints
S5-135
5.5.4
Transverse Construction Joints
S5-135
5.5.5
Sealing Joints
S5-135
5.5.6
Concrete Saw
S5-136
5.6
SURFACE TEXTURE
5.6.1
Texture of Running Surfaces
5.6.2
Measurement of Texture Depth : Sand Patch Method
5.6.2.1 Apparatus
5.6.2.2 Method
S5-136
S5-136
S5-137
S5-137
S5-137
5.7
ROUNDING OF EDGES
S5-137
5.8
CURING
S5-137
5.9
REMOVING FORMS
S5-138
5.10 OPENING TO TRAFFIC
S5-139
5.11 TREATMENT OF MANHOLES AND GULLIES
S5-139
5.12 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND

SURFACE REGULARITY
S5-139
Page 124
SECTION 5 - PORTLAND CEMENT

CONCRETE PAVEMENT
5.1
DESCRIPTION
This work shall consist of constructing a
Portland cement concrete pavement with
or without reinforcement in accordance
with this Specification, including all
relevant requirements of Section 9,
and in conformity with the lines,
levels, grades, dimensions and
crosssections shown on the Drawings.
Portland cement concrete shall consist
of a mixture of Portland cement, fine
aggregate, coarse aggregate and water,
with or without admixture.
5.2
MATERIALS
All materials shall conform to the
relevant requirements in Section 9 of
this Specification. In addition the
following requirements shall also be
complied with.
5.2.1
Cement
Cement shall be ordinary Portland
cement unless otherwise shown on
the Drawings or directed by the S.O.
5.2 2
Aggregate
Coarse aggregate to be used for at
least the top 50 mm of the slab shall
have a polished stone value of not
less than 40.
5.2.3
Joint Filler

5.2.4
Joint Sealants and Seals

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

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

AASHTO M153 or M213.
Page 125
(c) Gunning Grade Sealants

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

It shall have test certificates from an
approved testing laboratory to show
that the compound has a curing
efficiency of 90%.
The curing compound shall contain
sufficient flaked aluminium in finely
divided dispersion to produce
complete coverage of the sprayed
surface with a metallic finish. The
curing compound shall not react
chemically with the concrete to be
cured and shall not crack, peel or
disintegrate within 2 weeks after
application.
Waterproof Membrane
Plastic sheeting shall have a
minimum thickness of 125 um and
shall be of a quality as approved by
the S.O.
5.2.6
Curing Materials
The exposed surface of concrete
pavements shall be cured
immediately after the surface
treatment by the application of one
of the following curing materials :(a) White Pigmented Liquid
Membrane-Forming Compound
White pigmented liquid membraneforming compound shall conform to
the requirements of AASHTO
M148, Type 2.
(b) Aluminised Curing Compound
Aluminised curing compound
shall be stable and impervious to
evaporation of water from the
concrete surface within 60
minutes after application.
Page 126
TABLE 5.1 - SPECIFICATION FOR PREFORMED NATURAL RUBBER COMPRESSION

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

100 oC, maximum.
40
Ageing Resistance, maximum

change from unaged values after
72 hrs + 0 hrs at 100 oC :- 2 hrs
- hardness
- tensile strength
- elongation at break.
Ozone Resistance, 20%

elongation, 96 hours at
140 oC, 50 pphm.
Change in Volume after

immersion in water for 7 days at
laboratory temperature,
maximum.
Recovery of Finished Seals,

under 50% deflection, after
72 hrs + 0 hrs at 100 oC.
- 2 hrs
IRHD
%
%
0 to + 10
- 20
- 25
No cracking
0 to + 5
85
Note : All tests are in accordance with ISO Standards.
Page 127
5.3
5.3.1
Concrete
Concrete shall be of the grade shown
on the Drawings and shall comply
with the relevant requirements of
5.3.2
CONSTRUCTION
5.4.1
Preparation of Subgrade or Subbase

Prior to placing concrete pavement,
the underlying subgrade or subbase
shall have been shaped and
compacted in accordance with the
provisions of Sub-Sections 2.2.7 or
4.1.2 as appropriate and the
waterproof membrane laid as
required in the Drawings.
of finished subgrade or subbase, any
damage to or deterioration of the
subgrade or subbase shall be made
good to the satisfaction of the S.O.
before the waterproof membrane is
laid and the concrete pavement
constructed.
5.4.2
Prior to the placing of concrete, all

of the required joint assemblies such
as dowel bars, tie bars, etc., shall be
installed in accordance with the
requirements of Sub-Section 5.5. In
one-layer construction, the slab
reinforcement shall also be installed
and fixed in accordance with the
relevant requirements of Section 9.
Equipment
All equipment used such as batching
plant and mixers shall comply with
the relevant requirements of Section
9 of this Specification.
5.4
Construction by Machine
The concrete slab shall be
constructed either by fixed form or
by slip form paving plant in a
continuous process in either one or
two layers, as approved by the S.O.
In two-layer construction, the

thickness of the top layer shall be not
less than 50 mm or twice the
maximum size of the coarse
aggregate, whichever is the greater,
and shall be at least 15 mm thicker
than the depth of the groove former,
if used. Placement of reinforcement
and concreting of the top layer shall
be done immediately, and in any
case not more than 30 minutes, after
the completion of the bottom layer.
5.4.2.1 Fixed Forms, Rails and Guide
Wires For Machine Construction
(a) Fixed Forms and Rails
All forms and rails shall be made
of steel and be sufficiently robust
and rigid to support the weight
and pressure caused by the
paving equipment. Side forms
for use with wheeled paving
machines shall incorporate metal
rails firmly fixed at a constant
height below the top of the forms.
The forms shall be secured by
using not less than three pins for
each 3 m length, having one pin
fixed at each side of every joint.
Forms shall be tightly joined
together by a locked joint, free
from play or movement in any
direction.
Page 128
Forms shall be cleaned and oiled

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

form paving plant. (Each guide
wire shall be at a constant height
above and parallel to the required
edges of the slab within a vertical
tolerance of 3 mm. In addition,
one of the wires shall be at a con
stant horizontal distance from the
required edge of the pavement
within a lateral tolerance of 10
mm.
The guide wires shall be
supported from stakes not more
than 8 m apart by connectors
capable of fine horizontal and
vertical adjustment. The guide
wire shall be tensioned on the
stakes so that a 500 gramme
weight shall produce a deflection
of not more than 20 mm when
suspended at the mid-point
between any pair of stakes. The
ends of the guide wires shall be
anchored to fixing points which
shall be not closer to the edge of
the slab than the row of stakes
and in no circumstances shall a
guide wire be anchored to a
stake.
The stakes and guide wires shall
be checked and approved by the
S.O. prior to concreting.
5.4.2.2 Construction by Fixed Form
Paving Machine
A fixed form paving train shall
consist of separate powered
machines which spread, compact
and finish the concrete in a
continuous operation.
Concrete shall be discharged
without segregation into a hopper
spreader which is equipped with
the means to control its rate of
deposition on to the subbase or
on to the lower layer. . The con
crete shall be spread in each layer
Page 129
without segregation and to a

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

The regulation and finishing of
the surface of the slab shall be
carried out by a machine which
incorporates twin oblique
oscillating finishing beams which
shall be readily adjustable for
both height and tilt. The beams
shall weigh not less than 170 kg
per linear metre, be of rectangular
section and span the full width of
the slab. The leading beam shall
be vibrated. The beams shall be
supported on a carriage, the level
of which shall be controlled by
the average level of not less than
four points evenly spaced over at
least 3.5 m of the supporting rail,
beam, or slab, on each side of the
slab that is being constructed.
The final regulation and surface
finishing of the slab shall be
carried out after any wet forming
of joint grooves. After the final
regulation and before texture is
applied, any excess concrete on
top of the groove former shall be
removed.
When a concrete slab is
constructed in more than one
width, flanged wheels on the
paving machines shall not be run
directly on the surface of any
completed part of the slab. The
second or subsequent slabs shall
be constructed either by
supporting machines with flanged
wheels on flat- bottom section
rails weighing not less than 15
kg/m laid on the surface of the
completed slab, or by replacing
the flanged wheels on that side of
the machine by smooth flangeless
wheels. Before flangeless wheels
or rails are used, the surface
regularity of the slab over which
they are to pass shall comply
with Sub-Section 5.4.1 and its
surface shall be thoroughly
cleaned and brushed to remove
Page 130
all extraneous matter. Flangeless

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

guide wires by at least one sensor
attached to the paver. The
alignment and level of ancillary
machines for finishing, texturing
and curing of the concrete shall
be automatically controlled
relative to the guide wires or to
the surface and edge of the slab.
Slip form paving machines shall
have vibration of variable output,
with a maximum energy output
of not less than 2.5 kW per metre
of slab per 300 mm depth of slab
for a laying speed of up to 1.5 m
per minute or pro rata for higher
speeds. The machines shall be of
sufficient mass to provide
adequate reaction on the traction
units to maintain forward
movements during the placing of
concrete in all situations.
Joint grooves shall be constructed
in compliance with Sub-Section
5.5. The concrete shall be
compacted around the former by
a separate vibrating plate
compactor with twin plates. The
groove former shall be
compacted to the correct level by
another vibrating float which may
be included with the transverse
joint finishing beam. In addition
a hand held vibrating float, at
least 1 m wide, shall be drawn
over the surface along the joint.
Any excess concrete on top of the
groove former shall be removed
before the surface is textured.
Where a concrete surface slab is
constructed in more than one
width or where the edge needs to
be matched for level to another
section of surface slab, and the
surface levels at the edges are not
achieved, paving shall be carried
out over separate fixed side forms
supporting the edge to the
required levels.
Page 131
5.4.3
Construction by Hand-Guided
Method
Details of joints shall be as shown on

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

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

as described in Sub-Section 5.6.
The concrete shall be cured in
compliance with Sub-Section 5.8.
5.4.4
Manual Construction
Areas to be constructed by manual
method shall be agreed with the S.O.
The slabs shall be constructed in one
layer. Dowel bars, tie bars and
reinforcement, if specified, shall be
fixed in position as shown on the
Drawings.
The concrete shall be spread
uniformly without segregation or
varying degrees of pre-compaction,
by conveyor, chute or by other
concrete shall be struck off by a
screed so that the average and
differential surcharge is sufficient to
ensure that after compaction the
surface is to the required level.
The concrete shall be compacted by
internal poker vibrator or other
vibrations shall be at points not more
than 500 mm apart over the whole
Page 132
area of the slab, and adjacent to the

side forms or the edge of a
previously constructed slab.
As soon as surplus water has risen to

the surface, the pavement shall be
given a broomed finish.
The surface shall be regulated and

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

Construction
All side forms shall be made of
steel and be sufficiently robust
and rigid to withstand
construction forces. Timber
forms shall only be used for work
which is less than 200 m in
length.
The forms shall comply with
other requirements of SubSection 5.4.2.1 as appropriate.
5.5
JOINTS
Joints shall be constructed as specified
herein and/or as directed or approved by
the S.O. Before any joint materials are
set in place, the underlying pavement
course at those locations shall have been
Preformed expansion joint filler shall be
placed around each structure which
extends into or through the pavement
over the full interface with the concrete
pavement slab before concrete is placed.
5.5.1
Transverse Expansion Joints

The components for each transverse
expansion joint shall be assembled in
advance and placed in position as a
unit.
Each assembly shall consist of an
installing template, preformed joint
filler of the required dimensions in a
single piece, dowel bars and sleeves
of the required sizes and lengths at
the required locations, and spacing
and supporting elements for the
dowel bars, as shown on the
Drawings.
Page 133
The installing template shall be

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

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

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

(a) Sawn Grooves
When sawn grooves are specified
they shall be sawn in the con
crete after its initial set.
Grooves shall be at right angles
to the centre line of the
pavement, shall be true to line
and shall have the width and
depth shown on the Drawings.
All joints shall be sawn before
uncontrolled shrinkage cracking
takes place but not until the
concrete has hardened to the
extent that tearing and ravelling is
not excessive, usually 4 to 24
hours after placing. If extreme
conditions exist which make it
impracticable to prevent erratic
cracking by early sawing, formed
grooves shall be used.
Any procedure for sawing joints
that results in premature and
uncontrolled cracking shall be
revised immediately by adjusting
the sequence of cutting the joints
or the time interval involved
between the placing of the con
crete or the removal of the curing
medium and cutting of the joints.
Page 134
(b) Formed Grooves

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

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

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

When adjacent lanes of pavement
are constructed separately, steel side
forms shall be used which will form
a key along the longitudinal joint as
5.5.4 Transverse Construction Joints
Concreting operations shall be
planned such that transverse
construction joints shall be
constructed at designed transverse
expansion or contraction joints.
Transverse construction joints shall
be keyed or butt joints formed by
placing suitable bulkheads approved
by the S.O.
When there is an interruption of
more than 30 minutes in the
concreting operations, a transverse
construction joint shall be
constructed. As far as is practicable,
this construction joint shall be
formed at a designed transverse
expansion or contraction joint.
When this is not possible, transverse
constructed at least 3 metres from all
transverse expansion or contraction
joints. In such cases, tie bars 12 mm
in diameter and 1 metre long at 600
mm centres shall be placed at the
transverse construction joints. Wire
fabric or bar mat reinforcement shall
extend across all such transverse
construction joints.
5.5.5 Sealing Joints
Joints shall be sealed as soon after
completion of the curing period as
feasible and before the pavement is
opened to traffic, including
construction traffic. Immediately
prior to sealing, each joint shall be
thoroughly cleaned of all foreign
material, including membrane curing
Page 135
compound, and the joint faces shall

be clean and surface dry when the
seal is applied.
units and power to complete the

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

in accordance with the dimensions
Sealing material to be applied hot
shall be stirred during heating so that
localized overheating does not occur.
The pouring shall be done in such a
manner that the material will not be
spilled on to the exposed surfaces of
the concrete. Any excess material on
the surface of the concrete pavement
shall be removed immediately and
the pavement surface cleaned. The
use of sand or similar material as a
cover for the seal will not be
permitted.
Preformed compression seals for
sealing joints shall be of the crosssectional dimensions shown on the
Drawings. Seals shall be installed
using suitable tools, without
elongation, and secured in place with
an approved adhesive which shall
cover both sides of the concrete
joints. The seals shall be installed in
a compressed condition and shall at
time of placement be below the level
of the pavement surface by
approximately 5 mm. The seals
shall be in one piece for the full
width of each transverse joint.
Notwithstanding the above, all
sealants shall be applied or installed
manufacturer's instructions or
recommendations.
5.5.6
Concrete Saw
5.6
SURFACE TEXTURE
5.6.1 Texture of Running Surfaces
After the final regulation and before
the application of the curing
membrane, the surfaces of concrete
slabs to be used as running surfaces
shall be brush-textured in a direction
at right angles to the centre line of
the carriageway.
The type of brush and method of
application for surface texturing shall
be approved by the S.O. based on
trial brushing to be conducted by the
Contractor.
The texture depth shall be
determined by the sand patch test as
described herein.
The average texture depth for each
set of 10 tests shall not be less than
0.75 mm and not more than one test
of each set shall show a texture depth
of less than 0.65 mm. In no case
shall the maximum texture depth
exceed 2 mm.
When sawing of joints is specified,

the Contractor shall provide sawing
equipment adequate in number of
Page 136
5.6.2 Measurement of Texture Depth :

Sand Patch Method
31000 where D is the diameter of the of the

D x D patch in mm.
5.6.2.1 Apparatus
5.7
i) A cylindrical container - 25
ml capacity.
Where shown on the Drawings or

directed by the S.O., edges of concrete
slabs shall be rounded as follows.
ii) A flat wooden disc 64 mm in

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

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

300 um B.S. sieve and
retained on a 150 um B.S.
sieve.
At all transverse joints, any tool marks a

ppearing on the slab adjacent to the
joints shall be eliminated by brooming
the surface. In doing this, the rounding
of the edge of the slab shall not be
disturbed. All concrete on top of joints
shall be removed completely.
5.6.2.2 Method
The surface to be measured shall
be dried, any extraneous mortar
and/or loose material removed,
and the surface swept clean using
a wire brush both at right angles
and parallel to the centre line of
the carriageway. The cylinder
shall be filled with the sand,
tapping the base three times on a
hard surface to ensure
compaction, and striking off the
sand, level with the top of the
cylinder. The sand shall be
poured into a heap on the surface
to be tested. The sand shall be
spread over the surface, working
the disc with its face kept flat, in
a circular motion so that the sand
is spread into a circular patch
with the surface depressions
filled with sand to the level of the
peaks.
The diameter of the patch shall
be measured to the nearest 5 mm.
The texture depth in mm of
concrete surfaces shall be
calculated as:-
ROUNDING OF EDGES
5.8
CURING
The exposed surfaces of concrete
pavement shall be cured immediately
after surface texturing and rounding of
edges by treating with a curing
compound fulfilling the requirements of
Sub-Section 5.2.6. It shall be
mechanically sprayed on to the surface
at a rate of 0.22 to 0.27 litre per square
metre using a fine spray. The
mechanical sprayer shall incorporate an
efficient mechanical device for
continuous agitation and mixing of the
compound in its container during
spraying. For the sides of slip formed
slabs or when the side forms are
removed within the curing period, and
for small areas where a mechanical
distributor cannot be used, the
compound shall be sprayed by hand
lance at a rate of 0.27 to 0.36 litre per
square metre.
Page 137
The compound shall form a uniform,

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

protected from the effects of solar
radiation by the use of frames
covered with material with heat and
rain deflecting properties for not less
than 4 hours after application of the
curing compound.
Notwithstanding the foregoing, concrete
surfaces which are subjected to heavy
rainfall within 3 hours after the curing
compound has been applied shall be
resprayed, all as specified above at no
additional cost.
Concrete liable to be affected by running
water shall be adequately protected from
damage during the setting period.
5.9
REMOVING FORMS
Forms shall not be removed until the
freshly placed concrete has set for at
least 6 hours. The forms shall be
removed carefully so as to avoid
damage to the pavement.
As soon as forms are removed, the ends
of all expansion joints shall be cleaned
of concrete and the full width of the
filler exposed for the full depth of the
slab. Any areas showing a minor degree
of honeycombing shall be repaired with
1:3 cement mortar. Where the S.O.
considers that a major degree of
honeycombing is present, the work shall
be considered defective and shall be
removed and replaced at the expense of
the Contractor. In such cases, the
section of concrete removed shall be to
the full width and depth of the slab and
at least 3 metres long.
Page 138
5.10 OPENING TO TRAFFIC

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

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

traffic or other cause prior to its final
acceptance shall be repaired or replaced
all at the expense of the Contractor in a
manner suitably satisfactory to the S.O.
5.11 TREATMENT OF MANHOLES
AND GULLIES
Manhole covers, gullies and their frames
shall be isolated from the main
pavement slab as shown on the
Drawings and their surrounds cast in
separate operations.
Manholes and gully recesses shall be
formed by casting the main slab against
formwork boxes with vertical sides,
placed and fixed accurately. The
formwork boxes shall be removed
before the concrete around the manhole
or gully cover is to be placed and
preformed joint filler, 20 mm thick,
Page 139
SECTION 6
ROADSIDE FURNITURE
Page 140
SECTION 6 - ROAD FURNITURE

Page
6.1
CORRUGATED SHEET STEEL BEAM HIGHWAY GUARDRAIL
6.1.1
Description
S6-143
S6-143
6.1.2
6.1.2.1
6.1.2.2
Materials
Beam Element
Posts
S6-143
S6-143
S6-143
6.1.3
6.1.3.1
6.1.3.2
6.1.3.3
Installation of Guardrails
Setting Posts (Timber or Steel)
Placing Beams
Anchorages
S6-144
S6-144
S6-144
S6-144
6.1.4
6.1.4.1
6.1.4.2
Marking and Storage

Marking
Storage
S6-144
S6-144
S6-144
6.1.5
6.1.5.1
6.1.5.2
Basis of Acceptance
Beam Elements
Posts and Block-Outs
S6-144
S6-144
S6-145
6.2
TRAFFIC SIGNS
S6-145
6.2.1
Description
S6-145
6.2.2
Sign Definitions
S6-145
6.2.3
Sign Classification
S6-145
6.2.4
Standards
S6-146
6.2.5
6.2.5.1
6.2.5.2
6.2.5.3
6.2.5.4
6.2.5.5
6.2.5.6
6.2.5.7
6.2.5.8
6.2.5.9
Permanent Traffic Signs

Foundations
Posts
Sign Plate
Sign Faces
Backing Frames
Construction and Assembly
Location and Erection
Covering of Permanent Traffic Signs
S6-146
S6-146
S6-146
S6-147
S6-147
S6-148
S6-149
S6-149
S6-151
S6-151
Page 141

Page
6.2.6
S6-152
6.2.7
Traffic Signs On Gantries
S6-152
6.2.8
Preparation and Finish of Metal and Other Surfaces
S6-152
6.3
ROAD MARKINGS
S6-153
6.3.1
Description
S6-153
6.3.2
Road Marking Materials
S6-153
6.3.3
Preparation of Site
S6-153
6.3.4
Preparation of Material on Site
S6-154
6.3.5
Laying
S6-154
6.3.6
Protection of Markings
S6-154
6.3.7
Reflectorisation
S6-154
6.3.8
Thickness
S6-154
6.3.9
Tolerance on Width
S6-156
6.3.10
Defective Materials or Workmanship
S6-156
6.3.11
Clearing Up
S6-156
6.4
CONCRETE KERB
S6-157
6.4.1
Description
S6-157
6.4.2
Materials
S6-157
6.4.3
6.4.3.1
6.4.3.2
6.4.3.3
6.4.3.4
6.4.3.5
Installation of Kerbs
Excavation
Cast In Situ Kerb
Precast Concrete Kerb
Slipforming for Concrete Kerb
Backfilling
S6-157
S6-157
S6-157
S6-157
S6-158
S6-158
Page 142
SECTION 6 - ROAD FURNITURE

6.1
CORRUGATED SHEET STEEL

BEAM HIGHWAY GUARDRAIL
6.1.1
Description
and installation of corrugated sheet
steel beam highway guardrails
inclusive of bolts, nuts, posts and
other ancillary works, all in
accordance with this Specification,
and the Drawings, and as directed by
the S.O.
6.1.2
Materials
6.1.2.1 Beam Element

Unless otherwise specified on the
Drawings, corrugated sheet steel
beam highway guardrails shall
AASHTO Specification M180
for Class À' Type II (galvanised)
guardrail with effective length of
beam 3810 mm (12 feet 6
inches). Guardrails shall be
fabricated and furnished complete
with terminal or buffer sections,
connecting and splicing bolts,
nuts and washers, etc., all
conforming to the requirements
of AASHTO Specification M180
and as necessary for erecting the
guardrails as shown on the
Drawings or as required by the
S.O.
6.1.2.2 Posts

if used, shall be channel sections
of dimensions as shown on the
Drawings and shall be of the
same material as that used for the
posts. Both the posts and blockout pieces shall be hot-dip
galvanised in accordance with
(b) Timber Posts
Timber posts and block-out
pieces shall be of medium
hardwood (except the species
Merpauh and Rengas) as
classified by the Malaysian
Timber Industry Board in its
publication `Malaysian
Hardwood', and shall be treated
according to M.S. 733. The
preservative retention in the
outermost 25 mm shall not be
less than 16 kg per cubic metre.
Heavy hardwood can also be
used as an alternative with the
Guardrail timber posts and blockout pieces shall be of the
Drawings. The fibres of the block
should run in the same direction
as those of the post. The post
shall be sound and free from
loose knots or decay with no
cracks at the top. All cut faces
shall be smooth and square as
All timber components shall be
cut and drilled before treatment
with preservative.
(a) Steel Posts

Steel posts shall be channel
sections of dimensions as shown
on the Drawings and the material
shall conform to B.S. 449 Part 1
Grade 43. The block-out pieces,
Page 143
6.1.3
Installation of Guardrails
6.1.3.1 Setting Posts (Timber or Steel)

6.1.4
6.1.4.1 Marking
Before posts are erected, the

alignment and finished levels of
the guardrails shall be set
accurately on site for approval by
the S.O.
Post holes at the correct positions
shall be dug either manually or
mechanically to the required
level. The posts shall then be set
plumb in the holes with the front
face forming a smooth line to the
approval of the S.O. After the
posts are in place, the holes shall
be backfilled with grade 20/20
concrete compacted in such a
manner as not to displace the
posts from correct alignment as
shown on the Drawings. Posts
may be installed by means of
driving with suitable equipment if
the S.O. is satisfied that the
Contractor is capable of installing
the post to the designed depth,
line and level, accurately.
Posts shall be spaced as indicated
on the Drawings.
6.1.3.2 Placing Beams
The guardrail beams shall be
fixed and firmly bolted together
with the block-out pieces on to
the post to the lines and grades as
shown on the Drawings, and as
6.1.3.3 Anchorages
Anchorages shall be constructed
as shown on the Drawings and as
Marking and Storage
In addition to the marking

specified in AASHTO
Specification M180, the JKR
logo shall also be marked on each
beam element.
6.1.4.2 Storage
All galvanised beam elements,
terminal sections, bolts, nuts and
washers and posts shall be stored
under a cover that will protect
them from rain until they are
erected or used. While in
storage, the material shall not be
in direct contact with the soil and
there shall be a minimum space
of 300 mm between the lowest
most elements and the ground
surface.
6.1.5
Basis of Acceptance
6.1.5.1 Beam Elements

All material shall be subjected to
inspection and sampling in
accordance with AASHTO
Specification M180 at a sampling
rate of 1 in every 200 or as
arrange the testing facilities and
the test pieces as and when
requested by the S.O. The cost of
all sampling and testing shall be
borne by the Contractor. If, in
the subsequent installation, there
is detection of non-compliance
with the requirements of this
Specification through random
sampling carried out by the S.O.,
then the material of the lot will be
rejected and the Contractor shall
remove the same from the Site at
his own cost.
Page 144
6.1.5.2 Posts and Block-Outs
It shall include all excavation and

backfilling, all necessary
foundations, anchorages, fixtures
and fastenings, brackets, lighting
units and electrical installations
where required, application of paints
and finishes, etc., to complete the
work all to the satisfaction of the
S.O.
(a) Steel
For each lot of 200 pieces or less
of either steel posts or steel
block-outs supplied to the Site,
the Contractor shall submit
certificates from an approved
testing laboratory certifying
compliance with the properties
required and the mill certificate.
However, the S.O. reserves the
right to conduct further tests on
the materials supplied.
6.2.2
Sign Definitions
For the purpose of this Specification,
traffic signs are defined as follows :i) Non-illuminated signs are those
signs which are not lit either
internally or externally and shall
be retro-reflective;

arrange the testing facilities and
test samples at his own expense
as and when instructed by the
S.O. The steel which has been
rejected by the S.O. shall be
removed from the Site.
ii) Externally illuminated signs are

those which comprise either
retro-reflective or non-retroreflective facing with external
lighting luminaire.
(b) Timber
6.2.3
For each lot of 200 pieces or
less of either timber posts or
timber block-outs supplied to the
Site, the Contractor shall submit
a test report from an approved
testing laboratory certifying
compliance with specified timber
species and other qualities.
However, the S.O. reserves the
right to conduct further tests on
the materials supplied.
6.2
TRAFFIC SIGNS
Sign Classification
For the purpose of this Specification,
the following clasifications shall
apply :(a) Permanent Traffic Signs
Any of the traffic signs defined in
Sub-Section 6.2.2 above or any part
thereof as designated on the
Drawings or as directed by the S.O.
to remain in position upon
(b) Temporary Traffic Signs
6.2.1
Description
This work shall consist of the supply,
assembly, erection and installation
of sign faces, sign plates, posts and
backing frames, all in accordance
with the details shown on the
Drawings and as specified herein.
Any of the traffic signs defined in

Sub-Section 6.2.2 above or any part
thereof designed by the Contractor
with the approval of the S.O. which
will not remain in position at the
Page 145
6.2.4
Standards
All traffic signs shall, except where
specified otherwise, comply with the
requirements of ARAHAN TEKNIK
(JALAN) Series 2, published by
Cawangan Jalan, Ibu Pejabat JKR,
Kuala Lumpur.
6.2.5
Permanent Traffic Signs
6.2.5.1 General Requirements

Permanent traffic signs shall be
constructed, assembled, located
and erected as shown on the
S.O.
Each complete traffic sign or part
thereof shall be capable of
passing the tests specified in B.S.
873.
All externally illuminated traffic
signs shall comply with Category
1 luminance of B.S. 873 unless
otherwise shown on the
Drawings.
Before the commencement of
fabrication of any traffic sign,
Drawings, the Contractor shall
submit for the S.O.'s approval
the details of fabrication drawings
for all signs.
All traffic sign housings shall be
provided with vandal and
weather resistant locks. Keys, in
the quantities determined by the
S.O., shall be provided to the
S.O. Types of lock shall be kept
to a minimum.
Traffic signs shall be carefully
handled to prevent damage
(methods shall include the use of
proper slings), and shall be

transported and stored in
accordance with the
6.2.5.2 Foundations
The type and size of foundations
for permanent traffic signs shall
be as shown on the Drawings
and, unless otherwise stated
therein, shall comply with this
Specification.
All excavations, erection of
formworks, placing of
reinforcement, etc., for
foundations shall be carried out in
compliance with this
Specification and shall be
approved by the S.O. before
placing of concrete and
backfilling.
Drawings, signs supported by a
single post placed in the ground
shall have the post installed
centrally in 300 mm diameter
holes filled with grade 20/20
concrete complying with Section
9 of this Specification to within
450 mm of the ground surface.
The hole shall be excavated
either mechanically or manually.
Posts shall be supported for a
minimum of three (3) days after
placing the concrete. Backfilling
shall not take place until at least
48 hours after placing the
concrete, or other period agreed
by the S.O.
Where signs are illuminated,
provision shall be made for cable
entry through the foundation by
means of ducting as shown on
the Drawings.
Page 146
Where pockets are formed in

concrete foundations their plan
dimensions shall be 100 mm
larger than those of the post.
All backfilling of foundation pits
and reinstatement of existing
surfaces above the foundations
shall comply with the relevant
requirements of this
Specification.
6.2.5.3 Posts
Posts for permanent traffic signs
Drawings and shall comply with
B.S. 873.
Posts shall be of tubular hollow
section steel of not less than 50
mm outside diameter complying
with B.S. 1387.
Drawings, posts shall not
protrude above the top of the sign
unless supporting an external
luminaire where the protrusion
shall be kept to a minimum.
Signs erected on a single post
shall be positioned so that the
post is in the centre of the sign,
Drawings.
Compartments for electrical
equipment shall be as shown on
the Drawings. In the case of signs
supported by more than one post,
such compartments shall be on
the post furthest from the
carriageway unless otherwise

6.2.5.4 Sign Plates
All permanent sign plates shall be
as shown on the Drawings and
shall comply with B.S. 873.
Sign plates shall be made of 10
S.W.G. sheets of aluminium alloy
HS 30-WP conforming to B.S.
1470 with a minimum thickness
of 3 mm.
A sign plate not exceeding 1.2 m
in height and 2.4 m in width
shall be made from a single sheet.
Where more than one sheet is
used to make up a sign plate, the
sheets shall be rectangular, of
approximately the same size and
shape, and the position of the
joints shall be to the approval of
the S.O.
Sign plates shall be drilled at all
locations where rivets or bolts are
required for attaching the plate to
the backing frame or fixings
before application of the sign
face. However, riveting shall be
carried out only after the
application of the sign face.
Subject to the S.O.'s approval,
double sided "Very High Bond"
(V.H.B.) tapes may be used as an
alternative to rivets. Nevertheless,
the tape shall comply with the
following requirements :i) Peel Adhesion - 440 N per
100 mm;
ii) Tensile Adhesion - 910 kPa;
iii) Dynamic Shear -550 kPa.
Flange plates shall have holes or

slots as shown on the Drawings
to accommodate any holding
down bolts.
Page 147
Where top and bottom light spill

screens are required as shown on
the Drawings, these shall extend
for the whole width of the sign,
be fabricated out of the same
material as the sign plate and
shall have corners cut to the same
radius as the other corners of the
sign plate.
Top and bottom light spill screens
shall be considered part of the
sign plate and any stiffeners and
mounting fittings shall be
designed to accommodate the
combined size.
6.2.5.5 Sign Faces
Sign faces for permanent traffic
signs shall be as shown on the
the `Draft Malaysian Standard
Specification for Reflective Sign
Face Materials' (SIRIM
Reference D111 [ISCF]), and on
replacement of this draft, the
respective Malaysian Standard
Specification.
All retro-reflective plastic
sheeting shall be fixed in
accordance with the
S.O., sign faces shall be formed
from a single piece of plastic
sheeting.
Where, with the agreement of the
S.O., more than one plastic sheet
is used, the number of sheets
shall be kept to a minimum. All
faces up to 1 m in size shall be
produced with a single sheet and
no joint will be accepted.

Only vertical and horizontal
joints shall be permitted and all
joints in plastic sheeting shall be
overlapped by not less than 6
mm. The overlap in the
horizontal joints shall be from the
top and the vertical joints shall be
from the left; butt joints in plastic
sheeting will not be accepted.
Plastic sheeting shall be applied
evenly over the whole surface of
the sign plate and shall adhere
fully. It shall be free from twists,
cracks, folds or cuts, air bubbles
and other blemishes.
All plastic sheetings used on the
same sign shall be carefully
matched for colour to produce a
uniform appearance both by day
and by night. Non-uniform
shades of colour on any one sign
will not be accepted.
The edges of all plastic sheeting
shall be sealed. Edge sealing shall
be continuous and uniform and
shall also be applied to all bolt
and rivet holes.
A coat of clear lacquer shall be
applied to the whole of the face
and edges of each finished sign
plate at the time of fabrication.
The lacquer shall be continuous
and uniform and shall be of the
type specified or supplied by the
manufacturer of the sheeting
material.
Where sheeting is applied to
extruded sections by pressure
roller, it shall extend over the top
and bottom edges of these
sections by not less than 3 mm.
Page 148
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
Screen processed letters,
numerals, symbols and borders
shall be screen printed with
materials in accordance with the
sheeting manufacturer's
instructions. Any inks, pastes and
finishing coats used shall be
compatible with the sheeting
material.
The finish of all sign faces shall
be capable of passing the tests
described in B.S. 873, and the
standards of fabrication and
workmanship shall be such that
under normal conditions of
service and proper maintenance,
the sign faces shall last not less
than 5 years without any serious
blemishes or defects for
Engineering Grade retroreflective sheeting and 8 years
for High Intensity retro-reflective
sheeting. The Contractor shall
furnish to the S.O. a letter of
warranty for the specified period
for all sign faces from the
supplier of the sheeting or the
sign fabricator.
6.2.5.6 Backing Frames

fabricated from 40 mm x 40 mm
x 3 mm angles. The angles used
for the backing frames shall be
made from aluminium alloy
HE9-TE conforming to B.S.
1474.
The angles shall be welded,
bolted or riveted together to form
the backing frames as shown on
the Drawings.
Backing frames shall not project
beyond the face of the sign.
Where large signs are built in
sections, the backing frames of
these sections shall be bolted
together with 8 m diameter bolts
at not more than 200 mm
centres.
The details of joints between
angles of the backing frame and
of joints between sections of
large signs shall be to the
The sign plate shall be riveted or
bonded with double sided V.H.B.
tape to the backing frame after
the application of the sign face.
6.2.5.7 Construction and Assembly
Traffic signs shall be constructed
and assembled as shown on the
B.S. 873.
Backing frames for permanent

traffic signs shall be as shown on
the Drawings and shall comply
with this Specification.
All sign plates, backing frames,

purlins, posts and other
components shall be de-burred
prior to assembly.
Signs exceeding 600 mm in

height or width shall be stiffened
by means of angles while signs
exceeding 1 m in height or width
shall have a backing frame
Where framing and stiffening are

not an integral part of the sign
plate, their joints shall be welded
or joined with suitable brackets
utilising nuts, bolts and washers.
Page 149
Where purlins are adopted, they

shall be attached to each vertical
member of the backing frame and
the sign stiffening and framing
shall be continuous in the vertical
direction. Unless otherwise
permitted by the S.O., purlins
shall be spaced equally apart.
Connections shall be made at
every point where a purlin
crosses a post.
Where purlins are not adopted,
the sign stiffening and framing
shall be continuous in the
horizontal direction.
All rivets and other devices used
in the fixing of sign plates to their
stiffeners or backing frames, or
those used in the construction of
housings, shall be of a material
compatible with the materials
being joined.
Spacing of rivets or other devices
used in the fixing of sign plates to
their stiffeners or backing frames
shall be uniform and shall not
exceed 150 mm around the
outside edge of any sheet or
section of a sheet, and shall not
exceed 300 mm on cross braces.
Hollow rivets shall be filled with
a plastic plug flush with the head
of the rivet.
An additional washer of
neoprene, nylon or other material
approved by the S.O. shall be
used against the sign face to
protect it from the effects of any
metal nuts, bolts, washers and/or
screws.
Where traffic signs, including
external lighting luminaires or
their supports, are required to
have holding down bolt fixings,
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
requirements shown on the
Drawings.
Sign plates shall be connected to
posts by a method approved by
the S.O.
Banding systems shall be of
stainless steel.
Where ferrous components are
permitted, any drilling of such
components shall be completed
before the application of any
finish.
Any hole drilled to accommodate
rivets or bolts in plates with
plastic sheeting shall,
immediately prior to the
insertion of the rivet or bolt,
have a clear lacquer, as
recommended by the
manufacturer of the plastic
sheeting, applied to its edge to
prevent the ingress of moisture.
The surfaces of rivets or bolts
exposed on the sign face shall be
coloured by a material approved
by the S.O. to match that part of
the face.
Traffic signs to be erected on
road lighting columns shall have
fixings compatible with the
column cross-section and finish.
Unless otherwise permitted by
the S.O., columns shall not be
drilled and wiring shall be
contained in approved external
conduits.
In addition to the requirements of
this Specification, variable
message traffic signs shall be of a
type approved by the relevant
authorities.
Page 150
6.2.5.8 Location and Erection

The approximate location of each
permanent traffic sign shall be as
shown on the Drawings. All
traffic signs shall have their exact
location determined by the S.O.
and recorded on the as-built
Drawings.
All posts shall be erected plumb
and where two or more posts are
provided for any one sign, the
face of the posts shall be lined up.
Signs erected on two posts shall
have each post positioned so that
the distance from the centre of
the post to the edge of the sign
plate is 300 mm unless
Any pockets formed in concrete
foundations to receive the posts
shall immediately prior to
erection be cleaned out. The posts
shall be placed centrally in the
pockets and be bedded on and
filled up to finished foundation
level with grade 20/20 concrete.
Traffic signs mounted on posts,
except those on gantries, shall be
erected to have their faces plumb
and orientated in relation to the
carriageway in accordance with
2B/85.
Traffic signs mounted on gantries
shall be erected as shown on the
Drawings.
No traffic sign shall be
dismantled, resited or removed
without prior approval from the
S.O.

6.2.5.9 Covering of Permanent Traffic
Signs
Where it is required in the
Contract that permanent traffic
signs are to be blanked-out or are
to have an alternative message,
the covering to be adopted shall
comply with the following
requirements.
The covering shall be 1.5 mm
(16 S.W.G.) thick made from a
material compatible with that of
the sign plate, or a material
Cover plates shall be fixed by
means of 5 mm diameter stain
less steel bolts, washers and nuts
or non-ferrous rivets not more
than 600 mm apart, the bolts
passing through 12 mm
diameter, 5 mm thick plastic
distance pieces between the sign
face and cover plate. Any holes
remaining in the finished sign
face shall be filled with blocked
rivets coloured on the face by
methods approved by the S.O.
Where self-adhesive plastic film
is used, it shall be compatible
with the sign face materials and
be applied and removed in
compliance with the
Any loose covering used must be
sufficiently opaque to prevent
reflection from the covered sign
and be securely fastened to the
back of the sign. Under no
circumstances shall tape or other
adhesive material be applied to
the face of the sign. A minimum
space of 50 mm shall be left
between the covering and the
face to permit airflow over the
sign.
Page 151
Traffic signs which are to be

covered shall not be erected on
trafficked highways without the
covering in place.

6.2.7
Where traffic signs are erected on

gantries, the signs shall comply with
the relevant requirements of this
Specification.
Removal of any covering shall be

carried out with minimum
disturbance to traffic and only
after the S.O. has given his
approval.
Irrespective of any requirement in
the Contract to cover signs, any
traffic sign erected at such a time
that its legend does not relate
either wholly or in part to the
traffic movement and route in
operation, shall have its sign face
securely covered with one of the
materials described above until
such time as the S.O. authorises
its removal.
6.2.6

Temporary traffic signs shall be
constructed either as non-illuminated
or externally illuminated signs as
directed by the S.O.Location and
erection of temporary traffic signs
shall be in accordance with
2C/85. Erection of temporary traffic
signs mounted on posts shall comply
with Sub-Section 6.2.5.8.
Any temporary covering of
temporary traffic signs shall comply
with Sub-Section 6.2.5.9.
Removal of temporary traffic signs
shall be carried out as soon as they
become superfluous or a hazard to
traffic. Methods of removal and
making good shall be submitted to
the S.O. for approval beforehand.
Making good shall be carried out
immediately after removal of the
traffic sign to the satisfaction of the
S.O.
Traffic Signs On Gantries
Fabrication and construction of

gantries shall be as shown on the
Drawings and as directed by the S.O.
6.2.8
Preparation and Finish

of Metal and Other Surfaces
Traffic signs shall be prepared,
protected against corrosion and
finished in compliance with B.S.
873.
Faces of sign plates shall be prepared
to receive sign face materials in
compliance with B.S. 873 and in
accordance with the manufacturer's
recommendations.
Steel backing frames, fittings and
purlins shall be prepared and
protected in compliance with B.S.
873.
Steel posts and post housings shall
be prepared and protected in
compliance with B.S. 873.
Backs of aluminium or aluminium
alloy sheets forming plate signs and
external parts of luminaire housings
and other permanently exposed
components shall, to prevent retroreflection, be dulled with paint using
a method approved by the S.O.
Ferrous steel shall be finished both
inside and out by galvanising,
electro-plating or application of zinc
or aluminium spray or other e
quivalent finish approved by the S.O.
Aluminium and other metals shall be
left untreated unless otherwise
Page 152

Drawings, stainless steel shall be
left untreated except where the
component is visible against the
sign face when it shall be
coloured on the face by methods
External surfaces shall be
prepared and protected as
described in the Contract.
Cabinets and feeder pillars shall
have final coats of paint applied
on Site after final installation,
including the fitting of any
internal apparatus required as part
of the permanent Works. Internal
surfaces shall, unless otherwise
shown on the Drawings, receive
the same treatment as for external
surfaces except that final paint
coats shall be applied before
internal components are installed.
6.3
ROAD MARKINGS
6.3.1
Thermoplastic material shall

comply with the requirements of
B.S. 3262 Part 1. Yellow
thermoplastic material shall be of
standard colour B.S. 381C No.
356 (Golden Yellow).
(b) Road Marking Paint
Road marking paint shall comply
with the requirements of M.S.
164. Yellow paint shall be of
standard colour B.S. 381C No.
356 (Golden Yellow).
6.3.3
Preparation of Site
Thermoplastic material and road
marking paint shall be applied only
on a surface which is clean and dry.
It shall not be laid over loose
detritus, mud or extraneous matter or
over old material or paint marking
incompatible with the paint being
applied.
Description
This work shall consist of the supply
of road marking material and its
application to form continuous or
intermittent lines, letters, arrows,
symbols or figures. The markings
shall be white or yellow laid to the
dimensions and at the locations
shown on the Drawings and as
specified herein or as directed by the
S.O. The work includes the supply
of all labour, tools, equipment,
materials, and warning and traffic
guidance signs as necessary for the
safe and efficient completion of the
entire work.
6.3.2
(a) Thermoplastic Material
Road Marking Materials
A tack coat compatible with the

marking material shall be applied in
accordance with manufacturer's
instructions prior to the application
of thermoplastic material.
If a primer or undercoat is necessary
to ensure proper adhesion of the
marking paint to the road surface
without bleeding or other
discoloration, the primer or
undercoat shall be fully compatible
with the marking paint and the road
surface. The rate of application of
tack coat, primer or undercoat shall
be in accordance with the
manufacturer's instructions and to the
The marking material shall be one of

the types detailed below as indicated
on the Drawings or as directed by
the S.O.
Page 153
6.3.4
HStandard Specification For Road Works
Preparation of Material on Site
specified. When more than one coat

is used, the succeeding coat shall not
be applied until the previous coat has
fully set.

Thermoplastic material shall be
supplied in block or powder form. If
the material is supplied in block
form it shall be broken into pieces,
each weighing not more than 4 kg,
which shall be melted in a heater
fitted with a mechanical stirrer to
prevent local overheating.
A thermometer of sufficient accuracy
shall be used during laying to ensure
that overheating of the material does
not occur. Once molten hydrocarbon
resins shall be used within 6 hours
and wood and gum resins shall be
used within 4 hours. The material
shall not be heated beyond the
manufacturer's specified temperature
during application. Excess material
shall be discarded on completion of
application.
Road markings of a repetitive nature

other than centre lines, lane lines,
etc., shall, unless otherwise decided
by the S.O., be set out with stencils
which comply with the size and
spacing requirements as shown on
the Drawings.
6.3.6
All markings shall be protected from

traffic until they have dried
sufficiently so that no pick-up by
vehicle tyre will occur.
6.3.7
All paint shall be thoroughly stirred

before application to keep the
pigments in uniform suspension. The
use of thinners or other additives
shall not be permitted unless
otherwise approved by the S.O.
Laying
Centre lines, lane lines and edge
lines shall be marked by approved
mechanical means or as directed by
the S.O. Other markings shall be
applied by brush, spray, screed,
hand-propelled or self-propelled
machine according to the marking
configuration and the type of
marking material approved for use.
The rate of application of the
marking material for each coat shall
be that recommended by the
manufacturer unless otherwise
Reflectorisation
Solid glass beads to be incorporated
in marking materials prior to
application to road surfaces shall be
Class À' glass beads complying
with the requirements of Table 1 of
B.S. 6088 (see Table 6.1).
6.3.5
Protection of Markings
Solid glass beads for additional

surface reflectorisation shall be
Class `B' glass beads complying with
the requirements of Table 2 of B.S.
6088 (see Table 6.2).
6.3.8
Thickness
The determination of thickness shall
be in accordance with B.S. 3262
Part 3, Appendices B and C.
Page 154
TABLE 6.1 - CLASS À' GLASS BEADS : PARTICLE SIZE DISTRIBUTION, ROUNDNESS
AND DEFECTS
B.S.
Sieve
Percentage
Retained
1.18 mm
0 to 3
850 um
0 to 10
425 um
90 to 100
Min. % Spherical
Beads by mass
as tested in
accordance with
Appendix C
Max. % Defective
Beads as tested in
accordance with
Appendix D
70
30
TABLE 6.2 - CLASS `B' GLASS BEADS : PARTICLE SIZE DISTRIBUTION,

ROUNDNESS AND DEFECTS
B.S.
Sieve
(um)
Percentage
Retained
850
0 to 5
800
5 to 20
300
30 to 75
180
10 to 30
Below
180
0 to 15
Min. % Spherical Beads

by mass as tested in
accordance with
Appendix C
Max. % Defective Beads

as tested in accordance
with Appendix D
80
20
Page 155

6.3.10
Thermoplastic material shall be

laid to the following
thicknessess :-
Materials which are defective or

which have been applied in an
unsatisfactory manner or to
incorrect dimensions or in a
wrong location, shall be removed
by approved chemical or
mechanical means. To the extent
necessary, the road pavement
shall be made good and the
markings reapplied all at the
Contractor's own expense and to
i) for synthetic hydrocarbon

resin binder -screed lines : not less than 2
mm nor more than 5 mm;
-sprayed lines other than yellow
lines : not less than 1.5 mm;
-sprayed yellow edge lines (for
`no parking', `no waiting', etc.) :
not less than 0.8 mm.
Where directed by the S.O.,

existing markings shall be
removed in the same manner as
above.
ii) for gum or wood resin binders -screed lines : not less than 3 mm
not more than 5mm;
-sprayed lines other than yellow lines
: not less than 2 mm;
Defective Materials or
Workmanship
6.3.11
Clearing Up
The Contractor shall clean up all
spatters, splashes and smirches of
marking material completely to
-sprayed yellow edge lines (for

`no parking', `no waiting', etc.) : not
less than 2 mm nor more than 3 mm.
Road marking paint shall be laid to
give a wet film thickness of not less
than 315 microns and not more than
400 microns.
6.3.9
Tolerance on Width
The tolerance on the specified width
of the marking shall be within the
range of + 10% and minus 0%.
Page 156
6.4
CONCRETE KERB
6.4.1
Description
This work shall consist of the supply
and installation of cast in situ or
precast concrete kerbs constructed at
the locations and in accordance with
the lines, levels, grades, dimensions
and types as shown on the Drawings,
all in accordance with this
Specification.
6.4.2
Materials
Concrete for kerb sections shall be
grade 25/20 concrete unless
otherwise indicated on the
Drawings and shall conform to the
Specification.
Drawings, bedding shall be grade
10/25 concrete.
6.4.3
Installation of Kerbs
6.4.3.1 Excavation
Excavation shall be made to the
required depth and the base shall
be trimmed and compacted to a
firm and even surface. All soft
and unsuitable material shall be
removed and replaced with
suitable material as defined in
The bedding material shall then
be placed and compacted to form
a bed of required thickness as

6.4.3.2 Cast In Situ Kerb
When a cast in situ kerb is placed
next to a concrete pavement,
expansion joints in the kerb shall
be located in line with expansion
joints in the pavement. Expansion
joints shall be formed at the
intervals shown on the Drawings
using preformed filler 10 mm in
thickness in accordance with the
specification for the pavement
joint filler.
Concreting shall generally be in
accordance with the
Specification. Forms shall not be
removed within 24 hours of the
concrete being placed. Minor
defects shall be repaired with
mortar containing 1 part Portland
cement to 2 parts sand.
After placing and compaction,
the concrete shall be covered
with suitable material and kept
moist for a period of 7 days.
6.4.3.3 Precast Concrete Kerb
Precast concrete kerbs shall be
cast using steel moulds and shall
be of the types as shown on the
Drawings.
Each kerb shall be set so that its
front top arris conforms to the
line and grade required. All
spaces under the kerb shall be
filled with bedding material
which shall be thoroughly
tamped.
Page 157
Kerbs shall be laid with joints as

narrow as possible and filled with
mortar containing 1 part Portland
cement to 2 parts sand. Where a
Portland cement concrete
pavement is to be constructed
contiguous to a kerb, expansion
joints shall be constructed in the
kerb directly in line with
pavement expansion joints. The
expansion joint in the kerb shall
be 20 mm in width and shall be
filled with an expansion joint
filler of the same nominal
thickness as the pavement joint.
Any voids between filler and the
concrete kerb shall be filled with
mortar.

6.4.3.5 Backfilling
The spaces in the front and back
of each kerb shall be refilled to
the required elevation with
suitable material approved by the
S.O. which shall be tamped in
layers of not more than 150 mm
until properly compacted.
The finished work shall be true to
line, grade and level to within
10 mm and shall present a
smooth appearance free from
kinks and distortion visible to the
eye.
6.4.3.4 Slipforming for Concrete Kerb

In situ concrete kerbs shall be
laid by an approved automatic
kerbing machine or, if
practicable in the case of concrete
pavements, by the concrete
paver itself. The kerbs shall be
dense with regular sides, edges,
arrises and chamfers, finished to
a fine surface free from blow
holes and dragging, and shall be
impervious.
Page 158
SECTION 7
STREET LIGHTING
Page 159
SECTION 7 - STREET LIGHTING

Page
7.1
GENERAL
7.1.1
Scope of Work
S7 - 162
7.1.2
On Site Commissioning Tests
S7 - 162
7.1.3
As-Built Drawings
S7 - 162
7.1.4
Maintenance
S7 - 163
7.1.5
Traffic Safety and Control
S7 - 163
7.2
LOW VOLTAGE UNDERGROUND CABLES
7.2.1
General
S7 -164
7.2.2
Types of Cables
7.2.2.1 Power Cables S7 - 4
7.2.2.2 Earthing Conductors S7 - 4
S7 - 164
7.2.3
Lengths of Cables
S7 - 164
7.2.4
Cable Routes
S7 - 164
7.2.5
Cable Trenches
S7 - 165
7.2.6
Cable Ducts
S7 - 165
7.2.7
Cable Termination
7.2.7.1 Termination of PVC Insulated Armoured Cable
7.2.7.2 Termination of Paper Insulated Cables
S7 - 166
S7 - 166
S7 - 166
7.2.8
Cable Jointing
S7 - 167
7.2.9
Cable Markers
S7 - 167
7.2.10
Cable Laying and Installation
S7 - 168
7.3
STREET LIGHTING LUMINAIRES
7.3.1
Light Distribution Requirements
S7 - 170
7.3.2
7.3.2.1
7.3.2.2
7.3.2.3
7.3.2.4
7.3.2.5
Constructional Requirements
Luminaires
Lamps
Ballast
Capacitors
Ignitors
S7 - 170
S7 - 170
S7 - 171
S7 - 172
S7 - 172
S7 - 172
Page 160
page
7.4
FEEDER-PILLARS
S7 - 14
7.4.1
General
S7 - 172
7.4.2
Fabrication of Feeder-Pillars
S7 - 172
7.4.3
Factory Inspection
S7 - 173
7.4.4
Foundation
S7 - 173
7.4.5
Earthing
S7 - 173
7.4.6
Time Switches
S7 - 173
7.4.7
Contactors
S7 - 173
7.4.8
By-Pass Switches and Selector Switches
S7 - 173
7.5
COLUMNS AND BRACKETS S7 - 16
7.5.1
General
S7 - 174
7.5.2
Design Loading
S7 - 174
7.5.3
Fabrication of Column Sections
7.5.3.1 Doors and Door Openings
7.5.3.2 Service Slots
S7 - 174
S7 - 174
S7 - 174
7.5.4
Bracket Arms
S7 - 174
7.5.5
Base-Plates
S7 - 175
7.5.6
Baseboards
S7 - 175
7.5.7
Street Lighting Cut-Outs
S7 - 175
7.5.8
Earthing Terminals
S7 - 175
7.5.9
Cable Entry
S7 - 175
7.5.10
Erection of Columns
S7 - 175
7.5.11
Protection Against Corrosion
S7 - 176
Page 161

Tests on cables shall include
continuity, phasing out and insulation
resistance between conductors and
between conductors and sheaths by
employing a 500 V insulation
tester.The date of commissioning
shall be agreed to by the S.O. and the
Electrical Contractor shall ensure
that the installation is safe before the
cable is energised.
SECTION 7 - STREET LIGHTING
7.1
GENERAL
7.1.1
Scope of Work
This work shall comprise the design
of cabling works and the supply and
installation of all luminaires, lamps,
ballasts, capacitors, ignitors, feeder
pillars, columns, ducting and cabling,
and all necessary ancillary
equipment, together with the
transportation, storage, erection,
connection, testing and
commissioning of the same for a
complete street lighting system, all in
accordance with the Drawings and
this Specification. The work shall
also include cabling from the nearest
specified power source of the local
supply authority to the street lighting
system, if required.
7.1.2
On Site Commissioning Tests

On completion of the installation
work on site, the Electrical
Contractor shall, at his own expense,
arrange for all necessary tests to be
carried out on the installation by
competent personnel as part of the
tests required of him for the whole of
the installation under this Contract.
The S.O. reserves the right to be

present at all tests and the Electrical
Contractor shall give at least one (1)
week's notice in writing to the S.O.
for this purpose. In any case, no test
shall be carried out without prior
approval from the S.O. Copies of all
test certificates shall be submitted to
the S.O. within one (1) week of the
completion of the testing.
7.1.3
As-Built Drawings
Within three (3) calender months
from the practical completion of the
installation, one set of true-to-scale
negatives (110/115 g/sq.m A0 or A1
sizes) and four sets of prints of each
of the following as-built drawings
shall be submitted to the S.O. by the
Electrical Contractor :i) Site plans;
ii) Schematic wiring diagrams;
The tests to be carried out shall be as

prescribed in the latest edition of the
IEE Wiring Regulations and the
Electricity (Board Supplies) Rules
1949, and shall include other tests
deemed necessary by the S.O. In the
event that the installation fails to pass
any of these tests, the Electrical
Contractor shall take such measures
as are necessary to remedy the
defects and the installation shall not
be considered to have been
completed until all such tests have
been passed.
iii) Layout plans showing cable

routes with reference to easily
recognisable buildings and
structures, sizes and types of
cables, locations and types of
joints, cable ducts, street lighting
poles and luminaires, feeder
pillars and earthing points.
Page 162
These as-built drawings shall be

properly stencilled and shall
have, at the lower right hand
corner, the Electrical Contractor's
name and address, the date of
commissioning, the scale,
drawing number (this shall be
obtained from the S.O.) and title,
and the following particulars:-
ii) replacing any broken or defective

cable markers;
iii) making good any damage to
buildings, concrete areas, slopes,
drains, culverts, existing cables,
pipes, etc., which have not been
properly made good as a result of
the Electrical Contractor's work;
and
JABATAN KERJA RAYA

CAWANGAN ELEKTRIK
CONTRACT NO.
TENDER NO.
iv) carrying out any other work

deemed necessary by the S.O.
7.1.5
In addition, one (1) set of the asbuilt drawings shall be properly

framed and kept in the
switchroom.
If the as-built drawings submitted
are not acceptable by the S.O.,
the Electrical Contractor shall
amend and resubmit the drawings
within two (2) weeks from the
date of return of the drawings.
7.1.4
Maintenance
During the Defects Liability Period,
the Electrical Contractor shall per
form maintenance work for the
complete cabling and associated
works. All labour, materials, tools
and parts necessary to rectify the
defects due to manufacturing or
installation faults shall be supplied
and/or executed at no extra cost to
the Government. Maintenance work
shall be carried out as soon as the
Electrical Contractor has been
informed by the S.O. to do so.
Traffic Safety and Control

When work is being carried out
beside any public road or other
existing road, warning signs shall be
erected. The general arrangement
and location of temporary warning
signs shall be strictly in accordance
with ARAHAN TEKNIK (JALAN)
2C/85, published by Cawangan
Jalan, Ibu Pejabat JKR, Kuala
Lumpur, and shall be submitted by
the Electrical Contractor and
approved by the S.O. before work
commences.
Where it is necessary for any pit or
trench to be left open overnight,
flashing warning lamps shall be
placed at each end of the pit or
trench and at intervals not greater
than 10 m apart. In built-up areas,
barricades shall be erected along the
length of the pit or trench in addition
to the warning lamps.
Where necessary, flag-men shall be
stationed to control traffic.
The work to be performed shall

include but shall not be limited to the
following :i) replacing or making good any
defective cables, cable joints and
cable terminations;
Page 163
7.2
LOW VOLTAGE
UNDERGROUND CABLES
7.2.1
iii) B.S. 6480 Part 1 and shall

have high conductivity plain
copper stranded conductors,
insulated with strong longfibred paper, uniform in
texture, free from metallic
particles, mass impregnated
with non-draining insulating
oil compound suitable for a
voltage of between 600 and
1000 V, lead alloy sheathed,
double steel tape armoured
and served.
General
The Electrical Contractor shall
submit, for the approval of the S.O.,
a program of work for the excavation
of cable trenches, laying of cables,
reinstatement of trenches, etc., one
(1) week before the work is to be
executed.
7.2.2
Types of Cables
7.2.2.2 Earthing Conductors
7.2.2.1 Power Cables

Cables from street-lighting cutouts and earthing cables to
luminaires shall be 2.5 sq.mm
PVC/PVC cables bundled
together with cable ties and
terminated with lugs where
necessary.
Power cables shall be

manufactured and tested in
accordance with :i) M.S. 274 or B.S. 6346 and
shall have high conductivity
plain copper stranded
conductors, insulated with
PVC suitable for a voltage of
between 600 and 1000 V, laid
together and bedded with
PVC, armoured with
galvanised steel wires and
sheathed with PVC; or
ii) B.S. 6480 Part 1 and shall
have high conductivity plain
insulated with strong longfibred paper, uniform in
texture, free from metallic
particles, mass impregnated
with non-draining insulating
oil compound suitable for a
voltage of between 600 and
1000 V, lead alloy sheathed
and served; or
7.2.3
Lengths of Cables
The lengths of each type of cable
indicated on the Drawings and/or in
the B.Q. are for tendering purposes
only. The Electrical Contractor shall
as certain the length of each cable
required before placing orders for
cables. The actual length of each
cable installed shall be measured on
site and the Electrical Contractor
shall be paid according to the rate
specified in the Contract. The rates
quoted shall include any wastage due
to cutting to lengths, terminations,
etc.
7.2.4
Cable Routes
Cable routes shown on the Drawings
are for tendering purposes only. The
Electrical Contractor shall, after
consulting the S.O., peg out cable
routes for the S.O.'s approval prior to
excavation of the cable trenches.
Page 164
7.2.5
Cable Trenches
Unless otherwise specified, cable
trenches shall be 750 mm deep. They
shall be of sufficient width as to
enable provision of adequate spacing
between cables but in any case shall
not be less than 450 mm wide.
Trenches shall be as straight as
possible and shall have vertical sides
which shall be timbered where
necessary so as to avoid subsidence
damage. The bottoms of trenches
shall be firm and of smooth contour
and any objects likely to damage the
cable sheathing shall be removed.
Material excavated from trenches
shall be placed or removed so as to
prevent nuisance or damage to
adjacent areas or buildings.
Trench excavation and backfilling
shall be so executed that all roads,
walls, sewers, drains, pipes, cables,
structures, etc., shall be reasonably
secured against risk of subsidence
damage. Provision shall be made
during excavation and until interim
restoration has been completed for
reasonable access of persons and
vehicles to the areas of buildings
adjacent to the trenches.
Where a trench passes from a foot
way to a roadway or at other
positions where a change in level is
necessary, the bottom of the trench
shall rise and/or fall gradually.
7.2.6
Cable Ducts
At road crossings, sewerage pipe
crossings, water pipe crossings,
paved areas, concrete areas and
where specified by the S.O., cables
shall be protected by galvanised steel
pipes buried to a depth of 900 mm
below finished ground level. The
pipes shall be heavy duty pipes

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

S.O., the number of cables
installed in each duct shall be
such that the space factor shall be
not less than 60%. A drawn wire
shall be provided for each duct.
Unless specified to be provided
by others, the above galvanised
steel pipes and /or pitch fibre
ducts shall be provided by the
Electrical Contractor whether or
not they are shown on the
Drawings.
7.2.7
Cable Termination
Unless otherwise permitted, all cable
termination and jointing works shall
be carried out in the presence of the
S.O. A plastic laminated plate
engraved with details such as size of
cable, number of cores, date of com
missioning, date of jointing, length
of cable, distance of cable joint, etc.,
shall be securely fixed near the
termination.
7.2.7.1 Termination of PVC Insulated

Armoured Cables
PVC/SWA/PVC cables shall be
provided with compression cable
gland termination. The cable
gland shall be of gunmetal or
brass and shall grip both the inner
and outer PVC sheath of the
cable. It shall be so designed that
any strain on the cable is taken by
the steel wire armouring which
shall be effectively sealed
between the gland itself and the
outer cable sheath.

7.2.7.2 Termination of Paper Insulated
Cables
PILCDS and PILCDSTAS paper
insulated cables, unless otherwise
specified, shall be terminated by
the heat shrinkable method.
The cables shall be tested for
moisture before termination is
commenced. Samples of paper
both from the layers nearest to
and furthest from the conductor
shall be immersed in transformer
oil or paraffin wax heated to a
temperature of approximately
115C. If any residual moisture is
present, this will be detected
immediately through the presence
of bubbles. Samples of paper
shall be tested singly and shall
not be touched by hand, but shall
be gripped with a pair of
tweezers.
Phasing and insulation resistance
tests shall be taken on each length
of cable laid before termination is
commenced.
The heat shrinkable termination
materials used shall be supplied
in a complete kit to suit various
sizes of cable and to provide
stress controlled, non-tracking,
environmentally sealed
termination. They shall consist of
high permittivity, high resistivity,
heat shrinkable, stress controlled,
UV stable, non-tracking
polymeric materials and heatactivated sealants to prevent
ingress of moisture and
contamination.
Terminations shall meet the
performance tests of IEC 112,
IEC 446 and IEC 507, Section 3.
They shall also have the
following performance
characteristics :-
Page 166
i) A.C. Voltage withstand

for 15 minutes, 50 Hz :
4.0 kV phase to earth;
Core numbers printed on papers

shall be observed when jointing
and, whenever possible, such
numbers shall be maintained
throughout the system. Core
numbers `0', `1', `2' and `3' shall
denote neutral, red, yellow and
blue phases respectively. In the
case of 2-core cables, core number
`1' shall denote the phase conductor
and `0' the neutral. Crossing of cores
in the cable boxes shall be avoided
wherever possible and connections
shall be consistent with the foregoing
requirements.
ii) A.C. Voltage withstand

for 4 hours, 50 Hz :
iii) Impulse Voltage withstand 10
positive and 10 negative,
1.2/50 microseconds :
8.0 kV peak phase to earth;
iv) Continuous A.C. Voltage
v) Insulation Resistance
between phase conductor
and ground : > 1000
Megaohms.
7.2.8
Cable Jointing
Jointing of cables shall be
undertaken only by competent and
fully experienced jointers.
Cable boxes, compounds and
jointing materials used shall be of an
approved type. Every cable joint
shall be started and finished on the
same day.
Wherever cables are to be jointed in
the open during wet weather
conditions, the Electrical Contractor
shall take all necessary precautions
to prevent moisture from getting into
the cables. Where cable sheaths are
to be used as earth continuity
conductors, the glands shall have the
necessary contact surface to provide
a low resistance path under fault
conditions.
7.2.9
Cable Markers
Cable markers with lettering and
signs as shown on the Drawings
shall be provided by the Electrical
Contractor at every change of
direction of underground cable
routes and every 15 m on straight
runs. Cable markers shall be of
heavy duty reinforced concrete
construction and shall be approved
by the S.O.
The cable marker shall form a
trapezoidal block with a 100 mm
square top face and 150 mm square
bottom face, and shall be 400 mm in
height as shown on the Drawings.
The top face shall be indented in
bold lettering with the initials "L.V."
and a directional sign or signs
indicating the direction/directions of
the cable route. The cable marker
shall be buried to a depth of 300 mm
or any other depth as directed by the
S.O. Cable joint markers of similar
construction but with the symbol "X"
shall be provided and installed at
every cable joint in a similar manner.
Phasing and insulation resistance

tests shall be taken before jointing is
commenced.
Page 167
7.2.10
(a) Cable Laid Direct In Ground
All cables shall be handled, laid

and installed according to this
Specification, the latest edition of
the IEE Wiring Regulations, the
cable manufacturer's
recommendations and ERA
Reports, using proper installation
equipment, all to the satisfaction
of the S.O.
Before any cable is laid, the

trench shall be thoroughly
inspected and any debris and
other sharp objects shall be
removed. The bottom of the
trench shall be covered with a
layer of clean sand 75 mm thick.
The cables shall then be laid on
this bedding in an orderly manner
without overlapping and crossing
each other. 75 mm of clean sand
shall cover the laid cables and
shall be spread over the trench
before placing the cable
protective covers.
All cables shall be supplied in

complete lengths to suit the
circuits they serve and no straight
through joints shall be used.
Straight through joints in the
cable shall only be permitted in
very exceptional circumstances
such as those arising from
unavoidable limitations in
manufactured length. Where
straight through joints or other
approved joints are permitted by
the S.O., the cost of such joints
shall be borne by the Electrical
Contractor. No joints in the cable
will be allowed unless approved
in writing by the S.O.
The minimum bending radius of
the cables shall be in accordance
with Table 52 C of the latest
edition of the IEE Wiring
Regulations. Wherever cables are
cut, the ends shall be immediately
sealed in an approved manner
unless it is intended to proceed
with cable jointing or termination
immediately.
the S.O., no cable shall be laid
and/or covered up in the absence
of the S.O.
Cable protective covers shall be

of clay bricks. The bricks shall be
new, well burnt and in complete
pieces. They shall be laid
lengthwise from end to end along
the entire route of the
underground cable if the cable
size is not more than 120 sq.mm.
For cable sizes in excess of 120
sq.mm, more than one row of
bricks shall be laid. Each cable
shall be seperately protected by
these bricks and the cover shall
have at least 25 mm overhang on
each side of the cable.
The trench shall then be
backfilled with earth and shall be
compacted in layers of 150 mm
using a mechanical rammer. An
orange coloured multi-strand
nylon rope of minimum 6 mm
diameter shall be laid at a depth
of 300 mm along the trench to
identify the cable route. At every
10 m interval, an extra 2 m of
nylon rope shall be coiled and
laid. The finished surface shall be
left proud by 50 mm to allow for
subsidence and the Electrical
Page 168

for the removal of any surplus
material to a position indicated by
the S.O.
The surface of the refilled trench
shall be temporarily reinstated
and maintained in a thoroughly
safe condition until complete
consolidation of the soil has been
achieved. As soon as the soil has
consolidated, the trench shall be
made good to its original
condition, all to the satisfaction of
the S.O.
(b) Cable Installed In Precast
Concrete Trenches
Methods of installation of cables
in precast concrete trenches shall
be in accordance with Type L,
Type M, or Type N of Table 9A
of the latest edition of the IEE
Wiring Regulations. However, if
the method is not specified, the
cables shall be installed as
Cables laid in the bottoms of
trenches shall be in accordance
with Method Type L of Table 9A
of the latest edition of the IEE
Wiring Regulations.
Cables installed on trench walls
shall be in accordance with
Method Type M or Type N of the
latest edition of the IEE Wiring
Regulations and shall be secured
on a cable tray by means of
saddles at suitable intervals. In
the case of single core cables,
whether secured individually or
in a group to the cable tray, nonferrous saddles shall be used.
Cable trays shall be fabricated
from perforated hot-dipped
galvanised sheets finished in an
orange enamel.

The minimum thickness of the
sheet steel used shall be 1.5 mm
for cable trays with widths of up
to 300 mm, and 2.0 mm for
widths exceeding 300 mm. Cable
trays shall be supported at least
25 mm from the trench wall by
mild steel brackets at 600 mm
intervals. Brackets shall be
anti-rust treated and painted with
one coat of primer. Samples of
cable trays and brackets shall be
submitted to the S.O. for
approval prior to installation.
To provide electrical continuity,
all cable joints shall be bridged
by means of tinned copper tape
of dimensions not less than 25
mm x 3 mm. All saddles for
cables on cable trays shall be
installed by bolts, washers and
nuts. All tees, intersection units,
adaptor units, etc., shall be
factory manufactured unless
Trenches inside buildings shall be
filled with clean sand up to a
level above the cable ducts.
(c) Cable Run On Walls and
Under Floor Slabs
Cable run on walls and under
floor slabs shall be mounted on
perforated hot-dipped galvanised
sheet steel cable trays. The
construction and finish of the
cable trays and the method of
installation of cables on cable
trays shall be as described in SubSection 7.2.10 (b) above.
Cable trays shall be suspended
from floor slabs by hangers or
mounted on walls by brackets at
600 mm intervals. The materials
and finishes used for the hangers,
brackets and other suspending
and supporting structures shall be
Page 169
the same as those described for

brackets in Sub-Section 7.2.10
(b) above.
Where cable trays pass through
floors or fire resistant walls, the
surrounding holes shall be sealed
to the full thickness of the floor
or wall with non- hygroscopic
fire-resisting material of
minimum 2-hour fire rating as
approved by the Jabatan Bomba
Malaysia.
7.3
7.3.1
STREET LIGHTING
LUMINAIRES
Light Distribution Requirements

Unless otherwise specified, the
performance and light distribution of
street lighting luminaires shall be of
the Low Threshold Increment (LTI)
type.
The direction of maximum intensity
of flux shall lie between 0 and 65
of the downward vertical and the
maximum permissible value of the
intensity emitted at 90 and 80 shall
not exceed 10 cd/1000 lumens and
30 cd/1000 lumens respectively.
Each luminaire shall normally direct
two beams along the length of the
road. The polar light distribution
curves for the luminaire shall
generally be smooth and free from
any abrupt variations so that the
luminous intensity diminishes
smoothly and progressively from its
maximum.

7.3.2
7.3.2.1 Luminaires
All luminaires shall be new,
totally enclosed, dust proof,insect
proof and watertight and shall be
tested in accordance with B.S.
4533. All exposed parts shall be
of non-corrosive materials. The
luminaires shall provide the
requisite light distribution with
the size and type of lamp
specified. Each luminaire shall
consist of a lamp compartment
made up of an upper canopy or
housing and a lower bowl
assembly, a lampholder, cable
clamps, mains connectors and
earth terminations, as well as all
necessary control gear. The
control gear shall be pre-wired
and integral with the luminaire.
The luminaire wiring shall be of
a size and insulated with a
material that will more than
effectively withstand the current,
voltage and temperatures
expected within the luminaire
during both the starting and
operating modes in the ambient
temperature of the Site.
The lamp compartment of the
luminaire shall be accessible via a
hinged bowl made of ultraviolet
stabilised plastic material such as
acrylic which shall, in the closed
position, bed firmly upon a soft
resilient neoprene or non-ageing
felt gasket. The gasket shall be
positively secured in the
luminaire housing and shall be
weather-resistant. The bowl shall
be secured firmly to the luminaire
body by means of stainless steel
clips and hinged pins.In the
lowered position of the bowl, it
shall be restrained from
becoming detached or being
Page 170
blown towards the other portion

of the luminaire or the column
arm. If independent reflectors are
incorporated in the luminaire,
such reflectors shall be of high
purity aluminium mirrors,
chemically anodised to yield
optimum reflection of light
distribution. Full details of the
luminaire and accessories shall be
furnished as required in the
Appendices to this Specification.

The lamps supplied shall have a
mortality rate not greater than
10% at 5,000 switched operating
hours and shall not take longer
than 4 minutes after the initial
"switch on" to attain 80% of their
guaranteed output at the rated
voltage of 200/250 V and
frequency 50 Hz. The reignition
period after an interruption of the
supply shall not be longer than 1
minute to attain 80% of the
lumens output.
7.3.2.2 Lamps
(a) High Pressure Sodium Vapour
(HPSV) Lamps
High presssure sodium vapour
(HPSV) lamps shall conform to
IEC Publication 662 and shall
have a colour temperature of
approximately 21,000 K. The
majority of the light output shall
fall within the 560-610
nanometre waveband, i.e. in the
yellow/orange, range.
The lamps shall have an initial
luminous efficiency of
approximately 115 lumens per
watt for a 400 watt lamp and 100
lumens per watt for a 250 watt
lamp. The lumens output after
100 operating hours shall be
45,000 lumens for a 400 watt
lamp and 25,000 lumens for a
250 watt lamp.
The lamps shall be of tubular or
of any other approved shape and
shall have plated brass caps
securely fitted to the glass
envelopes. The cap shall be of
GESE40 material to fit the
luminaire supplied.
(b) Low Pressure Sodium Vapour

(LPSV) Lamps
Low pressure sodium vapour
(LPSV) lamps shall conform
to the requirements as laid
down in B.S. 3767. The
majority of the lumens output
shall be within the 580-590
nanometre waveband range.
The lamps shall have an
initial luminous efficacy of
approximately 160 lumens per
watt for a 135 watt lamp. The
lumens output after 100
operating hours shall be not
less than 50 lumens per watt.
The lamps shall be of tubular
shape with a bayonet cap
(B.C.), shall take no longer
than 11 minutes after initial
"switch on" to attain 90% of
of their quoted lumens output.
All LPSV lamps shall be
guaranteed for a minimum
operating life of 4,000
operating hours. All lamps
shall be suitable for use, in
conjunction with their control
gears, on 220/240 V supply
and shall be capable of being
started and operated at 10%
reduction in rated voltage.
Page 171
7.3.2.3 Ballast
The ballast shall be manufactured
to B.S. 4782. It shall be correctly
rated for its duty and shall be
designed to operate on a dual
mains voltage of 220/240 V by
means of suitable tappings. The
tappings shall be brought out to
marked terminals. The ballast
shall have laminated cores and
high conductivity windings with
power loss and noise kept to a
minimum.

7.4
FEEDER-PILLARS
7.4.1
General
Feeder-pillars shall be supplied
completely assembled with control
gear and all internal electrical and
mechanical inter-connections and
structural parts for voltages up to and
including 1,000 volts A.C. They
shall comply with and be tested to
the requirements of B.S. 5486.
7.4.2
Fabrication of Feeder-Pillars
7.3.2.4 Capacitors
Capacitors shall be manufactured
to B.S. 4017 and housed in
extruded aluminium canisters
with shrouded screw terminals.
They shall not be fused but shall
have an an external safety dis
charge resistor. The capacitor
shall be capable of raising the
power factor of each circuit to at
least 0.85 lagging.
7.3.2.5 Ignitors
Ignitors for the discharge lamps
shall be of the electronic /
superimposed pulse type rated for
the appropriate wattage. The unit
shall be capable of operating on a
voltage ranging from 200 to 250
volts. The unit shall be totally
enclosed with an external
terminal block for the supply
connection and a length of high
tension cable shall be included
for the lamp connection. It shall
be compatible with the normal
control gear.
The case of the unit shall carry a
label showing the connections
and listing the appropriate
voltage.

submit a design drawing of the
shape, size, electrical and mechanical
connections, materials, etc., of the
feeder-pillar for the approval of the
S.O. prior to manufacture. The
plinth, foundation work, etc., shall be
included in the design drawing.
The feeder-pillar housing shall
consist of a drip canopy, rigidly
welded channeled steel framework
manufactured from 2.64 mm (12
s.w.g.) sheet steel. It shall be hot-dip
galvanised and the process of
galvanising, treatment before
galvanising and treatment after
galvanising shall be as described in
Sub-Section 7.5.10 of this
Specification. On the front and rear
sides of the feeder-pillar, the
following sign shall be stencilled in
red paint using a lettering height of
90 mm :BAHAYA
415 V
LAMPU JALAN
The door of the feeder-pillar shall be
rigidly reinforced and hinged internally
to prevent unauthorised access. The
feeder-pillar shall be lockable with either
wedge-type locks protected by screw
Page 172
plugs or some other secret locks

approved by the S.O. The feederpillar shall be self-ventilated and
weather proof and such ventilation
openings shall be protected by wire
mesh to prevent the entry of vermin,
rodents and birds.

copper tape, precast concrete earth
chambers with covers, etc.
7.4.6
Time switches supplied for the

control of luminaires, etc., shall be of
the synchronous/step-by-step motorwound handset dial plug-in type.
They shall incorporate a 24-hour
spring reserve or a battery back-up
system. Time switches shall be rated
as specified in the Drawings and
shall be operational on a 220/240 V,
50 Hz supply.
A baseboard made of tufnol or

other approved treated hardwood
of at least 16 mm thickness shall
be included to mount equipment
such as time switches, contactors,
etc.
7.4.3
Factory Inspection
7.4.7
The Electrical Contractor shall make
arrangements to witness the
electrical tests and for joint
inspection to be carried out at the
factory prior to transportation to the
Site.
7.4.4
Earthing
The earthing system for the feederpillar shall comply with the Rules
and Regulations of the Supply
Authority, The British Code of
Practice C.P. 1013, the relevant
sections of the latest edition of the
IEE Wiring Regulations and the
Contract Drawings.
Each feeder-pillar shall be effectively
earthed using 4.8 mm x 16 mm
diameter steel core copper-jacketted
earth electrodes, 25 mm x 3 mm
Contactors
Contactors shall comply with B.S.
5424 with uninterrupted ratings,
mechanical duty Class 2 and a
utilisation category of at least AC3.
The contactor coils shall be fully
tropicalised and wound for
continuous operation for a 220/240
V, 50 Hz supply. The contacts of the
contactor shall be rated for the
breaking capacity of the connected
load.
Foundation
The Site of the foundation of the
feeder-pillar shall be filled where
required, compacted and levelled
before the reinforced concrete base
of minimum 250 mm height above
the finished earth level is
constructed. Cable entry ducts shall
also be provided.
7.4.5
Time Switches
7.4.8
By-Pass Switches and Selector

Switches
Single or three-phase by-pass
switches as applicable shall be
connected in parallel with the
contactors for use in the event of the
failure of the contactors. These shall
be manufactured to B.S. 5419 and
shall be capable of breaking the load
connected to the contactors without
undue ageing or damage.
A four-position selector switch shall
be provided to select the mode of
operation and shall be appropriately
labelled.
Page 173
7.5
COLUMNS AND BRACKETS
7.5.1
minimum overlapping position of 1.5

times the external across-faced
dimension.
General
7.5.3.1 Doors and Door Openings
All columns and brackets shall be of
tapered, octagonal, hot-dip
galvanised interchangeable sections
complying in all respects with the
Drawings. They shall be
manufactured to comply with B.S.
1840 and B.S. 5649 with Grade 43C
or 50C steel conforming to B.S.
4360. The base-plates and bracket
arms shall be manufactured as
seperate units suitable for mounting
or fixing on to the columns.
7.5.2
Weather proof doors shall be

provided with an anti-vandal
locking device over the door
opening of each column as
shown on the Drawings. The
complete locking device shall be
made from stainless steel. Door
openings shall have internal
reinforcement to compensate for
the loss of stiffness in the
columns caused by forming the
door openings.
Design Loading
7.5.3.2 Service Slots
The columns shall be designed to
withstand loadings comprising :-
For flange mounted types of

columns, cable entries shall be
through the flange plates via a
hole of suitable diameter as
shown on the Drawings. A
suitable duct for cable entry shall
also be provided at the concrete
base.
i) loads due to wind speeds of up to

27 m/sec.;
ii) loads due to the weight of the
columns, lighting luminaires and
bracket arms;
For planted root types of

columns, service slots shall be on
the same side and vertically
below the service doors.
iii) other applied loads if applicable.

7.5.3
Fabrication of Column Sections

Each column section shall be
mechanically formed and
longitudinally welded by the
continuous automatic gas shielded
electric arc process (M.I.G. process)
to B.S. 5135. The sections shall be
constructed so as to overlap each
other by a minimum of 1.5 times the
diameter of the immediate lower
section (external across-faced
dimension) and to be easily
assembled on site by using simple
tools without employing welding
techniques. The manufacturer shall
provide a mark on the finished
column section indicating the
7.5.4
Bracket Arms
Bracket arms shall be of suitable
outreach as indicated on the
Drawings and in the B.Q. The
bracket arms shall be octagonal in
shape for up to 2.0 m in length. For
bracket arms longer than 2.0 m in
length, the extra length shall be
formed from Grade 43C tubular steel
conforming to B.S. 4360. The
bracket arms shall be arranged so as
to give a 50 uplift as shown on the
Drawings. A tubular steel spigot of
appropriate dimensions for the
Page 174
luminaire shall be welded at the end

of each bracket arm. After welding,
etc., bracket arms shall be treated as
described in Sub-Section 7.5.10
before being hot-dip galvanised.
7.5.5
cables as appropriate. Cut-outs shall

be provided with adequate shrouding
to prevent cross-phasing or
accidental contact with live metal.
The fuse carriers shall be selfaligning and shall accept any of the
standard rated fuses for the purpose.
Each unit shall possess high
mechanical and di-electric strength
and shall be suitable for use in the
tropics. Samples of complete cut-out
units shall be submitted for the
Base-Plates
For flange mounted types of
columns, flange-plates of substantial
thicknesses as shown on the
Drawings shall be welded on to the
columns.
For planted root types of columns,
detachable anti-sink plates shall be
supplied.
7.5.8
Columns shall be provided with a

corrosion resistant terminal having
substantial contact surfaces for the
attachment of an earthing lead. This
terminal shall be provided close to
the door opening inside each
column. Where bolts are used, they
shall be not less than 6 mm in
diameter and shall be provided with
two suitable washers and nuts.
Base-plates, nuts and bolts, etc., shall

be hot-dip galvanised after
manufacture.
7.5.6
Baseboards
A piece of baseboard shall be
included in each base compartment
for cable termination or control gears
assembly. Baseboards shall be made
from fibre board of 10 mm
thickness. Alternative baseboards
made from galvanised perforated
metal may also be used with the
approval of the S.O. Baseboards
shall be made to the dimensions as
indicated on the Drawings and shall
be fixed securely in position inside
the columns.
7.5.7
Street Lighting Cut-Outs

Street lighting cut-outs shall be of a
type manufactured for use in street
lighting installations. They shall
have facilities for double fusing
loop-in loop-out terminals. The cutout bases shall have a supply cable
contact block rating of at least 50 A
and shall be capable of accepting
circular cable cores of up to 25
sq.mm copper 2-core or 4-core
Earthing Terminals
7.5.9
Cable Entry
Armoured cables brought into the
columns shall be provided with
compression cable gland
terminations.
An appropriate type of earthing
clamp shall be provided to bond the
armouring of the cables which shall
be effectively earthed.
7.5.10 Erection of Columns

Columns shall be installed in
accordance with the manufacturer's
recommendations and as shown on
the Drawings. The Electrical
Contractor shall peg out the positions
of the columns for the approval of
the S.O. before planting the columns.
Page 175
Columns shall be erected such that

the service doors shall face away
from on-coming traffic except at
parapets of bridges and retaining
walls. At such locations, the
orientation of the service doors shall
be determined by the S.O. After
erecting each column, backfill shall
be compacted by means of suitable
ramming equipment.
7.5.11 Protection Against Corrosion
Individual sections of the columns,
base-plates, doors and bracket arms
shall be protected against corrosion
by hot-dip galvanising the sections
both internally and externally, all in
accordance with B.S. 729. All
welding works shall be completed
before galvanising.

Treatment prior to galvanising shall
include degreasing, rinsing, pickling,
further rinsing and fluxing.
The minimum average weight of the
zinc coating shall be 460 g/sq.m for
any individual test area.
The galvanised columns and bracket
arms shall be of prime finish and of
good uniformity, i.e. they shall be
free from injurious defects such as
blisters, flux and uncoated spots.
The planted sections of columns and
the base-plates shall be factorycoated with bitumen using the hotdipping process conforming to
AASHTO M 190.
Page 176
SECTION 8
TRAFFIC SIGNALS
Page 177
SECTION 8 - TRAFFIC SIGNALS

Page
8.1
GENERAL
8.1.1
Scope of Work
S8-182
8.1.2
8.1.2.1
8.1.2.2
8.1.2.3
8.1.2.4
8.1.2.5
Design and Construction

Contractor's Responsibility
Cleanlines
Metric Range of preferred Dimensions
Self-Tapping Screw
Corrosion
S8-182
S8-182
S8-182
S8-182
S8-182
8.1.3
Compliance With Manufacturer's Instruction
S8-183
8.1.4
8.1.4.1
8.1.4.2
8.1.4.3
8.1.4.4
Component and materials

Conditions of Operation
Maintenance To Be Kept To A Minimum
Components
Metering
S8-183
S8-183
S8-183
S8-183
8.1.5
Identification of Equipment
S8-184
8.1.6
8.1.6.1
8.1.6.2
8.1.6.3
8.1.6.4
8.1.6.5
8.1.6.6
8.1.6.7
8.1.6.8
8.1.6.9
Protective Requirements
General
Insulating Bushes
Isolation From Main Supply
Earthing of Transformer Secondary Circuits
Current Loading of Wires
Danger Notices
Cable Connecting Units
Insulation
Whiskering of Tin
S8-184
S8-184
S8-184
S8-184
S8-184
S8-185
S8-185
S8-185
S8-185
8.1.7
Electricity Supply
S8-185
8.1.8
On-Site Commisioning Test Procedures
S8-185
8.1.9
Documentation
8.1.9.1 General
8.1.9.2 Hardware, Software and maintenance Manual
S8-186
S8-186
8.1.10
Guarantee of Supply
S8-187
8.1.11
Warranty Period
S8-187
Page 178

Page
8.2
LOW VOLTAGE UNDERGROUND CABLES
8.2.1
8.2.1.1
8.2.1.2
8.2.1.3
8.2.1.4
Type of Cables
Power Cables
Feeder Cables for Vehicle Detectors
Loop Cables for Vehicle Detectors
Earthing Conductors
S8-187
S8-187
S8-188
S8-188
S8-188
8.2.2
Cable Termination
S8-188
8.2.3
Cable Jointing
S8-188
8.2.4
Cable Markers
S8-188
8.3
SIGNAL LANTERNS
8.3.1
Standard Requirements
S8-189
8.3.2
Optical Requirements
8.3.2.1 Optical Arrangement for Drivers
8.3.2.2 Optical Arrangement for Pedestrians
8.3.2.3 Height of Signal
S8-189
S8-189
S8-189
S8-189
8.3.3.
8.3.3.1 Lamps
8.3.3.2 Target Boards
S8-190
S8-190
S8-190
8.4
SIGNAL POSTS AND MAST ARMS
8.4.1
S8-191
8.4.2
Cable Entry
S8-191
8.4.3
Connecting Facilities for Cables
S8-191
8.4.4
S8-191
8.4.5
Finish
S8-191
8.5
PEDESTRIAN PUSH-BUTTONS
8.5.1
S8-192
8.5.2
Location
S8-192
8.5.3
Pedestrian Demand Indicator
S8-192
8.5.4
Audible Signal
S8-192
Page 179

Page
8.6
TRAFFIC CONTROLLER
8.6.1
S8-1192
8.6.2
Housing
S8-193
8.6.3
Controller Mains Switch Board
S8-193
8.6.4
Facility Switch
S8-194
8.6.5
Pedestrian Facilities
S8-194
8.6.6
8.6.6.1
8.6.6.2
8.6.6.3
8.6.6.4
8.6.6.5
8.6.6.6
Logic Module
Microcomputer System
Input/Output Interfaces
Real 'Time-Of-Day' Clock
Operator Interface and Controller Display
Supply Monitor
Watchdog Timer
S8-194
S8-194
S8-195
S8-195
S8-195
S8-195
S8-196
8.6.7
Mains Supply Interruptions
S8-196
8.6.8
Circuit Breakers
S8-196
8.6.9
Inputs
S8-196
8.6.10
Interchangeability
S8-196
8.6.11
Vibration and Noise
S8-196
8.6.12
Radio Interference
S8-196
8.6.13
Safety
S8-196
8.6.14
Timing
S8-197
8.7
VEHICLE DETECTORS
8.7.1
S8-197
8.7.2
Number of Traffic Lanes
S8-197
8.7.3
Supply Voltage
S8-197
8.7.4
Equipment Construction
S8-197
8.7.5
Performance Requirements
S8-197
Page 180

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

Excavations
General
Excavation
Bedding of Excavation
Cable Ducts
Cable Laid Direct On The Ground
Cables Installed in Precast Concrete Trenches
Backfilling of Excavations And Reinstatements
Sensing Loop Slots
Maintenance of drains and Services During Excavations
Reinstatement of Drains and Precast Units
Completion of Works
Maintenance of Excavation
S8-198
S8-198
S8-198
S8-199
S8-199
S8-199
S8-200
S8-200
S8-201
S8-201
S8-201
S8-202
S8-202
S8-202
Traffic Arrangements
S8-203
General
Arrangement and Location of Signs Barriers and Barricades
Temporary Warning lamps
Use of Traffic Guidance Cones
Temporary Traffic Diversions
Temporary Traffic Control
Plant and Equipment
Vehicles
Maintenance of Signs, Lights, Barriers,Temporary Traffic
Diversions, etc.
S8-203
S8-203
S8-204
S8-204
S8-204
S8-204
S8-205
S8-205
8.8.3.1
8.8.3.2
8.8.3.3
8.8.3.4
8.8.3.5
8.8.3.6
8.8.3.7
8.8.3.8
8.8.3.9
8.8.3.10
8.8.3.11
8.8.3.12
8.8.3.13
8.8.4
8.8.4.1
8.8.4.2
8.8.4.3
8.8.4.4
8.8.4.5
8.8.4.6
8.8.4.7
8.8.4.8
8.8.4.9
S8-205
Page 181
SECTION 8 - TRAFFIC SIGNALS

8.1
GENERAL
8.1.1
Scope of Work
This work shall comprise the design
of cabling works and the supply and
installation of all signal lanterns,
traffic controllers, detectors, posts,
ducting and cabling, and switchgears
with all necessary ancillary
equipment, together with the
transportation, storage, erection,
connection, testing and
commissioning of the same for a
complete traffic signal installation,
all in accordance with the Drawings
and this Specification. The work
shall also include cabling from the
nearest specified power source of the
local supply authority to the traffic
control system, if required.
8.1.2

be responsibile for the design,
material quality and
workmanship of the system and
every part of the system offered,
whether manufactured by him or
supplied to him by other
manufacturers. Approval by the
S.O. does not relieve the
Contractor of these
responsibilities.
Materials shall as far as possible
be of Malaysian origin except
where such materials can be
shown to be unavailable in
Malaysia.
8.1.2.2 Cleanliness
Particular attention shall be given
in the design of the equipment for
the exclusion of dust, dirt, etc.,
especially in the case where
forced ventilation is employed.
The type of signal operation, number

of plans, number and sequence of
phases, cycle times, timings of each
phase, offset times, locations of
controllers and power source tapping
points, and other specific
requirements shall be as shown on
the Drawings.
8.1.2.3 Metric Range of Preferred

Dimensions
8.1.2.4 Self-Tapping Screws
8.1.2.1 Contractor's Responsibility

The Contractor shall design the
interconnecting signal cabling for
the proposed signal system as
cabling design drawings are to be
approved by the S.O. before
construction commences.
Equipment offered shall be in all
respects suitable for the
requirements and for the
environmental conditions
specified. The Contractor shall
Except as may be agreed for

practical reasons, design shall
make use of the metric range of
preferred dimensions and
tolerances.
Self-tapping screws shall be used

only for retaining duties. They
shall not be used for fixing
removable covers, nor for the
support of direct loads.
8.1.2.5 Corrosion
All equipment shall be designed
to resist corrosion in the
Malaysian environment for a
period of 20 years from the date
of installation.
Page 182
8.1.3
Compliance With Manufacturer's

Instructions
The Contractor shall ensure that the
equipment and parts used shall be
entirely suitable for the work to be
performed and that they shall be
manufactured to proper tolerances
and fit. He shall further ensure that
the loading of equipment shall under
all normal circumstances not exceed
the maximum laid down or agreed to
in writing by the manufacturer.
for the inspection of all equipment
and parts before their incorporation
in the Works to ensure that they
comply with the requirements of this
Specification and that they are not
defective in any way as regards
materials or workmanship. Should
any such non-compliance or defects
be found during the inspection, the
Contractor shall correct or cause to
be corrected such non-compliance
and defects, all at the Contractor's
expense and to the satisfaction of the
S.O.
8.1.4
Components and Materials

replaceable may be accepted with
the aproval of the S.O.
8.1.4.3 Components
All active and passive
components, their mounting and
the plugs, sockets and
connections, shall be designed
for a life expectancy of 20 years
as specified in Sub-Section
8.1.4.2. All shall operate well
within their ratings with due
consideration for the
environmental conditions and
temperature rises within cabinets
or enclosures.
Thermionic valves other than
cathode-ray tubes shall not be
used.
Metal oxide or grade II carbon
resistors shall be used. Grade I
carbon film resistors shall not be
used.
Where high dissipation power
resistors are used, metal oxide
resistors shall be used whenever
they are available, in preference
to wire wound types.
8.1.4.1 Conditions of Operation

The system shall be designed to
operate continuously. Account
shall be taken of equipment being
sited in all exposed locations.
8.1.4.2 Maintenance To Be Kept To A
Minimum
The materials and components,
excluding expendable items such
as lamps, shall be such as to
provide a life expectancy of up to
20 years unless specifically stated
otherwise in this Specification.
Components which have a
shorter life span but are easily
Metal can transistors shall be

used wherever possible.
Germanium transistors shall not
be used unless approved by the
S.O.
8.1.4.4 Metering
The equipment shall be provided
with waveforms and voltage test
points as necessary for indicating
circuit conditions.
Page 183
8.1.5
Identification of Equipment
The Contractor shall mark or label
clearly all modules, units and main
parts of the system with a functional
code or title, type number, trade
name and serial number. The
marking or labelling of main items
shall be clearly visible on the
outside. The labels and markings of
encased units or modules shall be
visible when the case or cover is
removed. Components shall not be
marked with circuit references. The
marking shall be adjacent to the
component. Markings required for
controls, maintenance or warning
shall be adjacent to the part
concerned. Markings shall maintain
legibility throughout the life of the
equipment in the specified
environmental conditions.
Techniques used shall be approved
by the S.O.
8.1.6
Protective Requirements

8.1.6.3 Isolation From Main Supply
S.O., systems shall be
completely isolated from the
mains supply by means of a
suitable double-wound
transformer which shall include
an earthed screen. The primary
and secondary output
terminations shall be separated in
an approved manner.
The main transformers at the
controller shall be provided with
primary tappings so that the
equipment operates with mains
supply in the range of 200 to 260
volts.
8.1.6.4 Earthing of Transformer
Secondary Circuits
When a dangerous voltage is
connected to the primary winding
of a transformer, the secondary
circuit shall be connected where
practicable to an earthed point.
8.1.6.1 General
8.1.6.5 Current Loading of Wires
All metal work not normally
required to carry current shall be
connected to an earth point
except where otherwise dictated
by transmission or other
requirements (such metal work
shall include cases, screens,
cores, cable glands, cable
conduits and cable sheaths, etc.).
8.1.6.2 Insulating Bushes
Insulating bushes shall be
provided wherever conductors
carrying dangerous voltages pass
through holes in metal parts and
where the conductors would be
likely to touch the edge of the
holes.
All wirings shall be suitably rated

to carry in excess of the current
permitted by their fuses, circuit
breakers or other current linking
devices. Similar precautions shall
be taken to reduce the possibility
of overheating components.
Provisions shall be made in the
equipment :i) to prevent damage to circuits
due to failure of any pulses,
power supplies or mains
supply;
ii) to prevent damage to power
supplies by inadvertent
removal of the load.
Page 184
8.1.6.6 Danger Notices

8.1.6.9 Whiskering of Tin
All equipment or units working

at a voltage at or above 150
volts D.C. or 100 volts A.C.
(RMS) shall be protected by an
approved cover, which shall be
removable. The cover shall have
a sign with a danger symbol
indication of the voltage. The
highest voltage to which access
can be had by removal of the
cover shall be shown, where
dangerous voltages exist.
Where non-insulated electronic

circuits are positioned within 4
mm of a non-insulated tinned
surface, a loose barrier of
insulated materials shall be
provided between the surface and
the connection to prevent the
possibility of unwanted contact.
Approved soldered-in-lead
through connectors are exempted
from this requirement.
8.1.7
Electricity Supply
8.1.6.7 Cable Connecting Units

Terminal strips and terminals
shall be clearly and indelibly
coded. Terminals carrying mains
electrical power shall be
segregated from other terminals.
Unless approved by the S.O., not
more than three cable cores shall
be retained by any terminal. All
wiring and cabling shall be neat,
adequately supported to prevent
vibration, and so arranged as to
prevent strain on individual
wires, particularly on hinged
panels.
8.1.6.8 Insulation
If no value is specified, the
insulation resistance between any
two parts not intended to be in
electrical contact shall not be less
than 100 megaohms when
measured at a voltage appropriate
to the equipment. Where `n' such
paths are effectively connected in
parallel, the resistance of the
combination shall be not less than
100/n megaohms.
The Contractor shall comply with all

LLN or the power source authority
requirements in getting an electricity
supply to the installation, and any
costs associated with obtaining this
supply shall be included in the
Tendered rates. The Contractor shall
ensure that the equipment supplied
will function correctly at the supply
voltage, and shall allow for normal
variation and surges.
8.1.8
On-Site Commissioning Test

Procedures
Testing and commissioning of all
equipment shall be successfully
completed within one (1) month
from the date of completion of the
installations.
The Contractor shall notify the S.O.
when the on-site commissioning
tests are to be undertaken. The
Contractor and the Supervisor shall
forward to the S.O. duly certified
copies of the test results when the
tests have been successfully
completed. When the S.O. has
received these test results and is
satisfied that the system has passed
the test, the S.O. shall notify the
Contractor in writing that the system
has passed the on-site
Page 185
commissioning tests. The S.O. shall

notify the Contractor in writing of all
faults detected during these tests. If
the S.O. decides the system is not in
accordance with the Contract, he
may reject the system, and he shall
inform the Contractor of the reasons
in writing within a reasonable time.
8.1.9
Documentation
8.1.9.1 General
System manuals for each
equipment associated with the
Contract shall be delivered to the
S.O. Reissues shall be provided
if site commissioning and testing
make this necessary.
All documentation shall be
indexed and shall carry an issue
number and date.
Two copies each of the
documentation shall be supplied
to the S.O.
All documentation shall be
produced in uniform style in A4
size. All diagrams relating to the
final documentation shall be
reduced to page height, bound
and correctly referenced to the
text. They shall fold clear of the
text for ease of use.
Great care shall be taken to
ensure that in the writing of all
documentation, expert familiarity
with apparently simple features is
not advertently assumed.
Difficulties should be anticipated.
All documentation shall be in
English or Bahasa Malaysia.

8.1.9.2 Hardware, Software and
Maintenance Manual
The manual shall contain
descriptions of the complete
hardware system followed by
maintenance procedures. A
description of the complete
software system shall also be
included.
The hardware description shall
start with the overall
configuration of the system, with
layouts showing the location of
every unit, with block diagrams
and an explanation of the
operation of the system.
Detailed descriptions of
component units shall explain
their operation. Block diagrams
showing the flow and interaction
of data, logic diagrams, circuit
diagrams with component
valves, and layout diagrams
shall be provided. Parts lists and
wiring schedules shall be
provided, but care shall be taken
to avoid these obscuring the
operational description.
Maintenance procedures shall
cover the diagnosis of faults,
testing and setting up
adjustments, replacement of units
and routine mechanical servicing.
The software description should
aim at enabling new programs for
an intersection to be written, and
to provide the basic standard
techniques used in writing the
system programs. Where
programming technique is
dependent on particular features
of the system, it is important that
program material is specially
written. This shall be in the form
of guidance, referring to
operational features in the
software manual.
Page 186
An as-built plan showing the

final wiring diagrams, pole
locations, controller locations,
detector placement, conduit runs
and timing plan shall be
included in each controller
cabinet.
The Contractor shall carry out any

repair within 24 hours of being
informed of the damages. Upon
failure to do so, the S.O. has the
option to appoint another party for
repair and the cost thus incurred will
be borne by the Contractor.
8.1.10 Guarantee of Supply

The Contractor shall be required to
ensure that for a period of not less
than 10 years from the date of
commissioning the system, a supply
of replacement components and
materials or their agreed equivalent
is available, as the S.O. may require.
A Contractor who is not a
manufacturer is required to submit a
letter from the manufacturer
certifying that the manufacturer will
support the equipments and
components.
All maintenance conducted shall be

entered into the Local Controller
Logbook, dated and signed by the
maintenance staff of the Contractor.
Repainting of the signal aspects,
posts, and local controllers shall be
performed just before the end of the
Warranty Period.
8.2
LOW VOLTAGE UNDER

GROUND CABLES
8.2.1
Types of Cables
8.2.1.1 Power Cables

8.1.11 Warranty Period
After acceptance of the installation,
the Contractor shall still be subject to
obligation of free servicing, change
in phasing, maintenance and free
replacement of all defective parts and
fused bulbs for a period of twelve
(12) months from the date of issue of
the Certificate of Completion. A
qualified Service Engineer provided
by the Contractor must be available
on 24 hours service a day to attend to
any breakdown at anytime including
public holidays.
All repairs and replacements
required during the Warranty Period
shall be carried out with despatch
and an adequate supply of spares
shall be available for this purpose.
The Contractor shall be liable for
damages if he does not undertake
remedial works within 24 hours.
Power cables shall be

accordance with M.S. 274 and
shall have high conductivity plain
insulated with PVC suitable for a
voltage of between 600 and 1000
V, laid together and bedded with
PVC, armoured with galvanised
steel wires and sheathed with
PVC. The copper conductors for
Mains Power cables running
from the power source to the
controller shall have a nominal
cross-sectional area not less than
16 sq.mm. Other interconnecting
signal cables shall be multicore
cables having copper conductors
of nominal cross-sectional area
not less than 1.5 sq.mm with a
minimum of 5 cores.
Page 187
The current rating of cables shall

comply with the appropriate
Tables of the latest IEE Wiring
Regulations for the class of
conductor used.

8.2.1.4 Earthing Conductors
Earthing conductors shall have a
nominal cross-sectional area of
2.5 sq.mm and earthing rods shall
have a minimum cross-sectional
area of 10 sq.mm.
8.2.1.2 Feeder Cables for Vehicle

Detectors
8.2.2
The material for feeder cables to
vehicle detectors shall be
screened, twisted balanced-twin
cables which shall be
accordance with M.S. 274. The
core conductors shall be of
annealed copper having a
nominal cross-sectional area of
1.5 sq.mm unless otherwise
specified. The cable shall have a
nominal characteristic impedance
(Zc) of 90 ohms at 50 kHz.
Unless otherwise permitted, all cable

termination and jointing works shall
be carried out in the presence of the
S.O. A plastic laminated plate
engraved with details such as size of
cable, number of cores, date of
commissioning, date of jointing,
length of cable, distance of cable
joint, etc., shall be securely fixed
near the termination.
PVC/SWA/PVC cables shall be
provided with compression cable
gland termination. The cable gland
shall be of gunmetal or brass and
shall grip both the inner and outer
PVC sheath of the cable. It shall be
so designed that any strain on the
cable is taken by the steel wire
armouring which shall be effectively
sealed between the gland itself and
the outer cable sheath.
The conductors shall be insulated.

The insulation shall be
waterproof and, when installed,
shall withstand a temperature of
70C without suffering damage or
deformation.
8.2.1.3 Loop Cables for Vehicle
Detectors
The material for inductive type
vehicle-detector loop cables shall
be in accordance with Australian
Standard 2276.3 unless
otherwise specified herein. Any
deviation from A.S. 2276.3 shall
be at the request of or subject to
the approval of the S.O. The
detector sensing shall be of a type
which can be easily assembled
from bulk cable on Site, and
Cable Termination
8.2.3
Cable Jointing
No cable jointing shall be allowed
for interconnecting signal cables.
Jointing of mains power cables shall
be allowed only when approved by
the S.O.
8.2.4
Cable Markers
Cable markers with lettering and
signs as shown on the Drawings
shall be provided by the Contractor
at every change of direction of
underground mains power cable
routes and at every 15 metres on
straight runs. Cable markers shall be
Page 188
of heavy duty reinforced concrete

construction and shall be approved
by the S.O.
The cable marker shall form a
trapezoidal block with a 100 mm
square top face and 150 mm square
bottom face, and shall be 400 mm in
height as shown on the Drawings.
The top face shall be indented in
bold lettering with the initials `L.V.'
and a directional sign or signs
indicating the direction/directions of
the cable route. The cable marker
shall be buried to a depth of 300 mm
or any other depth as directed by the
S.O. Cable joint markers of similar
construction but with the symbol `X'
shall be provided and installed at
every cable joint in a similar manner.
8.3
SIGNAL LANTERNS
8.3.1
All components, their installation
and performance, shall be in
accordance with A.S. 2144 unless
otherwise specified herein. Any
deviation from A.S. 2144 shall be at
the request of or subject to the
8.3.2

For horizontal overhead signals,
the coloured lens of the left-most
optical system shall be green,
the middle one amber, and the
right-most one red, as seen by the
driver.
Primary signals shall be fitted
with a type A visor and secondary
signals shall be fitted with a type
B visor as described in A.S.
2144.
8.3.2.2 Optical Arrangement for
Pedestrians
Each signal face shall contain
two optical systems arranged
vertically, each having a diameter
of not less than 295 mm nor
more than 305 mm, which shall
incorporate pedestrian symbols as
upper optical system shall
illuminate a red `DON'T WALK'
symbol and the lower one a green
`WALK' symbol. The optical
system spacings shall be as
8.3.2.3 Height of Signal
(a) Post-Mounted Signals
Intended For Drivers
Optical Requirements
8.3.2.1 Optical Arrangement for Drivers

Each signal face shall, unless
otherwise shown on the
Drawings, contain three optical
systems arranged vertically, each
having a diameter of not less
than 295 mm nor more than 305
mm. For post-mounted signals,
the coloured lens of the upper
optical system shall be red, the
middle one amber, and the lower
one green.
The height of signals shall be

such that when erected the centre
of the amber optical system shall
be not less than 2.4 metres nor
more than 4 metres above the
carriageway level. Where no
amber signal is installed these
dimensions apply to the centre of
the green signal.
Page 189
(b) Light Signals Intended For

Pedestrians
iv) overall length : 44 mm

maximum;
The height of signal shall be

such that when erected the
height of the lower edge of
the housing enclosing the green
signal shall be not less than 2.1
metres nor more than 2.6 metres
above the carriageway level.
v) overal diameter : 12 mm
maximum;
(c) Overhead Mounted Traffic

Control Light Signals
The height of overhead mounted
signals shall be such that when
erected, the lowest point of the
signal head assembly shall be not
less than 5.5 metres nor more
than 8.5 metres above the
carriageway level.
8.3.3
vi) nominal operating voltage :

11.7 V.
Each tungsten halogen lamp shall

be provided with an appropriate
transformer complying with the
requirements of B.S. 9720,
mounted within the signal head
and connected to a terminal block
which may be mounted remotely.
Wiring between the lamp holder
and the transformer and the
terminal block shall be in
compliance with the requirements
of M.S. 136 and B.S. 6007.
8.3.3.2 Target Boards
8.3.3.1 Lamps
The lamp used in the optical
system, to meet the requirements
of A.S. 2144 Section 3, shall be
a 12 V, 50 W, long life tungsten
halogen lamp.
The bulb shall be clear,
uncoloured and the filament shall
only be used in the horizontal
position. The lamp shall meet the
following requirements as tested
in A.S. 2144 :i) nominal lumens :
ii) nominal life :
820
lm at 12 V;
2000 hours
continuous
burning at
12 V input;
iii) nominal colour temperature :

2850 K at 12 V input;
Unless otherwise specified, a

target board shall be provided
with each signal face intended for
vehicle drivers, extending not less
than 275 mm above the centre
of the upper optical system nor
less than 275 mm below the
centre of the lower optical
system. It shall extend not less
than 280 mm horizontally either
side of the vertical centre line of
the optical system. Other types
of target boards shall be as shown
on the Drawings. The target
boards shall be manufactured
from a durable resilient material
and shall be stiffened where
necessary to resist distortion due
to wind and extreme ambient
temperature. All target boards
shall have an orange border not
less than 45 mm nor more than
55 mm wide.
Page 190
8.4
SIGNAL POSTS AND MAST

ARMS
8.4.1

8.4.3
Provision shall be made for the

connection of terminating and inter
connecting cables coming from
within the post or mast arm and of
cables from the traffic signal
lanterns.
All signal posts, signal mast arms
and mountings of signal lanterns
shall be as shown on the Drawings.
The posts and mast arms shall be so
designed and constructed as to
provide adequate support and
stability for the signal head assembly.
8.4.4
Mast arms shall be tubular hollow

sections of steel of a generally
tapered form mounted on a baseplate
Where possible, the signal should

have a clearance of 300 mm to 450
mm behind the kerb line. The post
shall be at a distance not less than 1
metre before the edge line.
Every post shall be provided with

one nickel-plated brass earthing
screw located within the post, 25
mm below the top.
In areas where there is no kerb, the

steel posts should be erected so that
the signal head is clear of the
shoulder (or usable area) and
should not be less than 2 m nor
more than 3 m from the edge of the
nearest traffic lane.
The posts and mast arms shall be

capable of having holes drilled in the
vertical section, 1 metre above the
ground, for the mounting of one
pedestrian push-button assembly in
accordance with Sub-Section 8.5.
All posts and mast-arms shall have

their exact location determined by
the S.O. and recorded on the as-built
Drawings.
Cable Entry
Buried posts shall incorporate a
cable-entry aperture as shown on the
Drawings. Baseplate-mounted posts
shall provide for entry of the cable
into the interior of the post through a
hole in the baseplate having a
diameter not less than the inside
diameter of the post.

The posts and mast arms shall be
erected at the approximate locations
as shown on the Drawings. On
roadways whose edges are defined
by a raised kerb, the posts shall be
erected so that no part of the signal
head other than overhead signals
projects over the roadway.
All signal posts shall be of tubular

hollow section of steel with a
nominal diameter of 100 mm and
fitted with a weather-proof cap to
prevent ingress of water.
8.4.2
Connecting Facilities for Cables
8.4.5
Finish
interior and exterior of steel posts
shall be protected by a finish
complying with the requirements of
M.S. 740.
Page 191
The exterior surface of steel posts shall be

painted with alternate black and orange bands
of 300 mm width in weather resisting plastics
material as specified in Clause 6 of B.S. 873,
Part 1, and as shown on the Drawings.
Any surface cut after galvanizing, painting, or
the application of the plastics finish, shall be
wire brushed and given two coats of good quality zinc-rich paint in accordance with B.S.
4652.
8.5
PEDESTRIAN PUSH-BUTTONS
8.5.1
All pedestrian push-buttons, their
mechanism and operation, shall be
in accordance with A.S. 2353
unless otherwise specified herein.
Any deviation from A.S. 2353 shall
be at the request of or subject to
8.5.2
Location
Pedestrian push-button detectors
shall be provided facing the footpath
at each end of each crosswalk where
pedestrian actuated signals are
required as shown on the Drawings.
8.5.3
Pedestrian Demand Indicator

When the button is pressed, an
internally illuminated panel shall
light up bearing the legend `NANTI',
which shall be white on a black or
blue background. It shall continue to
be displayed until the cross signal
(green man) commences. The
pedestrian demand indicator shall be
provided with all pedestrian pushbuttons unless otherwise shown on
the Drawings.

8.5.4
Audible Signal
An audible signal shall, unless
otherwise specified, be provided
with all pedestrian push-buttons in
accordance with A.S. 2353.
8.6
TRAFFIC CONTROLLER
8.6.1
A controller is the complete timing
mechanism which controls the
signal phases at an intersection. The
controller shall be microprocessorbased consisting of :i) a microprocessing unit;
ii) interfacing for inputs and outputs;
iii) ancillary equipment.
The control equipment and
components shall be housed in a
weatherproof cabinet as specified in
Sub-Section 8.6.2.
The controller shall be able to
provide four phases and shall be
capable of expansion to at least eight
phases by the addition of modules on
site, which shall be in addition to any
special phase required in connection
with start up sequences, all reds,
etc. It shall also provide a variety of
timing functions and differing
operational modes. The controller
unit shall be capable of operating a
minimum of eight plans in a 24 hour
period. All active and passive
components, their mountings and
plugs, sockets and connections
shall be suitable for their application.
Page 192
8.6.2
Housing
All means of access shall be

protected by locks of different
patterns and the corresponding locks
and keys shall be identical for
controller housings of the same
make, type and series. Not less
than two keys of each type shall be
supplied with each controller and
they shall be handed over to the S.O.
after the completion of testing and
commissioning.
The housing shall have a

weatherproof enclosure for the
protection of :i) the logic module;
ii) interfacing and/or lamp switching
modules;
iii) power supplies;
A log book shall be provided in each

housing for the purpose of
maintenance and inspection records.
The log book shall be attached to the
housing by a cord or similar method
to prevent removal from the housing
cabinet. A pocket or shelf shall be
provided within the housing for its
storage.
iv) a `call-recorded' tranformer;

v) mains switch board;
vi) facility switch;
vii)shelf space for mounting of
vehicle detectors.
The housing cabinet shall be in
accordance with A.S. 2578, Part 1,
unless otherwise specified herein.
Any deviation from A.S. 2578, Part
1, shall be at the request of or
subject to the approval of the S.O.
Housing shall be manufactured from
such material approved by the S.O.
Appropriate means of entry and
support for cables shall be provided.
Sufficient ventilation shall be
provided to prevent condensation
inside the cabinet under all weather
conditions. Charcoal or some other
dehydration agent shall be placed in
the housing as directed by the S.O.
All non-current carrying metal parts
shall be bonded together and
effectively earthed in accordance
with CP 1013.
8.6.3
Controller Mains Switch Board

The controller mains switch board
shall consist of :i) one mains switch and one mains
fuse (rated 30 A);
ii) one isolation switch together with
a fuse to control mains supply,
active to all lamps;
iii) one flashing yellow feature
switch and fuse;
iv) one equipment switch and fuse
(rated 15 A) to supply four
sub-circuits labelled as :. controller
. detectors
. auxiliary
. general purpose outlet;
v) neutral link;
vi) earth link.
Page 193
The controller shall be suitable for

operation at 240 V + 6%, 50 Hz +
1%, single phase A.C. supply.
8.6.4
When the pedestrian indications are

allowed an exclusive phase, the
pedestrian steady green shall be
controlled by the appropriate control
command and followed by the
flashing green pedestrian signal. The
intergreen periods shall be inserted
before the pedestrian steady green
and between the end of the flashing
green and the start of the next
vehicle phase green. It shall be
possible to operate the pedestrian
phase with or without pedestrian
detection. This shall be selected by a
switch or other methods within the
controller, subject to the approval of
the S.O.
Facility Switch
A facility switch shall be provided to
switch the signal lanterns to ON,
OFF or FLASH or other facilities
such as manual operation. The
switch shall only control the signal
lamps and flashing yellow circuits
while leaving the control equipment
fully operative.
Access to this facility shall be via a
separate locked door or some other
means which does not give access to
the controller. The facility shall be
located not less than 1 metre from
the ground level.
8.6.5
Pedestrian Facilities
Pedestrian indications shall be
allocated as exclusive phases or be
connected in parallel to a green
phase(s).
When the pedestrian indications are
connected in parallel to a green
vehicle phase, the steady pedestrian
green shall commence at a preset
period adjustable to 0, 1, 2, 3, 4
or 5 seconds before or after the start
of the green vehicle phase. The
steady pedestrian green shall persist
until the end of a preset period.
It shall be followed by the flashing
pedestrian green. The flashing
pedestrian green shall flash at 76 to
84 flashes per minute, and the lamp
shall be on for between 50% to
70% of the time. The amber signal
terminating the vehicle green phase
shall not commence until a preset
period adjustable to 0, 1, 2, 3, 4 or
5 seconds has elapsed after the
termination of the flashing pedestrian
green.
8.6.6
Logic Module
Arrangement of the microprocessor
based logic module shall be subject
to the approval of the S.O.
8.6.6.1 Microcomputer System

The microcomputer system shall
contain a stored program in readonly-memory (ROM). Part or all
of the ROM shall be
reprogrammable. The stored
program shall permit the traffic
controller to be operated in
different traffic modes as
follows :i) isolated traffic-actuated
operation;
ii) cableless/Synchronous
operation;
iii) fixed time operation.
All information relating to a
particular signal installation,
such as number of plans, signal
groups, detector logic, time
setting and description of logical
Page 194
and conditional features, shall be

contained in the reprogrammable
ROM.
Time settings may be stored by
means of :i) reprogrammable ROM; and
ii) battery back-up RAM.
The RAM settings shall be such
that they may be changed by
means of a detachable keyboard
while the controller is
functioning. The reprogrammable
ROM shall be separate from the
CPU and its associated circuitry
to facilitate field servicing.
8.6.6.2 Input/Output Interfaces
The Contractor shall provide for
the approval of the S.O., detailed
technical information on the
input and output interfaces.
Inputs include those from vehicle
detectors, pedestrian push
buttons and signal links. The
output shall be to the vehicle
signal lamps, pedestrian lamps,
wait indicators and signal
linking.
8.6.6.3 Real `Time-of-Day' Clock
For cableless/synchronous
linking operations, a hardware
clock shall be provided. The
circuit generating the hardware
clock shall be backed up by a
standby battery for up to 48
hours or more (when fully
charged).

The clock shall derive its timing
from two sources, either from the
50 Hz mains supply or a crystal
oscillator. When the mains
supply is normal, the 50 Hz
mains frequency shall provide the
time. The crystal reference signal
shall be phase locked to the
mains frequency by a digital
phase locked loop. The real time
clock shall provide time in
seconds, minutes, hours and
days to the microprocessor via a
data bus.
8.6.6.4 Operator Interface and Controller
Display
A keyboard display unit shall be
provided as an operator interface
with the controller logic module.
Visual indicators shall be
provided to indicate the status of
various traffic parameters such as
the phase currently running, base
phase step for each phase,
demand for each phase, pedestri
an demands recorded, etc.
When operated in link mode, the
display shall be able to provide
all traffic parameters associated
with the appropriate link mode.
8.6.6.5 Supply Monitor
All D.C. power supplies to
various cards in the logic module
shall be constantly monitored to
ensure correct operation of the
controller.
The monitor shall be arranged so
that if one or more of the supply
output voltages falls below
certain preset levels, the power
failure detection circuit will
activate to cause the controller to
black out the intersection.
Page 195
The mains supply voltage shall

also be monitored. Any voltage
drop below certain levels shall
cause a black out situation.

8.6.10 Interchangeability
All parts shall be interchangeable
with like parts for equipment of the
same make, type and series.
8.6.6.6 Watchdog Timer

8.6.11 Vibration and Noise
A watchdog timer shall be used
to detect failure of the
microprocessor system to execute
its traffic control program. Any
failure to execute traffic
instruction shall black out the
intersection.
8.6.7
The apparatus shall be reasonably

quiet and the mechanism shall not
cause undue vibration. The
apparatus shall be constructed so as
to reduce to a minimum any damage
to lamps and equipment due to
vibration caused by traffic.
Mains Supply Interruptions

8.6.12
In the event of a mains supply
interruption equal to or less than
50 milliseconds, the controller shall
continue to function correctly. When
a controller commences to fail (after
a mains supply interruption in
excess of 50 milliseconds) it shall
shut down for the duration of the
mains interruption plus a nominal
period of about 5 - 10 seconds. At
the expiration of this nominal period
the controller shall commence
operation at an all red state. This
state shall persist for at least 5
seconds and shall be followed by
the pre-selected phase.
8.6.8
Circuit Breakers
Appropriate fuses or circuit breakers
shall be provided by the Contractor
for the connection of the controller to
the mains supply. A mains isolation
switch shall also be provided.
8.6.9
Inputs
All inputs shall be suitably protected
against high voltage peaks and short
circuits.
Radio Interference
The design of equipment shall be
such as to prevent interference to
telegraphic, telephonic or
radiotransmissions. The
apparatus will be considered to
meet this requirement, as far as
radio interference is concerned,
if the interference produced by it
does not exceed the limits laid
down in M.S. 71 and B.S. 800.
8.6.13
Safety
Where right of way signals are
shown for any controlled traffic
in one phase, it shall not be
possible through failure of any
operating component of the
controller to give a right of way
signal to a conflicting traffic
signal.
The Contractor shall satisfy the
S.O. as to how the conflicting
green state can be detected and
what action is to be taken on its
detection. The use of two
independent safeguard systems is
favoured. A method of testing
the operation of the safeguards
shall be provided.
Page 196
The Contractor shall satisfy the

S.O. as to how the conflicting
green state can be detected and
what action is to be taken on its
detection. The use of two
independent safeguard systems is
favoured. A method of testing
the operation of the safeguards
shall be provided.
8.6.14
VEHICLE DETECTORS
8.7.1
All equipment, its construction and
performance, shall be in accordance
with A.S. 2703 unless otherwise
specified herein. Any deviation from
A.S. 2703 shall be at the request of
or subject to the approval of the
S.O.
8.7.2
8.7.3
Number of Traffic Lanes

The loop detector shall sense traffic
flow on one to four traffic lanes
depending on where it is installed. It
shall sense traffic moving in one
direction only and detection on a two
way road shall be achieved by using
two sets of detectors so that the
information obtained for each
direction is separate.
Supply Voltage
The detectors shall operate on 240
V + 6%, 50 Hz + 1% single phase
A.C. power supply. Power shall be
supplied from the traffic controller.
8.7.4
Equipment Construction
for the manufacture, installation and
commissioning of the detector
system.
Timing
The duration of all periods timed
by the controller shall be within
+ 10% of the nominal time when
the applied main voltage is within
the range between + 10% of the
nominal value and + 4% of its
nominal frequency. This shall
apply to those timing
arrangements which measure
selected fixed periods. The
flashing rate of any flashing
signals shall be between 76 and
84 flashes per minute within the
same voltage and frequency
limits.
8.7
8.7.5
Performance Requirements
The detector shall respond to any
vehicle, except bicycles and
trishaws, normally encountered on
public roads travelling at any speed.
The Contractor shall satisfy the S.O.
with respect to the accuracy of the
detector unit in terms of false or nil
presence actuation at normal
operating sensitivity for all types of
vehicles including high-bodied
vehicles and multi-axle vehicles.
8.8
ROADWORKS
8.8.1
General
The Contractor shall carry out all
necessary roadworks in connection
with the installation of the system.
These shall include any roadworks
associated with :i) installation of Local Controller
and Detector Recording
housings;
ii) installation of signal poles and
heads;
iii) installation of cable ducting;
Page 197
If an existing conduit has been

installed across the road carriageway,
all cross-carriageway cabling shall
be carried by this conduit.

8.8.3
Excavation, Backfilling
Reinstatement and Maintenance of
Excavations
8.8.3.1 General
8.8.2
Permission to Excavate Road

The Contractor shall apply to the
S.O. for approval to excavate the
roadway. This approval shall not be
unreasonably withheld.
The application shall be made not
less than seven (7) days before the
commencement of the work.
The Contractor shall comply with the
following conditions and other
additional instructions from the
S.O. :i) trenching in sidetables, footpaths
and carriageways shall be
excavated, backfilled, reinstated
and maintained as specified in
this Sub-Section;
ii) cables to be laid in carriageway
shall be at least 750 mm below
the carriageway level;
iii) cables running longitudinally in
footpaths and side-tables shall be
at least 600 mm clear of the
edge of the kerb line or
carriageway and at least 750 mm
below the adjacent carriageway
channel level;
iv) no work shall be done during
traffic peak hours unless
The Contractor shall cause as

little obstruction as possible to
the general public during the
execution of all works under this
Contract, and shall pay due
regard to the interests and
convenience of the public and of
all private persons who have
property in or are resident in the
neighbourhood of the works.
The Contractor shall ensure that
no delay occurs between opening
excavations, laying cables,
backfilling and reinstatement and
that these actions form a
continuous process.
8.8.3.2 Excavation
Each trench shall be excavated to
the required level and materials
taken out shall not be re-used
unless otherwise specified or
For excavation in side-tables,
turfs shall be carefully removed,
stacked and periodically watered
for later re-use. The remaining
excavated materials may be
stockpiled on the Site for later
backfilling but excavated topsoil
shall be kept separate.
For excavation in carriageways
and footpaths, selected granular
materials, excavated premix and
subbase may be stockpiled on
Site for later backfilling. All
other unsuitable excavated
material must be removed to
spoil on the day it is excavated.
Page 198
All excavated materials shall be

kept clear of the carriageways at
all times.
All sides of excavations shall be
vertical. In soft or unstable
ground the sides shall be
adequately supported.
All excavations shall be kept free
of standing water.
If, for unavoidable reasons, a
trench running laterally across a
road cannot be backfilled and
must be left open overnight or for
a longer period, then steel plates,
securely bolted and adequate to
take traffic loading, shall be
placed across the trench and the
section of road opened to traffic.

necessary to cross drains, culverts
or similar obstructions which are
too deep for the cables to be
buried below, galvanised steel
pipes shall be provided. The
pipes shall be supported at each
end in a concrete block and
shall project through the blocks
into the ground to a depth of a
least 750 mm. All ducts shall be
extended at least 600 mm beyond
paved areas, concrete areas,
drains, road crossings, pipe
crossings, etc.
S.O., the number of cables
installed in each duct shall be
such that the space factor shall
not be less than 60 %. A drawn
wire shall be provided in each
duct.
8.8.3.3 Bedding of Excavation

Before ducts are laid, the trench
beds shall be levelled and sand
placed on the bed and hand
tamped to a thickness of not less
than 75 mm. All ducts shall be
covered by a layer of sand hand
tamped to a thickness of at least
75 mm above the crown of the
duct.
8.8.3.4 Cable Ducts
At road crossings, sewerage pipe
crossings, water pipe crossings,
paved areas, concrete areas and
areas specified by the S.O.,
cables shall be protected by
galvanised steel pipes buried to a
depth of 900 mm below
finished ground level. The pipes
shall be heavy duty pipes,
complying with B.S. 1387,
complete with screwed and
socketed joints. Unless otherwise
specified, the pipes shall be 150
mm in diameter. Where it is
Unless specified to be provided

by others, the above galvanised
steel pipes shall be provided by
the Contractor whether they are
shown on the Drawings or not.
8.8.3.5 Cable Laying and Installation
All cables shall be handled, laid
and installed according to this
Specification, the IEE Wiring
Regulations, cable manufacturer's
recommendations and ERA
Reports by using proper
installation equipment.
All cables shall be supplied in
complete length to suit the
circuits they serve and no straight
through joints shall be used.
Straight through joints in the
cable will only be permitted in
very exceptional circumstances
such as those arising from
unavoidable limitations in
manufacturing length. If straight
through joints or other approved
Page 199
joints are permitted by the S.O.,

the cost of such joints shall be
borne by the Contractor. No
joints in the cable will be allowed
unless approved in writing by the
S.O.
The minimum bending radius
of the cable shall be in
accordance with Table 52C of
the IEE Wiring Regulations (15th
Edition). Wherever cables are
cut, the ends shall be
immediately sealed in an
approved manner unless it is
intended to proceed with cable
jointing or termination straight
away.
the S.O., no cable shall be laid
and covered up in the absence of
the S.O.
8.8.3.6 Cable Laid Direct On The

Ground
Where trench beds have been
covered with sand, the cables
shall then be laid on this bedding
in an orderly manner without
overlapping and crossing each
other. After laying the cables, a
layer of 75 mm clean sand shall
cover the cables and shall be
carefully spread over the trench
before placing the cable
protective covers.
The cable protective covers shall
be clay bricks. The bricks shall
be new, well burnt and in
complete pieces. They shall be
laid lengthwise from end to end
along the entire route of the
underground cable if the cable
size is not more than 120 sq.mm.
For cable sizes exceeding 120
sq.mm, more than one row of

the underground cable if the
cable size is not more than 120
sq.mm. For cable sizes
exceeding 120 sq.mm, more
than one row of bricks shall be
laid. Each cable shall be
separately protected by these
bricks and the cover shall have at
least 25 mm overhang on each
side of the cable.
An orange coloured, multi-strand
nylon rope of minimum 6 mm
diameter shall be laid at a depth
of 300 mm along the trench to
identify the cable route. At every
10 metres interval, an extra 2
metres length of nylon rope shall
be coiled and laid.
8.8.3.7 Cables Installed in Precast
Concrete Trenches
Methods of installation of cables
in precast concrete trenches shall
be in accordance with Table 9A
of the IEE Wiring Regulations
(15th Edition) for Type L, Type
M or Type N cables. However,
if the method is not specified, the
cables shall be installed as
Cables laid at the bottom of
trenches shall be Type L cables
in accordance with Table 9A of
the IEE Wiring Regulations (15th
Edition). Cables installed on the
trench walls shall be Type M or
Type N cables in accordance
with Table 9A of the IEE Wiring
Regulations (15th Edition) and
the cables shall be secured on a
cable tray by means of saddles at
suitable intervals. In the case of
single core cables, whether
secured individually or in groups
to the cable tray, non ferrous
saddles shall be used.
Page 200
The cable tray shall be fabricated

from perforated hot-dipped
galvanised sheets finished in an
orange enamel. The minimum
thickness of the sheet steel used
shall be 1.5 mm for cable trays
with widths of up to 300 mm
and shall be 2.0 mm for widths
exceeding 300 mm. The cable
tray shall be supported at least
25 mm from the trench wall by
mild steel brackets at 600 mm
intervals. The brackets shall be
treated with anti-rust and painted
with one coat of primer. Samples
of the cable tray and brackets
shall be submitted to the S.O. for
approval prior to installation.
To provide electrical continuity,
all cable joints shall be bridged
by means of tinned copper tape
of dimensions not less than 25
mm x 3 mm. All saddles for
cables on cable trays shall be
installed using bolts, washers
and nuts. All tees, intersection
units, adaptor units, etc., shall
be factory manufactured unless
8.8.3.8 Backfilling of Excavations and
Reinstatements
For excavations in sidetables,
berms and slopes, the excavated
material shall be replaced in 150
mm layers in the reverse order to
which the material was
excavated. Each layer shall be
compacted with a power driven
rammer. The top 150 mm of
the excavation and adjacent
disturbed ground shall be filled
with good loamy topsoil and
hand tamped. Approved quality
grass turfs shall be closely and
continuously fitted over the
topsoiled area where necessary
and directly pegged down to
prevent displacement.

For excavations in carriageways
and footpaths the backfilling shall
be done in 150 mm layers to
within 300 mm of the surface
level using clean sand and
suitable excavated granular
material or other approved
granular material. Each layer
shall be compacted using a power
driven rammer. The next 230
mm of backfill shall consist of
crushed aggregate roadbase con
forming to Sub-Section 4.1.4 of
this Specification, laid and
compacted by a power driven
rammer. A tack coat of cationic
bituminous emulsion shall be
applied on the crushed aggregate
surface and a 75 mm thick layer
of compacted asphaltic premix
shall be placed as the final layer,
all in accordance with the
relevant requirements of Section
4 of this Specification.
8.8.3.9 Sensing Loop Slots
The Contractor shall be
responsible for providing the slot
in the roadway for the loop
sensor; the installation and
jointing of the loop feeder cable;
the backfilling of the slot in the
roadway; and the slot or trenches
for the feeder cables, all as
8.8.3.10 Maintenance of Drains and
Service During Excavations
The Contractor shall ensure that
he has full knowledge of the
location of all drains and services
in the area of any excavation
prior to the excavation
commencing. The Contractor
shall ensure that all precautions
are taken not to disturb such
drains and services and shall be
Page 201
responsible for their maintenance

during the reinstatement of such
excavations.
The Contractor should note if the
Site of the Works is subject to
frequent and heavy rainfall and
all precautions shall be taken to
maintain existing drainageways
to prevent flooding.
8.8.3.11 Reinstatement of Drains and
Precast Units
The Contractor shall carry out the
reinstatement of all existing
precast channel drains, gulleys,
pavement slabs, dividers, kerbs,
etc., which have been affected by
any trench opening. Only
excavated units in a sound and
undamaged condition may be
replaced, otherwise the
Contractor shall supply and lay
similar new units. The units shall
be replaced to the original lines
and levels and shall be bedded,
backed and jointed to the
8.8.3.12 Completion of Works
On completion of reinstatement
works at any one site, the
Contractor shall clear away all
debris, surplus materials and
plant and leave the site in a clean
and tidy condition. The
Contractor shall carry out any
further remedial works as
directed by the S.O. and shall
obtain the S.O's written approval
for the reinstatement works.

8.8.3.13 Maintenance of Excavation
The Contractor shall be entirely
responsible for the proper
maintenance and good condition
of each excavation and each
reinstatement up to a period of
three (3) calendar months after
the date of the S.O.'s written
approval of such reinstatement
works.
All excavation sites prior to,
during, and after reinstatement
shall be maintained in a sound
and firm condition, free from
depressions, humps, loose stones
and any other similar defects
such as not to constitute danger
or unreasonable nuisance to
traffic or members of the public.
Loose materials or stones shall
not be allowed to accumulate
over or around any excavation,
but shall be promptly swept clear.
Any part of reinstatement in a
footpath or carriageway that
settles more than 15 mm below
the adjacent undisturbed surface
level shall promptly be resurfaced to a level not more than
15 mm above the adjacent
undisturbed surface level. The
resurfacing shall be carried out by
applying a prime/tack coat and
asphaltic premix as specified in
The Contractor shall be required
to maintain a small mobile gang
of workmen for the above
purpose, and a regular system of
daily inspection shall be instituted
for all trenches awaiting
temporary and permanent rein
statement. Should the Contractor
default in the maintenance of
excavations and reinstatement
where, in the S.O.'s judgement,
Page 202
such default would constitute in

any way a traffic hazard, then
the S.O. shall have the power to
attend forthwith to such defects
and the entire cost of the work
plus 25% shall be borne by the
Contractor.
Before the expiration of the
maintenance period of each item
of work, the Contractor shall
write to the S.O. for final
inspection of the work to
determine any outstanding
defects which have to be
rectified. The Contractor will
only be absolved of all the
responsibilities of the
maintenance after such defects
are rectified to the satisfaction of
the S.O.
In the event that the Contractor
fails to notify the S.O. of the date
of expiration of the maintenance
period and has not arranged for
the inspection of the work, the
maintenance period of each item
of work shall be deemed to have
been extended by the Contractor
due to his fault to such time until
the final inspection is carried out.
8.8.4
Traffic Arrangements
8.8.4.1 General
Obstructions and excavations
shall be adequately fenced and
guarded at all times for the
protection of all persons who use
the roadway. Particular attention
shall be paid to the positioning of
the barriers. The whole
obstruction or excavation shall be
completely fenced off, but
unnecessary blocking of traffic
lanes shall not be permitted.
Roads shall not be used for the
unnecessary storage of materials.

On multilane roads, not more
than one traffic lane in either
direction shall be closed except as
may be otherwise directed by the
S.O. On roads of not more than
one traffic lane in each direction,
the Contractor shall ensure that
both lanes are kept open during
peak periods as previously
defined. This may be
accomplished by the use of steel
plates as specified in Sub-Section
8.8.3.2.
When the work is such that the
simultaneous closing of several
lanes cannot be avoided and
would cause undue interference
with traffic, the work should
either be carried out at night or
during weekends. However, the
S.O. may give permission for the
simultaneous closing of lanes for
emergency works or other works
as deemed necessary.
8.8.4.2 Arrangement and Location of
Signs, Barriers and Barricades
The general arrangement and
location of temporary signs at
works in progress shall be strictly
in accordance with ARAHAN
TEKNIK (JALAN) 2C/85,
published by Cawangan Jalan,
Ibu Pejabat JKR, Kuala Lumpur,
and shall be submitted by the
Contractor and approved by the
S.O. before work commences.
Work on a road involving less
than one-third of a traffic lane
and work on a footpath in the
immediate vicinity of the
carriageway of a high speed road
shall be deemed to be minor
obstructions. In these cases, as it
will not be necessary to close up
one full lane, shorter barriers
shall be used.
Page 203
All traffic signs used in

temporary signing must be
reflectorised. When practicable,
signs shall be sited where they
will receive maximum benefits
from street lighting.
8.8.4.3 Temporary Warning Lamps
Temporary warning lamps shall
be used during the hours of
darkness in conjunction with all
temporary signs, barriers and
other traffic control devices
which are to remain in position at
night. Lamps shall be kept alight
at all times during the hours of
darkness.
Warning lamps shall consist of
standard battery operated flashing
lights and shall be placed at
salient points of the site every
night.
8.8.4.4 Use of Traffic Guidance Cones
When a portion of a roadway is
closed to traffic by the use of
barriers, barricades or signs,
traffic guidance cones shall be
placed on the road so as to guide
traffic smoothly from the wide
section to the narrow section in
which a portion of the roadway
has been closed to traffic.
Cones shall be used only when
the work is in progress or where
there is a watchman who can
reposition any of the cones which
may have been dislodged by the
traffic. Otherwise they shall be
removed from the roadway when
work ceases at night. At night,
continuously operating flashing
lights shall be used to guide the
traffic.

Cones shall be of rubber or
equivalent flexible material and
shall be bright orange in colour.
8.8.4.5 Temporary Traffic Diversions
For the duration of the work, a
satisfactory roadway shall be
provided for the traffic. Where a
sufficient width of carriageway is
not available, a temporary traffic
diversion shall be constructed if
possible. The extra carriageway
shall be properly maintained in a
smooth and hard condition at all
times for the duration of the
work.
The maintenance of pedestrian
movement shall be provided by
construction of temporary walks,
barricades and handrails. Certain
areas along the construction site
may be restricted to pedestrian
use where such restrictions are in
the interest of pedestrian safety.
8.8.4.6 Temporary Traffic Control
It is essential that traffic control at
the site be exercised diligently
and by competent personnel, if
the need arises.
The methods of temporary traffic
control are :i) Police supervision : this
applies where the works are
of a very short duration with
some special feature, such as
a busy road junction;
ii) Manually operated 'Stop' and
'Go' signs : this applies at
works of short duration,
provided that traffic is not
dense. Red and green flags
should, under no
Page 204
circumstances, be used for

traffic control, but could be
used to supplement the disc
signs.

flashing lights on the top of the
vehicles. They should also have a
plate on the rear side with the
words `SLOW MOVING' or
`KENDERAAN PERLAHAN'.
8.8.4.7 Plant and Equipment

In all cases where traffic is
permitted to use the whole or a
portion of the existing road, all
plant items and similar
obstructions shall be removed
from the road at night, if at all
practicable. During the day, a red
flag shall project beyond the
extremity of all plant items (other
than vehicles) adjacent to the
traffic lane.
8.8.4.9 Maintenance of Signs, Lights,

Barriers,Temporary Traffic
Diversions, etc.
Signs, lights, barriers and other
traffic control devices shall be
maintained in good order and in
the correct position day and
night. Signs shall be neat, clear
and legible at all times.
Temporary traffic diversions shall
be maintained in good order at all
times.
Plant and equipment shall be lit at

night if within 5 metres of the
edge of the carriageway by two
red lights suspended vertically
from the point of obstruction
nearest to the carriageway. The
lights may be omitted in cases
where there are permanent
obstructions, such as trees less
than 5 metres from the edge of
carriageway and the plant or
equipment are not closer to the
road than the permanent
obstructions.
8.8.4.8 Vehicles
Vehicles which carry out
operations on the road and which
are required to travel slowly or to
stop at frequent intervals should
be made as conspicuous as
possible. This shall be achieved
by painting such vehicles a
distinctive colour, and/or
painting their rear portions with
diagonal stripes of a contrasting
colour, and/or providing
Page 205
SECTION 9
CONCRETE
Page 206
SECTION 9 - CONCRETE
Page
9.1
DESCRIPTION
S9-211
9.2
MATERIALS
S9-211
9.2.1
Cement
9.2.1.1 Transportation and Storage
S9-211
S9-211
9.2.2
9.2.2.1
9.2.2.2
9.2.2.3
9.2.2.4
9.2.2.5
Aggregates
Coarse Aggregates
Fine Aggregates
Grading
Sampling and Testing of Aggregates
Storage of Aggregates
S9-211
S9-211
S9-211
S9-211
S9-212
S9-213
9.2.3
Water
S9-213
9.2.4
Admixtures
S9-214
9.3
CLASSIFICATION OF CONCRETE MIXES
S9-214
9.3.1
Requirements for Prescribed Mixes
S9-214
9.3.2
9.3.2.1
9.3.2.2
9.3.2.3
9.3.2.4
Requirements for Designed Mixes

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

9.3.3.1 Workability
9.3.3.2 Concrete Grade
9.3.3.3 Minimum Cement Content
9.3.3.4 Maximum Cement Content
9.3.3.5 Total Chloride Content
9.3.3.6 Maximum Sulphate Content
9.4
S9-218
S9-218
S9-218
S9-218
S9-219
S9-220
COMPLIANCE WITH SPECIFIED REQUIREMENTS
9.4.1
Prescribed Mix
S9-220
9.4.2
Designed mix
9.4.2.1 Characteristic Strength
9.4.2.2 Sampling and Testing
9.4.2.3 Testing plan
S9-221
S9-221
S9-221
S9-222
9.4.3
S9-223
Additional Cubes
Page 207

Page
9.5
9.5.1
Supervision
S9-223
9.5.2
Batching and Mixing
S9-223
9.5.3
Transporting
S9-224
9.5.4
Placing
S9-224
9.5.5
Temperature Requirements
S9-226
9.5.6
Compaction
S9-226
9.5.7
Curing and protection
9.5.7.1 Normal Curing
9.5.7.2 Accelerated Curing
S9-227
S9-227
S9-228
9.5.8
S9-228
9.6
Ready-Mixed Concrete
CONSTRUCTION WITH CONCRETE
9.6.1
Construction Joints
S9-228
9.6.2
Fixing Blocks, Brackets, built-In-Bolts, Holes, Chases, etc.
S9-229
9.6.3
9.6.3.1
9.6.3.2
9.6.3.3
9.6.3.4
9.6.3.5
9.6.3.6
Precast Concrete Construction

Manufacturer Off the Site
Storage
Handling and Transport
Assembly and Erection
Forming Structural Connections
Protection
S9-230
S9-230
S9-230
S9-230
S9-230
S9-231
9.7
STEEL REINFORCEMENT
9.7.1
Description
S9-231
9.7.2
Materials
S9-231
9.7.3
9.7.3.1
9.7.3.2
9.7.3.3
9.7.3.4
9.7.3.5
Construction Method
Cutting and Bending of Reinforcement
Fixing of Reinforcement
Splicing
Supporting and Spacer Blocks
Welding of Reinforcement
S9-232
S9-232
S9-232
S9-233
S9-233
S9-233
Page 208

Page
9.8
FORMWORK AND SURFACE FINISH FOR STRUCTURE
9.8.1
9.8.1.1
9.8.1.2
9.8.1.3
9.8.1.4

Description
Voids In Concrete
Form Lining
Projecting Reinforcement, Fixing Devices
S9-234
S9-234
S9-235
S9-235
9.8.2
Finishes
9.8.2.1 Formed Surfaces
9.8.2.2 Unformed Surfaces
9.8.2.3 Remedial Treatment of Surfaces
S9-235
S9-236
S9-236
9.8.3
Preparation of Formwork Before Concreting
S9-237
9.8.4
Removal of Formwork
S9-237
Page 209
SECTION 9 - CONCRETE
9.1
DESCRIPTION
construction of all structures or parts of
structures to be composed of Portland
cement concrete with or without steel
reinforcement, except for reinforced
concrete pipe culverts, which shall be
constructed in accordance with the
provisions of Section 3.9, and Portland
cement concrete pavement, which shall
be constructed in accordance with the
provisions of Section 5. The work
shall be carried out all in accordance
with this Specification and the lines,
levels, grades, dimensions and crosssections shown on the Drawings and as
9.2

Manufacturer's certificates of test will, in
general, be accepted as proof of
soundness. Additional tests shall be
carried out on any cement which
appears to have deteriorated through
age, damage to containers, improper
storage or any other reason. In any
event, the batch of cement which has
been sampled and tested and found not
to have complied with the requirements
shall be rejected and removed from the
Site.
9.2.1.1 Transportation and Storage
The cement shall be transported
to the Site in covered vehicles
adequately protected against
water. It shall be stored in a
weather-proof cement store to the
approval of the S.O. and shall be
taken for use in the Works in the
order of its delivery into the store.
Cement delivered in bulk shall be
stored in silos of an approved
design.
MATERIALS
9.2.1
Cement
The cement to be used throughout
the work shall be Portland cement
obtained from an approved
manufacturer. The cement shall be
described under one of the following
headings :i) Ordinary Portland Cement
- the cement shall comply with
M.S. 522;
ii) Rapid Hardening Portland
Cement
M.S. 522;
iii) Moderate Sulphate Resisting
Portland Cement
B.S. 12;
9.2.2
Aggregates
Aggregates shall be naturally
occurring sand, gravel or stone,
crushed or uncrushed except as
otherwise specified, and shall
comply with M.S. 29. They shall be
obtained from a source approved by
the S.O. and shall be hard, strong,
durable and clean. They shall be free
from adhering coatings and shall not
contain any harmful material in
sufficient quantity so as to affect
adversely the strength, durability and
impermeability of the concrete.
Marine aggregates shall not be used
unless otherwise specified.
iv) Sulphate Resisting Portland

Cement
B.S. 4027.
Page 210
9.2.2.1 Coarse Aggregate
9.2.2.3 Grading
Coarse aggregate shall comply

with M.S. 29.
(a) Coarse Aggregate

The grading of coarse aggregate
shall be analysed as described in
M.S. 30 and shall be within the
limits given in Table 9.1.
9.2.2.2 Fine Aggregate

Fine aggregate shall comply with
M.S. 29. If it is found necessary,
the fine aggregate shall be
washed and screened to the
TABLE 9.1 - COARSE AGGREGATE

B.S.
410
Test
Sieve
% Passing By Weight
Nominal Size of
graded aggregate
(mm)
37.5mm
to
5.0 mm
20.0mm 14.0 mm
to
to
5.0 mm 5.0 mm
75.0
100
63.0
37.5
Nominal Size of
single-sized aggregate
63.0
mm
37.5
mm
20.0
mm
14.0
mm
10.0
mm
100
85 - 100
100
95 - 100
100
0 - 30
85 - 100
100
20.0
30 - 70
95 - 100
100
0-5
0 - 20
85 - 100
100
14.0
90 100
85 - 100
0-5
0 - 20
0 - 45
85 - 100
0-5
0 - 10
0 - 20
10.0
10-
35
25 - 55
40 - 85
5.0
0-
0 - 10 0
0 10
2.36
Page 211
(b) Fine Aggregate

The grading of fine aggregate shall be analysed as described in M.S. 30 and shall be with
in the limits of one of the grading zones given in Table 9.2.
TABLE 9.2 - FINE AGGREGATE
B.S. 410
Test
Sieve
% Passing By Weight
Grading
Zone 1
Grading
Zone 2
Grading
Zone 3
Grading
Zone 4
10.0 mm
100
100
100
100
5.0 mm
90 - 100
90 - 100
90 100
95 100
2.36 mm
60 95
75 100
85 100
95 100
1.18 mm
30 - 70
55 90
75 100
90 100
600 um
15 - 34
35 59
60 70
80 100
300 um
5 - 20
8 30
12 40
15 50
150 um
0 - 10
0 10
0 - 10
0 - 15
9.2.2.4 Sampling and Testing of

Aggregates
Samples of the fine and coarse
aggregates approved by the S.O.
shall be kept on Site, and shall
give a fair indication of the
general quality of the aggregates
for comparison with the
aggregates delivered during the
course of the work.
Tests shall be carried out on

samples of the latter taken at
intervals as required by the S.O.
The method of sampling and
testing shall be in accordance
with M.S. 30 and other standards
as specified in Table 9.3. Any
batch of aggregate rejected by the
S.O. shall be removed from the
Site.
Page 212
TABLE 9.3 - TESTING OF AGGREGATE
Properties
Test Methods
Grading
M.S. 30
Table 9.1 & Table 9.2
Elongation Index
M.S. 30
not exceeding 30%
Flakiness Index
M.S. 30
not exceeding 25%
Water Absorption
M.S. 30
not exceeding 1.5%
Clay, Silt and Dust
M.S. 30
not exceeding 2%
Organic Impurities
M.S. 30
not exceeding 0.4%
Aggregate Crushing
Value
M.S. 30
not exceeding 20%
AASHTO Test
Method T104
loss not exceeding 12%
Chloride Content
B.S 812
Part 4
not exceeding 0.06% by

weight
of chloride ions
Sulphate Content
B.S 1377
Test 9
Soundness Test
(Sodium Sulphate)
9.2.2.5 Storage of Aggregates

Separate storage facilities with
adequate provision for drainage
shall be provided for each
different size of aggregate used.
Aggregate shall be handled and
stored so as to minimise
segregation and contamination.
Limits
not exceeding 0.4% be

weight of SO3
9.2.3
Water
Water shall comply with the
requirements of M.S. 28. It shall be
clean and free from harmful matter
and shall be from a source approved
by the S.O. The Contractor shall
make adequate arrangements to
supply and store sufficient water at
the work site for use in mixing and
curing concrete. All costs for
installing and maintaining the supply
shall be borne by the Contractor.
Page 213
9.2.4
Admixtures
Admixtures which contain calcium

chloride or calcium formate as the
active constituents shall not be used
for structural concrete containing
reinforcement, prestressing tendons
or other embedded metal.
Suitable admixtures may be used in

concrete mixes with the prior
approval of or as directed by the
S.O.
All requirements for sampling,
acceptance tests, uniformity tests,
independant tests, chloride content,
information to be provided by
manufacturer, compliance and
storage certificates and marking shall
be in accordance with M.S. 922.
9.3
CLASSIFICATION OF
CONCRETE MIXES
The concrete mixes shall be

classified as :(a) Prescribed Mix
All admixtures shall be used strictly

in accordance with manufacturer's
instructions.
Before allowing the admixture to be
used in the work, relevant tests based
on trial mixes shall be carried out.
The trial mix shall be made using
job-site materials and under job-site
conditions. A control mix shall be
made using a conventional trial mix,
that is without using the admixture,
to determine the water/cement ratio
and mix proportions required to give
the specified strength with the
required slump. Using the same mix
proportions as in the control mix, a
test shall be prepared using the
recommended dosage of the
admixture. The results of relevant
tests obtained from the control mix
and test mix shall be compared. The
S.O. may allow the use of the
admixture only when the results are
found to be satisfactory and
comparable to the effects as claimed
by the manufacturer. Table 9.4 of
admixture acceptance test
requirements shall be complied with.

concrete that contains constituents in
the specified proportions.
(b) Designed Mix
The Contractor shall select the mix
proportions and unless otherwise
specified, the workability, in order to
satisfy the strength and other
requirements of the Contract.
9.3.1
Requirements for Prescribed Mixes

concrete mix shall be as detailed in
Table 9.5 which shows the weights
of cement and total dry aggregates,
in kilograms, to produce
approximately one cubic metre of
fully compacted concrete, together
with the percentages by weight of
fine aggregates in total dry
aggregates.
Page 214
9.3.2
Requirements for Designed Mixes
9.3.2.1 Target Mean Strength

The concrete mix shall be
designed to have at least the
required minimum cement
content and to have a target mean
strength greater than the required
characteristic strength by at least
the current margin.
The current margin for each
particular type of concrete shall
be determined by the Contractor
and shall be taken as the lesser
of :i) 1.64 times the standard
deviation of cube tests on at
least 100 separate batches of
concrete of nominally similar
proportion of similar materials
and produced over a period
not exceeding 12 months by
the same plant under similar
supervision, but not less than
2.5 N/sq.mm for concrete of
grade 15 or 3.75 N/sq.mm
for concrete of grade 20 or
above;

Where there are insufficient data
to satisfy (i) or (ii) above, the
margin for the initial mix design
shall be taken as 7.5 N/sq.mm
for concrete of grade 15 and 12
N/sq.mm for concrete of grade
20 or above. This margin shall
be used as the current margin
only until sufficient data are
available to satisfy (i) or (ii)
above. However, subject to the
approval of the S.O., when the
specified characteristic strength
approaches the maximum
possible strength of concrete
made with a particular aggregate,
a smaller margin not less than 5
N/sq.mm for concrete of grade 15
or 7.5 N/sq.mm for concrete of
grade 20 or above may be used
for the initial mix design.
ii) 1.64 times the standard

deviation of cube tests on at
least 40 separate batches of
concrete of nominally similar
proportions of similar
materials and produced over a
period exceeding 5 days but
not exceeding 6 months by
the same plant under similar
supervision, but not less than
5 N/sq.mm for concrete of
grade 15 or 7.5 N/sq.mm for
concrete of grade 20 or above.
Page 215
TABLE 9.5 - PRESCRIBED MIXES FOR GENERAL USE

PER CUBIC METRE OF CONCRETE
Grade of
Concrete
15P
28-day
Characteristic
Strenght of
Concrete
(N/sq.mm)
Nominal Max.
Sizes of
Aggregate
(mm)
40
20
Workability
Medium
High
Medium
High
Slump Limits
(mm)
50 -100
100 - 150
25 - 75
75 - 125
Cement (kg)
250
270
280
310
Total aggregate
(kg)
1850
1800
1800
1750
30 - 45
30 - 45
35 - 50
35 50
Cement (kg)
300
320
320
350
Total aggregate
(kg)
1850
1750
1800
1750
Fine aggregate
(%)
25 - 35
25 40
25 40
20 - 45
Cement (kg)
340
360
360
390
Total aggregate
(kg)
1800
1750
1750
1700
25 - 35
25 - 40
25 - 40
30 - 45
15
Fine aggregate
(%)
20P
25P
20
25
Fine aggregate
(%)
Fine aggregate is expressed as a

percentage by weight to the total
dry aggregates. The lower value
shall be used for finer grading.
9.3.2.2 Suitability of Proposed Mix
Proportions
The Contractor shall submit for
the approval of the S.O., prior to
the supply of any designed mix,
the following :-
i) the nature and source of each

material;
ii) appropriate existing data as evidence
of satisfactory previous performance
for target mean strength, current
margin, workability and
water/cement ratio; OR
full details of tests on trial mixes
carried out in accordance with SubSection 9.3.2.3;
Page 216
iii) the proposed quantities of

each material per cubic metre
of fully compacted concrete.
9.3.2.3 Trial Mixes
The Contractor shall give notice
to enable the S.O. to be present at
the making of trial mixes and
preliminary testing of the cubes.
The Contractor shall prepare trial
mixes, using samples of approved
material typical of those he
proposes to use in the Works, for
all grades to the satisfaction of
the S.O. prior to commencement
of concreting.
Sampling and testing procedures
shall be in accordance with M.S.
26. Three separate batches of
concrete shall be made. The
workability of each of the three
trial batches determined by
means of the slump test,
compacting factor test or vebe
consistometer test in accordance
with M.S. 26, shall be
appropriate to the proposed uses
and methods of placing and
compaction of the mix and shall
be approved by the S.O. Six
cubes shall be made from each
batch. Three from each set of six
shall be tested at an age of 7 days
and three at an age of 28 days.
The average strength of the nine
cubes tested at 28 days shall
exceed the specified characteristic
strength by the current margin
minus 3.5 N/sq.mm. The
approved trial mix shall then be
designated as the "designed mix"
and its corresponding workability
as the "designed workability".

During production, the S.O. may
require additional trial mixes to
be made before a substantial
change is made in the materials
or in the proportion of the
materials to be used. Trial mixes
need not be carried out when
adjustments are made to the mix
proportions in accordance with
9.3.2.4 Control of Strength of Designed
Mixes
(a) Adjustment to Mix
Proportions
Adjustment to mix proportions
shall be made subject to the
approval of the S.O. in order to
minimise the variability of
strength and to maintain the
target mean strength. The
specified limits of minimum
cement content and maximum
water/cement ratio shall be
maintained. Changes in cement
have to be declared. Such
adjustment shall not be taken to
imply any change in the current
margin.
(b) Change of Current Margin
A change in the current margin
used for judging compliance with
specified characteristic strengths
becomes appropriate when the
results of a sufficiently large
number of tests show that the
previously established margin is
significantly too large or too
small.
Page 217
Recalculation of the margin shall

be carried out in accordance with
Sub-Section 9.3.2.1. Although a
recalculated margin is almost
certain to differ numerically from
the previous value, the adoption
of the recalculated value will not
generally be justified if the two
values differ by less than 18%
when based on tests on 2 separate
batches or less than 11% when
based on tests on 100 separate
batches, or less than 5% when
based on tests on 500 separate
batches.
On the adoption of a recalculated
margin it shall become the
current margin for the judgement
of compliance with the specified
characteristic strength of concrete
produced subsequent to the
change.
9.3.3
Requirements for Concrete
9.3.3.1 Workability
The workability of the fresh
concrete shall be such that the
concrete is suitable for the
conditions of handling and
placing so that after compaction,
it surrounds all reinforcement,
tendons and ducts and completely
fills the formwork.
Workability of the concrete shall
be within one of the following
limits :i) Slump
- 25 mm or one-third of
the "designed
workability", whichever is
the greater.

- 0.04 where the "designed
workability" is between 0.8
and 0.9.
- 0.05 where the "designed
workability" is 0.8 or less.
iii) Vebe
- 3 seconds or one-fifth
of the "designed
workability", whichever is
less.
9.3.3.2 Concrete Grade
The grade of concrete to be used
in the Works shall be as stated on
the Drawings and in the Bill of
Quantities.
(Concrete grade shall be
designated as GRADE X/Y
where `X' is the numerical value
of the characteristic strength in
N/sq.mm as determined from
test cubes at 28 days, and `Y' is
the nominal size of aggregate in
mm. For a prescribed mix, a
suffix `P' shall be added after
`X').
9.3.3.3 Minimum Cement Content
The minimum cement content
shall be in accordance with Table
9.6 unless otherwise shown on
the Drawings.
9.3.3.4 Maximum Cement Content
The maximum cement content
shall not exceed 550 kg/cu.m
unless otherwise described in the
Contract or agreed by the S.O.
ii) Compacting Factor

- 0.03 where the
"designed workability" is
0.9 or more.
Page 218
TABLE 9.6 - MINIMUM CEMENT CONTENT AND MAXIMUM FREE

WATER/CEMENT RATIO FOR DESIGNED MIX
Exposure
Surfaces sheltered from

severe rain :-
Prestressed
Concrete
Reinforced
Concrete
Plain
Concrete
Nominal max.
size of
aggregate
(in mm)
40
20
Nominal max.
size of
aggregate
(in mm)
40 20
Nominal max.
Size of aggregate
(in mm)
40 20
(kg/cu.m)
(kg/cu.m)
(kg/cu.m)
Max.
Free
Water/
Cement
Ratio
1) surface protected
by a water-proof
membrane;
2) internal surfaces,
whether or not subject
to condensation;
300 320
270 300
250
280
0.55
3) surfaces continuously
buried and/or submerged
under water.
1) soffits;
2) surfaces exposed to
driving rain, alternate
wetting and drying
e.g.in contact with
backfill.
1) surfaces exposed to
the action of sea
water with abrasion
having a pH of 4.5
or less.
320
350
350
380
9.3.3.5 Total Chloride Content

The total chloride content of the
concrete mix arising from the
aggregate or any other source
shall not in any circumstances
exceed the limits in Table 9.7
expressed as a percentage
relationship between chloride
ions and weight of cement in the
mix.
320
350
270
300
0.50
350
380
320
350
0.45
Tests shall be carried out in

accordance with B.S. 1881 for
each grade of concrete, to
demonstrate that these limits are
not exceeded.
Page 219
TABLE 9.7 - MAXIMUM TOTAL CHLORIDE
Type of Concrete
Maximum Total Chloride

(%)
Reinforced Concrete
made with cement complying
with M.S. 522.
0.35 for 95%
of test results
with no result
greater than 0.50.
Plain Concrete
containing embedded metal
and made with cement complying
with M.S. 522.
Concrete made with

cement complying with B.S. 4027.
0.2
Prestressed Concrete and

Structural Concrete that is steam
cured.
Notes on Table 9.7 :(1) % Chloride ionsx 1.648

= % equivalent sodium
chloride.
(2) % Chloride ionsx 1.56
= % equivalent anhydrous
calcium chloride.
0.1
9.4
COMPLIANCE WITH SPECIFIED

REQUIREMENTS
9.4.1
Prescribed Mix
A prescribed mix shall be judged on
the basis of the specified mix
proportions. The workability shall be
chosen to suit the construction
requirements.
9.3.3.6 Maximum Sulphate Content

The total estimated sulphate
content of any mix, including that
present in the cement shall not
exceed 4.0% by weight of
cement in the mix. Tests shall be
carried out in accordance with
B.S. 1881 for each grade of
concrete to demonstrate that these
limits are not exceeded.
Notwithstanding this, strength tests

shall be carried out during the
progress of work. The rate of
sampling shall be as per Rate 2 for
ordinary structural concrete as in
Table 9.8. For each sampling, three
test cubes shall be made. One test
cube from each sample-batch shall
be tested for the 7-day compressive
strength.
Page 220
If the cube strength falls below

75% of the 28-day compressive
strength, then the S.O. may direct
the Contractor to take necessary
steps to review the process of the
production of concrete for future
use.
The remaining two test cubes
from the sample-batch shall be
tested for the 28-day compressive
strength. The appropriate
strength requirement shall be
considered to be satisfied if at
least one of the following is
complied with :i) none of the two test cubes is
below the specified
compressive strength;
ii) the average strength of the
two test cubes is not less than
the specified compressive
strength and the difference
between the two strengths is
not more than 20% of the
average strength.
In the event that the results of the
test do not meet the specified
requirements, the S.O. shall
determine the action to be taken
in respect of the concrete member
represented by the sample-batch
test cubes. Such action may
include demolition of the
member. The Contractor shall, if
required by the S.O., take cored
samples from the hardened
concrete member and carry out
the compressive strength test.

9.4.2
Designed Mix
9.4.2.1 Characteristic Strength

The characteristic strength of
concrete is that 28-day cube
strength, below which not more
than 5% of the test results may
be expected to fall. Compliance
with the specified characteristic
strength shall be judged by tests
made on cubes at an age of 28
days.
9.4.2.2 Sampling and Testing
All sampling and testing of
constituent materials shall be
provisions of the appropriate
available Malaysian Standards.
In particular, sampling and testing
of fresh and of hardened concrete
shall be carried out in accordance
with the provisions of M.S. 26.
The rate of sampling shall be as
given in Table 9.8, but not less
than one sample shall be taken
from each source of production
on each day that concrete of any
particular grade is used.
Page 221
TABLE 9.8 - MINIMUM RATE OF SAMPLING
Rate
Volume of concrete from

which a sample shall be taken
Rate 1
(Prestressed Concrete)
Every 10 cu.m
or every group of 10 batches *
Rate 2
(Ordinary Structural
Concrete)
Every 20.0 cu.m

Rate 3
(Mass Concrete)
Every 50 cu.m
* The sample shall be taken

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

from the same sample shall be
tested for the 28-day
compressive strength. The
average strength of the two cubes
shall constitute the 28-day
compressive strength of the
sample.
For compliance purposes :i) the average 28-day strength
determined from any group of
four consecutive samples shall
exceed the specified
characteristic strength by at
least 0.5 times the curent
margin.
The current margin shall be taken
as 7.5 N/sq.mm for concrete of
grade 15 or 12 N/sq.mm for
concrete of grade 20 or above
unless, in accordance with SubSection 9.3.2.1 or 9.3.2.4 (b), a
smaller margin has been
established to the satisfaction of
the S.O.
Page 222
In this respect, consecutive

samples are samples taken at
intervals not exceeding 14 days.
In all cases, at least four samples
shall be taken of concrete on the
first day of concreting for each
grade of concrete to be used in
the Works, irrespective of the
volume of concrete produced or
the sampling rate.

9.4.3
Additional cubes may be reuqired for

various purposes. These shall be
made and tested in accordance with
M.S. 26 but the methods of sampling
and the conditions under which the
cubes are stored shall be varied
according to the purpose for which
they are required.
ii) Each individual sample test result

shall be at least 85% of the
specified characteristic strength.
For determining the cube strength of

prestressed concrete before transer or
of concrete in a member before
striking formwork, sampling shall be
at the point of placing and the cubes
shall be stored as far as possible
under the same conditions as the
concrete in the members.
If any one sample test result fails to

meet the second requirement (ii),
then that result may be considered to
represent only the particular batch of
concrete from which the sample test
cubes were taken.
If the average strength of any group
of four consecutive sample test
results fails to meet the first
requirement (i), or more than one
sample test result in a group fails to
meet the second requirement (ii),
then all the concrete in all the
batches represented by all such
sample test results shall be deemed
not to comply with the strength
requirements.
For the purpose of this Sub-Section,
batches of concrete represented by
groups of four consecutive sample
test results shall include the batches
from which samples were taken to
obtain the first and the last sample
results in the group of four, together
with all the intervening batches.
Additional Cubes
The extra cubes shall be indentified

at the time of making and shall not
be used for the normal quality
control or compliance procedures.
9.5
9.5.1
Supervision
The Contractor shall ensure the
required standard of control over
materials and workmanship. The
S.O. shall be afforded all reasonable
opportunity and facility to inspect the
materials and the production of
concrete, to take any samples and to
make any test.
9.5.2
Batching and Mixing

The quantities of cement, fine
aggregate and various sizes of coarse
aggregate shall be measured by
weight unless otherwise approved
by the S.O. A separate weighing
machine shall be provided for
weighing the cement. Alternatively
the cement may be measured by
using a whole number of bags in
each batch. The quantity of water
Page 223
shall be measured by volume or

by weight. Any solid admixtures
to be added shall be measured by
weight but liquid or paste ad
mixtures may be measured by
volume or weight.
The batch weight of aggregate
shall be adjusted to allow for the
moisture content of the aggregate
being used. The accuracy of the
measuring equipment shall be
within :-
Mixing plant shall be thoroughly

cleaned before changing from
one type of cement to another.
The water content of each batch
of concrete may be adjusted so as
to produce a concrete of the
workability required.
9.5.3
Concrete shall be transported from

the mixer to the formwork as rapidly
as practicable by methods which will
prevent segregation or loss of the
ingredients and maintain the required
workability. It shall be deposited as
near as practicable in its final
position to avoid rehandling. The
concrete shall be conveyed by chutes
or concrete pumps only with
permission from the S.O.
3% of the quantity of cement

per batch;
3% of the quantity of water
per batch;
3% of the quantity of total
aggregate per batch;
5% of the quantity of
admixture per batch.
The mixer shall comply with the
requirements of B.S. 1305 or
B.S. 4251 where applicable. The
mixing time shall be not less than
two minutes or more than five
minutes after all the ingredients
have been placed in the mixer.
For cements other than ordinary
Portland cement, the mixing
time shall not be less than that
recommended by the
manufacturer and subject to the
S.O.'s approval of the trial mix.
Mixers that have been out of use
for more than 30 minutes shall be
thoroughly cleaned before any
fresh concrete is mixed. Unless
otherwise agreed by the S.O., the
first batch of concrete through the
mixer shall then contain only
two-thirds of the normal quantity
of coarse aggregate.
Transporting
9.5.4
Placing
For all concrete whether mixed on or
off the site of the Works, each batch
shall be placed and compacted with
in 2 hours of adding the cement to
the dry aggregates and within 45
minutes (or any other period of time
as approved by the S.O. if admixture
is used) of adding water to the
cement and aggregates. Concrete
shall not be placed in any part of the
structure until the S.O.'s approval
has been obtained. If concreting is
not started within 24 hours of
approval given, approval shall again
be obtained from the S.O.
All formwork and reinforcement
contained in it shall be clean and free
from standing water immediately
before the placing of the concrete.
Concreting shall be carried out
continuously between and up to pre
determined construction joints in one
sequence of operation. In the event
of unavoidable stoppage in positions
Page 224
not predetermined, the concreting

shall be terminated on a
horizontal plane and against
vertical surfaces by the use of
stopping-off boards.
Fresh concrete shall not be placed
against in situ concrete which has
been in position for more than
45 minutes (or any other period
of time as approved by the S.O. if
admixture is used) unless a
construction joint is formed in
accordance with Sub-Section
9.6.1. When in situ concrete has
been in place for 4 hours, no
further concrete shall be placed
against it for a further 20 hours.
Except where otherwise agreed
by the S.O., concrete shall be
deposited in horizontal layers to a
compacted depth not exceeding
450 mm where internal vibrators
are used; or 300 mm in all other
cases. The surface of the
concrete shall be maintained
reasonably level during placing.
Concrete shall not be dropped
into place from a height
exceeding 1500 mm. When
trunking or chutes are used, they
shall be kept clean and used in
such a manner as to avoid
segregation.
The Contractor shall maintain an
experienced steel fixer at the site
of reinforced concrete works
during the placing of concrete to
reposition any reinforcement
which may be displaced during
the work.

No concrete shall be placed in
flowing water. Underwater
concrete if deemed unavoidable
by the S.O. shall be placed in
position by tremies or pipelines
from the mixer. Concrete to be
placed under water shall be an
approved mix with the amount of
cement increased by 20%.
During and after concreting under
water, pumping or dewatering
operations in the immediate
vicinity shall be suspended until
the S.O. permits them to
continue. Where the concrete is
placed by a tremie, the following
requirements shall be
applicable :i) unless otherwise agreed by
the S.O, when concreting of
bored piles is being carried
out under water, temporary
casing shall be installed to the
full depth of the borehole so
that fragments of ground can
not drop from the sides of the
hole into the concrete as it is
placed;
ii) the hopper and tremie pipe
shall be a closed system. The
bottom of the tremie shall be
kept as far as practicable
beneath the surface of the
placed concrete;
iii) the tremie pipe shall be large
enough with due regard to the
size of aggregate. For 20 mm
aggregate the tremie pipe
shall be of diameter not less
than 150 mm and for larger
aggregate, larger diameter
tremie pipe shall be required;
Page 225
iv) unless otherwise agreed by

the S.O., the first charge of
concrete shall be placed with
a sliding plug pushed down
the tube ahead of it to prevent
mixing of concrete and water;
v) the tremie pipe shall always
penetrate well into the
concrete with an adequate
margin of safety against
accidental withdrawal if the
pipe is surged to discharge the
concrete;
vi) the concrete shall be
deposited wholly by tremie
and the method of deposition
shall not be changed part way
up to prevent the laitance
from being entrapped within
the structure;
vii)all tremie pipes shall be
scrupulously cleaned after
use.
9.5.5
Temperature Requirements
During hot weather, additional
precautions shall be taken to prevent
premature setting and loss of water
during placing of concrete in the
formwork. These precautions shall
include :i) no concrete having an internal
temperature exceeding 33C
shall be deposited;
ii) concrete shall not be placed in
formwork or around
reinforcement whose temperature
exceeds 36C;
iii) newly placed concrete shall be
protected from direct sunlight and
from loss of moisture by
covering, shading or other means;

iv) no concrete shall be placed
when the air temperature at
the point of deposition
exceeds 36C.
9.5.6
Compaction
Unless otherwise agreed by the S.O.,
concrete shall be thoroughly
compacted by vibration and
thoroughly worked around the
reinforcement, tendons, or
duct formers, around embedded
fixtures and into corners of the
formwork to form a dense
homogenous mass free from voids
and which will have the required
surface finish when the formwork is
removed. Vibration shall be applied
continuously during the placing of
each batch of concrete until the
expulsion of air has practically
ceased and in a manner which does
not promote segregation of the
ingredients.
The concrete maintained between the
two walls of formwork shall be
compacted by vibrating of the
internal type and concrete in slabs
with no formwork on its upper
surface shall be compacted either by
vibrators of the pan type or by a
vibrating screed.
The internal vibrators shall be
inserted and withdrawn slowly and at
a uniform pace of approximately
100 mm per second. Compaction
shall be deemed to be completed
when cement mortar appears in an
annulus around the vibrator. Over
vibration leading to segregation of
the mix must be avoided. The
internal vibrators shall be inserted at
points judged by the area of mortar
showing after compaction, with a
certain allowance made for
overlapping, and they shall not be
allowed to come into contact with
Page 226
the formwork or the

reinforcement and shall be
inserted at a distance of not less
than 75 mm from the former.
The pan vibrator shall be placed
on the surface of the concrete
which shall have previously been
tamped and levelled leaving an
allowance in height for
compaction until the cement
mortar appears under the pan.
The vibrator shall then be lifted
and placed on the adjoining
surface and this operation shall be
repeated until the whole surface
has been compacted.
Alternatively a vibrating screed
spanning the full width of the
surface may also be used.
Whenever vibration has to be
applied externally, the design of
formwork and disposition of
vibration shall receive special
consideration to ensure efficient
compaction and to avoid surface
blemishes. The mix shall be such
that there will be no excess water
on the top surface on completion
of compaction.
External vibrators shall be firmly
secured to the formwork which
must be sufficiently rigid to
transmit the vibration and strong
enough not to be damaged by it.
Internal vibrators shall be capable
of operating at not less than
10,000 cycles per minute and
external vibrators at not less than
3,000 cycles per minute.
Sufficient vibrators in serviceable
condition shall be on Site so that
spare equipment is always
available in the event of break
down.
Concrete shall not be subjected to

any disturbance within 24 hours
after compaction. No standing or
flowing water shall be allowed to
come into contact with exposed
concrete surfaces during the first
two hours after placing and
compaction of the concrete.
9.5.7
Curing and Protection

All work shall be protected from
damage by shock or overloading or
falling earth or flowing water, etc.
9.5.7.1 Normal Curing

Exposed surfaces, immediately
after compaction, shall be
protected from the sun and rain in
a manner approved by the S.O.
All concrete, after it has set, shall
be kept continuously damp until
thoroughly cured. Provision shall
be made for adequate water
distribution to all parts of the
Works, so that if required, this
treatment can be continued
efficiently throughout the whole
period of construction. In order
to keep the concrete continuously
damped, all exposed surfaces
shall be covered with
continuously damped gunny bags
or shall have water impounded
on them for the full period of
curing which shall be not less
than 7 days.
Other methods of curing may be
used subject to the approval of
the S.O.
Page 227
9.5.7.2 Accelerated Curing

Elevated temperature curing may
be used only with ordinary
Portland cement. After the
completion of the placing of the
concrete, 4 hours shall elapse
before its temperature is raised.
The rise in temperature within
any period of 30 minutes shall
not exceed 10C and the
maximum temperature attained
shall not exceed 70 C. The rate
of subsequent cooling shall not
exceed the rate of heating. The
use of accelerated curing methods
for concrete containing other
types of cement or any admixture
shall be subject to the approval of
the S.O.
9.5.8
Ready-Mixed Concrete
Ready-mixed concrete shall comply
with the requirements of M.S. 523.
The concrete shall be carried in
purpose-made agitators operating
continuously or truck mixers. The
concrete shall be compacted and in
its final position within 2 hours of
the introduction of cement to
aggregate and within 45 minutes (or
any other period of time as approved
by the S.O. if admixture is used)
after the addition of water to the
cement-aggregate mix unless
otherwise agreed by the S.O. The
time of such introduction shall be
recorded on the Delivery Note
together with the weight of the
constituents of each mix.
Ready-mixed concrete delivered to
the job site shall be accompanied by
manufacturer's certificates stating
the details of mix proportions by
weight, grade of concrete, type and
size of aggregate, date and time of
production, type and dosage of
chemical admixtures and other
relevant production details in

suitable format. In addition the
manufacturer shall supply to the S.O.
test certificates for testing of
materials, indicating the sources of
supplies and other relevant details.
9.6
CONSTRUCTION WITH
CONCRETE
9.6.1
Construction Joints
The position and detail of any
construction joints not described in
the Contract shall be subject to the
approval of the S.O. and shall be so
arranged as to minimise the
possibility of the occurance of
shrinkage cracks.
If for any reason the Contractor has
to interrupt a planned pour for more
than 45 minutes (or any other period
of time as approved by the S.O. if
admixture is used), additional
positioned and constructed as
The number of construction joints
shall be kept as few as possible
consistant with reasonable
precautions against shrinkage.
Concreting shall be carried out
continuously up to construction
joints. The joints shall be at right
angles to the general direction of the
member and shall take due account
of shear and other stresses.
Concrete shall not be allowed to run
to a feather edge and vertical joints
shall be formed against a stop board.
The top surface of a layer of concrete
shall be level and flat unless design
considerations make this undesirable.
Joint lines shall be so arranged that
they coincide with features of the
finished work, wherever possible.
Page 228
At horizontal construction joints,

gauge strips about 25 sq.mm in
section shall be placed inside the
forms along all exposed surfaces to
ensure a straight joint on those
surfaces.
If a kicker (i.e. starter stub) is used
it shall be at least 70 mm high and
carefully constructed. It is preferable
for the kicker to be incorporated with
the previous concrete. Where
possible, the formwork shall be
designed to facilitate the preparation
of the joint surface, as the optimum
time for treatment is usually two to
four hours after placing.
Where vertical construction joints
are necessary in mass concrete
structures, reinforcing bars shall be
placed across the joints so as to make
the structure monolithic, all to the
Prior to recommencement of
concreting on a joint, the surface of
the concrete against which new
concrete will be cast shall be free
from laitance and shall be roughened
to the extent that the largest
aggregate is exposed but not
disturbed. Care shall be taken to
avoid damaging the lines of the joint.
Care shall also be taken that the joint
surface is clean and damp but not
wet. Immediately before the fresh
concrete is placed against the joint,
fresh cement mortar shall be applied
to the exposed surface.
Where the S.O. considers that
special preparation is necessary, e.g.
for an in situ structural connection,
preparation shall be carried out,
preferably when the concrete has set
but not hardened, by spraying with a
fine spray of air and water or
brushing with a stiff brush
sufficiently to remove the outer
mortar skin and expose the larger

aggregates without disturbing them.
Where this treatment is
impracticable, sand blasting or a
needle gun shall be used to remove
the surface skin and laitance.
Hardened surfaces shall not be
hacked.
9.6.2
Fixing Blocks, Brackets, Built-InBolts, Holes, Chases, etc.

All fixing blocks, brackets, built-inbolts, holes, chases, etc., shall be
accurately set out and formed and
carefully sealed prior to the concrete
being placed. No cutting away of
concrete for any of these items shall
be done without the permission of
the S.O.
Bolts and other inserts to be cast into
the concrete shall be securely fixed
to the formwork in such a way that
they are not displaced during the
concreting operations, and that there
is no loss of materials from the wet
concrete through holes in the form
work.
Unless shown otherwise on the
Drawings or instructed by the S.O.,
reinforcement shall be locally moved
so that the minimum specified cover
is maintained at the locations of
inserts, holes, chases, etc.
Temporary plugs shall be removed
and the threads of built-in-bolts shall
be proved to be free and shall be
greased before handing over any part
of the Works.
Page 229
9.6.3
Precast Concrete Construction
9.6.3.1 Manufacture Off the Site

After the method of manufacture
has been approved, no changes
shall be made without the consent
of the S.O.
The Contractor shall inform the
S.O. in advance of the date of
commencement of manufacture
and casting of each type of item.

9.6.3.3 Handling and Transport
Items shall be lifted only at points
described in the Contract or
otherwise agreed by the S.O. and
shall be handled and placed
without impact. The method of
lifting, the type of equipment and
transport to be used, and the
minimum age of the items to be
handled shall be subject to the
9.6.3.4 Assembly and Erection
When the S.O. requires tests to

be carried out, no items to which
the tests relate shall be dispatched
to the Site until the tests have
been satisfactorily completed and
the results approved by the S.O.
All items shall be indelibly
marked to show the item mark as
described in the Contract, the
production line on which they
were manufactured, the date on
which the concrete was cast and,
if they are of symmetrical
section, the face that will be
uppermost when the member is
in its correct position in the
Works.
9.6.3.2 Storage
When items are stored, they shall
be firmly supported only at the
points described in the Contract.
The accumulation of trapped
water and deleterious matter in
the units shall be prevented. Care
shall be taken to avoid rust
staining and efflorescence.
Items shall be stacked in such a
manner that their removal in cor
rect order of age is facilitated.
The method of assembly and

erection described in the Contract
shall be strictly adhered to on
Site.
Immediately a unit is in position,
and before the lifting equipment
is removed, temporary supports
or connections between items, as
necessary, shall be provided.
The final structural connections
shall be completed as soon as is
practicable.
9.6.3.5 Forming Structural Connections
No structural connections shall be
made until approval has been
given by the S.O.
S.O., the composition and
water/cement ratio of the in situ
concrete or mortar used in any
connection and the packing of
joints shall be in accordance with
the assembly instructions.
Levelling devices shall only be
released or removed with the
Page 230
9.6.3.6 Protection
At all stages of construction,
precast concrete units and other
concrete associated therewith
shall be properly protected to
prevent damage to permanently
exposed surfaces, especially
arrises and decorative features.
9.7
STEEL REINFORCEMENT
9.7.1
Description
The work shall consist of furnishing
and placing reinforcing steel in
and in conformity with the Drawings
or as directed by the S.O.
9.7.2
Materials
Hot rolled mild steel and high yield
bars shall comply with the
requirements of M.S. 146, as
denoted on the Drawings. Cold
worked steel bars shall comply with
the requirements of B.S. 4461.
Hard drawn mild steel wire shall
M.S. 144.
Steel fabric reinforcement shall
M.S. 145 and shall be delivered to
the Site in flat sheets.
Bar-mats shall conform to the
requirements of M.S. 146 and shall
consist of bars of the sizes and
spacings as shown on the Drawings.
Dowel bars shall be plain round
bars conforming to the
requirements of M.S. 146. They
shall be free from burring or other
deformations restricting slippage in
the concrete. Dowel bar sleeves

used for debonding shall be of
approved synthetic material. The
closed end of the sleeve shall be
filled with 25 mm thick
compressible foam filler and the
sleeve shall fit tightly over the length
of bar to be debonded.
The Contractor shall furnish
manufacturer's certificates for rein
forcement supplied by him, and
these shall be submitted for
acceptance by the S.O. before any
material is brought onto the Site.
The characteristic strengths of steel
reinforcement are given in Table
9.9.
TABLE 9.9 - CHARACTERISTIC
STRENGTH OFSTEEL REINFORCEMENT
Designation
Nominal
Sizes
( mm )
Characteristic
Strength, fy
( N/sq.mm )
Hot rolled grade

250 ( M.S. 146 )
All sizes
250
Hot rolled grade

460 ( M.S. 146 )
All sizes
460
Cold worked
( B.S. 4461 )
All sizes
460
Up to and
including 12
485
Hard drawn steel

wire( M.S. 144 )
Binding wire shall be 1.6 mm

diameter soft annealed steel wire
complying with the requirements of
B.S. 1052.
The Contractor shall, on request,
furnish the S.O. with samples of
reinforcement brought onto the Site,
not withstanding any previous
acceptance on the manufacturer's test
certificates. The reinforcement
represented by by the sample may
Page 231
be rejected by the S.O. and shall, if it

fails to meet the Specification,
require its removal from the Works
Site.
Steel reinforcement shall be stored in
clean and dry conditions. When
placed in the Works it shall be clean
and free from loose rust, mill scale,
oil, grease, paint, dirt or anything
which may reduce its bond with
concrete.
If directed by the S.O., the steel
shall be brushed or otherwise
cleaned before use, at the
Contractor's expense.
9.7.3
9.7.3.1 Cutting and Bending of

Reinforcement
Bars shall be of their correct
lengths and bent to the exact
shapes required before being
fixed in the work.
Bars shall be cut and bent cold by
the application of slow, steady
pressure or in an approved barbending machine. Bending at
temperatures in excess of 100 oC
may only be carried out with the
S.O.'s approval and under his
supervision. Except where
otherwise indicated on the
Drawings, bars shall be bent and
measured in accordance with
B.S. 4466.
Cold worked and hot rolled bars
shall not be straightened or bent
again once having been bent.
Where it is necessary to bend
mild steel reinforcement already
cast in the concrete, the internal
radius of bend shall be not less
than twice the diameter of the
bar.

Special care shall be taken that
the overall length of bars with
multiple bends is accurate and
that after bending and fixing in
position the bars remain in place
without wrap or twist.
9.7.3.2 Fixing of Reinforcement
The number, size, length, form
and position of all reinforcing
bars, links, stirrups, spacer bars
and other parts of the steel
reinforcement, shall be in
accordance with the Drawings.
Reinforcement shall be secured
against displacement. Unless
specified otherwise, the actual
concrete cover shall be not less
than the required nominal cover
minus 5 mm. In a member
where the nominal cover is
dimensioned to the links, spacers
between the links and formwork
shall be of the same dimension as
the nominal cover.
the S.O., all intersecting bars
shall be tied together with
binding wire and the ends of the
wire shall be turned into the main
body of the concrete.
The Contractor shall take
particular care that the
reinforcement is laid out correctly
in every respect and temporarily
suspended by annealed wire or
supported on concrete blocks or
other approved spacers in the
forms to prevent displacement
before or during the placing and
compacting of concrete.
Page 232
Stirrups and distance pieces shall

be kept tight to the bars they
embrace or support and all
reinforcement shall be kept away
from the face of the concrete at
the distances shown on the
Drawings.
No concrete shall be placed until
the reinforcement has been
inspected and approved by the
S.O.
Reinforcement temporarily left
projecting from the concrete at
construction or other joints shall
not be bent out of position during
the periods in which concreting is
suspended except with the
9.7.3.3 Splicing
Laps and joints including lapping
bars, sleeving, threading and
other mechanical connections
shall be made strictly in
accordance with the method
specified and at the positions
9.7.3.4 Supporting and Spacer Blocks
Supporting and spacer blocks
required for ensuring that the
reinforcement is correctly
ositioned shall be as small as
possible consistent with their
purpose, of a shape acceptable to
the S.O., and designed so that
they will not overturn when the
concrete is placed. They shall be
made of concrete with 10 mm
maximum aggregate size and
they shall be of at least the same
strength and material source as
the adjacent concrete. Wire cast
in the block for the purpose of
tying it to the reinforcement shall

be as described in Sub-Section
9.7.2. Other types of spacers
may be used only with the
9.7.3.5 Welding of Reinforcement
Reinforcement in structures shall
not be welded except where
detailed on the Drawings or
required by the Specification. If
the reinforcement needs to be
welded, the reinforcement shall
B.S. 4360.
Welding shall be carried out in
B.S. 638. Butt welds shall be of
the double V type and two butt
weld bond tests shall be carried
out on a specimen prepared to
represent each form of butt
welded joint used in welding the
reinforcement and for each
position of welding. The method
of making butt weld tests shall be
that laid down in B.S. 709. The
specimen shall pass the test to the
approval is accorded to use the
joint which the specimen
represents.
Welded joints shall not be made
at bends in reinforcement.
S.O., joints in parallel bars of the
principal tensile reinforcement
shall be staggered in the
longitudinal direction at a
distance not less than the end
anchorage length for the bar.
All welding shall be performed
by a competent welder approved
by the S.O.
Page 233
The S.O. shall be informed in

advance of when welding is to be
carried out so that he may
supervise and inspect the work.
Welding shall not be performed
in the field during rain or other
adverse conditions.
9.8
FORMWORK AND SURFACE

FINISH FOR STRUCTURE
9.8.1
9.8.1.1 Description
Formwork shall include all
temporary or permanent forms
required for forming the concrete,
together with all temporary
construction required for their
support.
The design and construction of
formwork shall be carried out by
competent persons. Where
required by the S.O., strength
and deflection calculations and
drawings of the proposed form
work shall be submitted by the
Contractor for prior approval.
Not withstanding any approval
by the S.O. with respect to the
design submitted by the
Contractor, the responsibility or
the adequacy and safety of the
design shall remain with the
Contractor.
The formwork shall be
sufficiently rigid and tight to
prevent loss of grout or mortar
from the concrete at all stages of
construction and shall be
appropriate for the methods of
placing and compacting.

Formwork (including supports)
shall be sufficiently rigid to
maintain the forms in their
correct position, shape, profile
and dimensions. The supports
shall be designed to withstand the
worst combination of forces due
to self weight, formwork weight,
formwork forces, reinforcement
weight, wet concrete weight,
construction and wind loads,
together with all incidental
dynamic effects caused by
placing, vibrating and
compacting the concrete.
Where internal metal ties are
permitted they or their removable
parts shall be extracted without
damage to the concrete and the
remaining holes filled with
mortar of the same strength as the
cast concrete. No permanently
embedded metal parts shall have
less than the specified cover to
the finished concrete surface.
Except for ties used for anchoring
void formers all ties shall be at
least 1.2 metres apart and
through bolts will not be
permitted on exposed faces. All
holes left by ties shall be made
good within one day of the
removal of the formwork using a
mortar of the same strength as the
cast concrete.
The formwork shall be so
arranged as to be readily
dismantled and removed from the
cast concrete without shock,
disturbance or damage. Where
necessary, the formwork shall be
so arranged that the soffit form,
properly supported, can be
retained in position for such
period as may be required by the
condition of the maturing
concrete or the Specification. If a
component is to be prestressed
Page 234
whilst still resting on the soffit

form, provision shall be made to
allow for elastic deformation and
any vibration in weight
distribution. As far as practicable,
formwork joints shall coincide
with construction joints.
reinforcement and prestressing

cable ducts, to demonstrate that
the proposed methods of fixing
the formers and placing concrete
around them and the
reinforcement will produce voids
within the tolerances, surrounded
with properly compacted
concrete of the required strength.
9.8.1.2 Voids In Concrete

Voids, where shown on the
Drawings, shall be formed with
non-recoverable void formers of
expanded polystyrene, or by
other methods approved by the
S.O. They shall not deviate by
more than 12 mm from the
positions shown on the Drawings,
nor shall the cross-section deviate
from the specified shape by more
than 12 mm.
Void formers shall be secured and
adequately anchored to prevent
movement or flotation outside the
limits specified above, during the
concreting operation.
Anchor ties secured to the soffit
form will be permitted providing
they comply with the
9.8.1.1.
The attention of the Contractor is

drawn to the inflammation nature
of expanded polystyrene and he
shall take all necessary
precautions to minimise the risk
of fire.
Concreting of voided slabs in
structures shall not commence
until the model test has been
completed and approved by the
S.O.
9.8.1.3 Form Lining
The type and treatment of any
lining (plywood, metal, plastic,
etc.) of the forms shall be
ppropriate to the concrete finish
required.
9.8.1.4 Projecting Reinforcement, Fixing
Devices
Where holes are needed in form
to accomodate projecting
reinforcement or fixing devices,
care shall be taken to prevent loss
of grout when concreting or
damage when removing forms.
Void formers of expanded

polystyrene need not be vented.
Hollow void formers shall be
vented by the provision of 50
mm diameter holes between each
void and the soffit at positions
9.8.2
As soon as possible and at least
three (3) months prior to the
casting of the first deck slab with
voids, the Contractor shall
construct a model of a size and
form to be agreed with the S.O.
using the proposed formers,
method of fixing, and simulating
Finishes
9.8.2.1 Formed Surfaces

Formed concrete surfaces shall
have one of the following classes
of finish. Unless otherwise
specified, all exposed concrete
surfaces shall be of Class F2, all
Page 235
unexposed surfaces shall be of

Class F1 and Class F3 finish
shall be used only where shown
on the Drawings.

After the concrete has been
properly cured, the surface shall
be rubbed down where necessary,
to produce a smooth and even
surface.
(a) Class F1
9.8.2.2 Unformed Surfaces
This finish shall be obtained by
the use of properly designed
formwork of closely jointed sawn
timber or other approved
material. Small blemishes caused
by entrapped air or water may be
expected but the surface shall be
free from voids and
honeycombing.
(b) Class F2
(a) Class U1
The concrete shall be uniformly
levelled and screeded to produce
a plain, ridged or broom
roughened surface. No further
work shall be applied to the
surface unless it is used as the
first stage for a Class U2 or
Class U3 finish.

the use of properly designed
formwork of closely jointed
wrought boards, approved ply
wood or other approved
material. Only very minor surface
blemishes shall occur, with no
staining or discolouration.
(b) Class U2
(c) Class F3
(c) Class U3

the use of properly designed steel
forms or plastic coated plywood
or wrought boards or other
approved material. The surface
shall be improved by carefully
removing all fins and other
projections, thoroughly washing
down and then filling the most
noticeable surface blemishes with
a cement and fine aggregate paste
to match the colour of the
original concrete. Form release
agent shall be carefully chosen to
ensure that the surface shall not
be stained or discoloured.
When the moisture film has

disappeared and the concrete has
hardened sufficiently to prevent
laitance from being worked to the
surface, a Class U1 surface shall
be steeltrowelled under firm
pressure to produce a dense,
smooth uniform surface free from
trowel marks.
After the concrete has hardened

sufficiently, the concrete Class
U1 surface shall be floated by
hand or machine to produce a
uniform surface free from screed
marks.
9.8.2.3 Remedial Treatment of Surfaces

Any remedial treatment of
surfaces shall be agreed with the
S.O. following inspection
immediately after removing the
formwork and shall be carried out
without delay.
Page 236
Any concrete, the surface of

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

Concreting
Before concreting, all forms shall be
thoroughly cleaned out, free from
sawdust shavings, dust, mud or
other debris.
The inside surfaces of forms shall,
except for permanent formwork, or
unless otherwise agreed by the S.O.,
be coated with an approved nonstaining form oil or other approved
material to prevent adhesion of the
concrete. Such release agents shall
be applied strictly in accordance with
the manufacturer's instructions and
shall not come into contact with the
reinforcement or prestressing
tendons and anchorages. For any
exposed surface only one release
agent shall be used throughout the
entire area.

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

columns, piles, foundation
plinths and precast items.
3 days
Underside of slabs.
14 days
Underside of beams.
28 days
All formwork shall be inspected by

the S.O. after preparation and
immediately prior to depositing
concrete and no concrete shall be
deposited until approval of the
formwork has been obtained from
the S.O.
9.8.4
Removal of Formwork
The Contractor shall inform the S.O.
and obtain his approval before
striking any formwork, but such
approval shall not relieve the
Contractor of his responsibilities for
the safety of the work.
The removal shall be done in such a
manner as not to damage the
concrete, and shall take place at
times to suit the requirements for its
curing.
Page 237
The periods stated above are based

on the use of ordinary Portland
cement. They may be changed if
other types of cement are used,
subject to the S.O.'s agreement.
For prestressed in situ decks,
temporary supports shall not be
removed until the deck is stressed to
Where it is intended that formwork
is to be reused it shall be cleaned and
made good to the satisfaction of the
S.O.
Following the removal of formwork,
no further loads shall be imposed
upon concrete until at least after the
completion of the curing period or
until such later time as in the opinion
of the S.O. the concrete shall have
attained sufficient strength to safely
withstand such loads. Full design
loads shall not be applied to any
structure until all load bearing
concrete is at least 28 days old.
Page 238
SECTION 10
PILING WORKS
Page 239
SECTION 10 - PILING WORKS

Page
10.1
DESCRIPTION
S10-245
10.2 GENERAL REQUIREMENTS FOR TOLERANCE

10.2.1
Setting Out
S10-245
10.2.2
Position
S10-245
10.2.3
Verticality
S10-245
10.2.4
Rake
S10-245
10.2.5
Forcible Corrections
S10-245
10.2.6
Piles Out of Alignment or Position
S10-245
10.2.7
Records
S10-245
10.3
PRECAST REINFORCED CONCRETE PILES
10.3.1
Description
S10-246
10.3.2
10.3.2.1
10.3.2.2
10.3.2.3
Materials
Concrete
Reinforcement
Pile Shoes
S10-246
S10-246
S10-246
S10-246
10.3.3
Manufacture and Storage of Precast Reinforced Concrete Piles
10.3.3.1 Casting
10.3.3.2 Handling and Storage
S10-246
S10-246
S10-247
10.3.4
10.3.4.1
10.3.4.2
10.3.4.3
10.3.4.4
10.3.4.5
S10-247
S10-247
S10-247
S10-248
S10-248
S10-249
Installation of Precast Reinforced Concrete Piles

Pitching of Piles
Driving of Piles
Repair of Damaged Pile Heads
Lengthening of Piles
Cutting and preparation of Pile Heads
Page 240

Page
10.4
PRESTRESSED SPUN CONCRETE PILES
10.4.1
Description
S10-250
10.4.2
10.4.2.1
10.4.2.2
10.4.2.3
10.4.2.4
Materials
Concrete
Reinforcement
End Plates
Pile Shoes
S10-250
S10-250
S10-250
S10-250
10.4.3
10.4.3.1
10.4.3.2
Manufacture and Storage of Prestressed Spun Concrete Piles

Casting
Handling and Storage
S10-250
S10-250
S10-251
10.4.4
10.4.4.1
10.4.4.2
10.4.4.3
Installation of Prestressed Spun Concrete Piles

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

10.5.1
10.5.2
10.5.2.1
10.5.2.2
10.5.2.3
Description
Materials
Concrete and Reinforcement
Permanent Casings
Drilling Fluid
10.5.3
10.5.3.1
10.5.3.2
10.5.3.3
10.5.3.4
10.5.3.5
10.5.3.6
10.5.3.7
10.5.3.8
10.5.3.9
10.5.3.10
Boring Operations
Diameter of Piles
Boring
Temporary Casings
Stability of Piling Excavations Using Drilling Fluid
Spillage and Disposal
Pumping of Boreholes
Continuity of Construction
Enlarged pile Bases
Cleanliness of Pile Bases
Inspection
S10-252
S10-252
S10-253
S10-253
S10-253
S10-253
S10-253
S10-254
S10-254
S10-254
10.5.4
10.5.4.1
10.5.4.2
Placing of Reinforcement
Joints in Longitudinal Bars
Positions of Reinforcement
S10-254
S10-254
S10-254
S10-252
S10-252
S10-252
S10-252
Page 241

page
10.5.5
10.5.5.1
10.5.5.2
10.5.5.3
10.5.5.4
10.5.5.5
Concreting Operations
Placing Concrete
Workability of Concrete
Compaction
Placing Concrete In Dry borings
Placing Concrete Under Water or Drilling Fluid
S10-254
S10-254
S10-254
S10-255
S10-255
S10-255
10.5.6
10.5.6.1
10.5.6.2
10.5.6.3
Extraction of Casing
Workability of Concrete
Concrete Level
Vibrating Extractors
S10-256
S10-256
S10-256
10.5.7
10.5.7.1
10.5.7.2
10.5.7.3
Construction of Pile Heads

Water levels
Cutting and preparation of Pile heads
Temporary Backfilling Above Pile Casting Level
S10-257
S10-257
S10-257
S10-257
10.6 STEEL H-SECTION PILES

10.6.1
Description
S10-257
10.6.2
Materials
S10-257
10.6.3
10.6.3.1
10.6.3.2
Manufacture and Storage of Steel H-Section Piles

Manufacture
S10-257
S10-257
S10-258
10.6.4
10.6.4.1
10.6.4.2
10.6.4.3
Installation of Steel H-Section Piles

S10-258
S10-258
S10-258
S10-258
10.7 STEEL PIPE PILES

10.7.1
Description
S10-258
10.7.2
Materials
S10-258
10.7.3
10.7.3.1
10.7.3.2
10.7.3.3
10.7.3.4
10.7.3.5
10.7.3.6
10.7.3.7
Manufacture and Storage of Steel Pipe Piles

Welding
Fabrication of Piles
Matching of Pile Lengths
Straightness of Piles
Fabrication of Piles On Site
Marking of Piles
S10-258
S10-258
S10-259
S10-259
S10-259
S10-259
S10-259
S10-259
Page 242

Page
10.9.4
10.9.4.1
10.9.4.2
10.9.4.3
10.10
Installation of Pressure-Treated Timber Piles

Cutting and preparation of Pile heads
S10-264
S10-265
S10-265
BAKAU PILES
10.10.1
Description
S10-265
10.10.2
Materials
S10-265
10.10.3
Delivery and Inspection of Bakau Piles
S10-266
10.10.4
10.10.4.1
10.10.4.2
10.10.4.3
10.10.4.4
Installation of Bakau Piles

Pitching of Piles
Driving of Piles
Cutting and Preparation of Pile Heads
S10-266
S10-266
S10-266
S10-267
S10-267
10.11
PILE TESTING
10.11.1
Test Piles
S10-267
10.11.2
Preliminary Pile Load Tests
S10-267
10.11.3
Production Pile Load Tests
S10-267
10.11.4
10.11.4.1
10.11.4.2
10.11.4.3
Testing Procedure
Preparation of Test Pile
Method of Loading
Measurement of Settlement
S10-267
S10-267
S10-267
S10-268
10.11.5
10.11.5.1
10.11.5.2
10.11.5.3
Method of Testing
General
Maintained Load Test
Constant Rate of Penetration (CRP) Test
S10-268
S10-268
S10-269
S10-269
10.11.6
Submission of Results
S10-269
10.11.7
Interpretation of Test Results
S10-269
10.11.8
Load Testing of Bakau Piles
S10-270
Page 244
SECTION 10 - PILING WORKS

deviation of the finished pile from
the specified rake or the rake shown
on the Drawings is 1 in 25.
10.1 DESCRIPTION
10.2.5 Forcible Corrections
This work shall consist of the supply,
installation and testing of piles in
accordance with this Specification and
the lines, levels, grades and crosssections shown on the Drawings and as
10.2 GENERAL REQUIREMENTS

FOR TOLERANCES
Forcible corrections to concrete piles

shall not be permitted. Forcible
corrections may be permitted to
other types of piles if approved by
the S.O. However, no forcible
corrections shall be made to piles
which have deviated beyond the
permissible limits specified in SubSections 10.2.2, 10.2.3 and 10.2.4
above.
10.2.1 Setting Out

10.2.6 Piles Out of Alignment or Position
Setting out shall be carried out using
the data and reference points as
Immediately before installation of
the pile, the pile position shall be
marked with suitable identifiable
pins, pegs or markers.
10.2.2 Position
For a pile cut off at or above ground
level the maximum permitted
deviation of the pile centre from the
centre points shown on the Drawings
shall not exceed 75 mm in any
direction. For a pile cut off below
ground level an increase in this
tolerance is permitted in accordance
with Sub-Sections 10.2.3 and
10.2.4 hereinbelow.
10.2.3 Verticality
The maximum permitted deviation
of the finished pile from the vertical
is 1 in 75.
10.2.4 Rake
The piling rig shall be set and
maintained to attain the required
rake. The maximum permitted
The Contractor shall, if ordered by

the S.O., extract and reinstall any
pile which has deviated out of
position or alignment by more than
the specified limit, or alternatively
the substructure shall be modified to
the approval of the S.O. The cost of
such extraction and reinstallation or
any extra cost in the design and
construction of a modified
foundation shall be borne by the
Contractor if, in the opinion of the
S.O., such extra works have been
made necessary due to the error
and/or negligence of the Contractor.
10.2.7 Records
The Contractor shall keep records of
the installation of each pile as
required by the S.O. and shall
submit two signed copies of these
records to the S.O.not later than at
noon of the next working day after
the pile has been installed. The
signed records shall form part of the
records for the Works.
Any unexpected driving or boring
conditions shall be noted in the
records.
Page 245
10.3 PRECAST REINFORCED

CONCRETE PILES

Other means of jointing
reinforcement, such as by means
of mechanical couplings shall be
to the approval of the S.O.
10.3.1 Description
10.3.2.3 Pile Shoes
and installation of precast reinforced
concrete piles, inclusive of pitching
and driving, lengthening and cutting
and preparation of pile heads, all in
and to the details shown on the
Drawings.
10.3.2 Materials
10.3.2.1 Concrete
10.3.2.2
The type of pile shoes to be

used shall be as shown on the
Drawings and shall comply
with the following as relevant :i) "Chilled-hardened" cast iron
shoes as used for making grey
iron castings to B.S. 1452,
Grade 10; or
ii) Mild steel to B.S. 4360,
Grade 50B; or
Unless otherwise specified,

ordinary Portland cement shall be
used for the casting of piles.
iii) Cast steel to B.S. 3100, Grade

A.
The materials and workmanship

shall be as specified under
The grade of concrete and the
details of reinforcement to be
used shall be as shown on the
Drawings.
Mild steel straps cast into the

shoes shall be as shown on the
Drawings. Rock shoes where
required shall consist of wrought
iron shoes and mild steel straps
cast into "Chilled-hardened" cast
iron blocks, as shown on the
Drawings.
Reinforcement
The main reinforcing bars in piles
not exceeding 12 m in length
shall be in one continuous length
unless otherwise approved by the
S.O.
In piles exceeding 12 m long,
joints shall be permitted in main
longitudinal bars at 12 m nominal
intervals. Joints in adjacent bars
shall be staggered at least 1 m
apart along the length of the pile.
Joints shall be butt welded as
specified in Sub-Section 9.7.5 of
this Specification.
10.3.3 Manufacture and Storage of Precast

Reinforced Concrete Piles
10.3.3.1 Casting
The length of piles to be cast
Drawings, subject to revision by
the S.O. Based on the results of
pile driving resistance and/or load
tests carried out on piles driven
on the site, the S.O. may from
time to time order the lengths of
piles to be modified.
Page 246
Piles shall be cast on a horizontal

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

thicknesses shall be provided
between piles at the lifting points.
10.3.4 Installation of Precast Reinforced
Concrete Piles
10.3.4.1 Pitching of Piles
Piles shall be pitched accurately
in the positions as shown on the
Drawings. At all stages during
driving and until the pile has set
or been driven to the required
length, all exposed piles shall be
adequately supported and
restrained by means of leaders,
trestles, temporary supports or
other guide arrangements to
maintain position and alignment
and to prevent buckling and
damage to the piles.
10.3.4.2 Driving of Piles
Each pile shall be driven
continuously until the specified
set and/or depth has been
reached, unless otherwise
driving equipment used shall be
of such type and capacity to the
approval of the S.O. A follower
(long dolly) shall not be used
unless otherwise approved by the
S.O.
A detailed record of the driving
resistance over the full length of
each pile shall be kept. The log
shall record the number of blows
for every 0.5 m of pile
penetration. The Contractor shall
inform the S.O. without delay if
an unexpected change in driving
characteristics is encountered.
Where required by the S.O. set
shall be taken at approved
intervals during the driving to
establish the behaviour of the
piles.
Page 247
A set shall be taken only in the

presence of the S.O. unless
otherwise approved. The
Contractor shall provide all
facilities to enable the S.O. to
check driving resistances. The
final set of a pile other than as
friction pile, shall be recorded as
the penetration in millimeters per
10 blows. The temporary
compression of the pile shall be
recorded if required.
Piles shall be driven in an
approved sequence to minimise
the detrimental effects of heave
and lateral displacement of the
ground. When required, careful
levelling from a datum unaffected
by the piling shall be made on
the pile heads already driven,
before and after driving
subsequent piles. Piles which
have been displaced as a result
of driving adjacent piles shall be
redriven to the required
resistance.
10.3.4.3 Repair of Damaged Pile Heads
If a pile is to be subjected to
further driving, concrete in the
damaged pile head shall be cut
off square at sound concrete,
and all loose particles shall be
removed by wire brushing, fol
lowed by washing with water.
Care shall be exercised to ensure
that the reinforcement in the pile
head is not in any way damaged.
Any damaged reinforcement
satisfaction of the S.O. The head
shall be replaced with concrete of
an approved grade. The new
head shall be cast truly in line
with the remainder of the pile and
be properly cured and allowed to
harden sufficiently to develop
the strength necessary for further

driving. If a pile has been driven
to the required set or depth but
sound concrete of the pile is
below cut-off level, the pile shall
be made good to the cut-off level
as described above.
10.3.4.4 Lengthening of Piles
Where piles have to be
lengthened, other than by means
of welding of steel plates as
detailed on the Drawings, the
reinforcement shall be stripped of
all surrounding concrete for a
distance equal to thirty times the
diameter of the main
reinforcement measured from the
pile head for spliced joints and
300 mm for butt welded joints
and all lateral reinforcement shall
be removed. The lengthening
bars shall butt on the exposed
bars in true alignment and shall
be butt welded as specified or
shall be spliced with bars of the
same diameter as the main pile
bars, 60 diameters in length and
lapping the main bars for a
distance of 30 diameters above
and below the joint, and shall be
securely bound with 1.63 mm
soft annealed iron wire. New
binders of similar size shall be
provided and spaced at half the
centres of the binders in the main
body of the pile and shall be
securely bound with 1.63 mm
soft annealed iron wire and the
pile extended by concreting in
properly constructed mounds to
the length required.
Page 248
Care shall be taken to form the

joint between the old and new
concrete as specified
hereinbefore. The extension shall
be truly in line with the
remainder of the pile, , and be
properly cured and allowed to
harden sufficiently to develop the
strength necessary for further
driving.
10.3.4.5 Cutting and Preparation of Pile
Heads
When a pile has been driven to
the required set or depth, the head
of the pile shall be cut off to the
level specified or shown on the
Drawings. The length of
reinforcing bars projecting above
this level shall be as shown or
specified on the Drawings. If the
length of reinforcing bars left
projecting is insufficient, then
they shall be extended by
either of the following
methods :-

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

The extension bars shall butt on
the projecting bars in true
alignment and shall be
butt welded in accordance with
Sub-Section 9.7.3.5 of this
Specification.
Page 249
10.4 PRESTRESSED SPUN

CONCRETE PILES
10.4.1 Description
and installation of prestressed spun
concrete piles,inclusive of pitching
and driving, lengthening and cutting
and preparation of pile heads, all in
Drawings.
10.4.2 Materials
10.4.2.1 Concrete
Unless otherwise specified,
ordinary Portland cement shall be
used for the casting of piles. The
materials and workmanship shall
be as specified under Section 9
of this Specification. The grade
of concrete to be used shall be as
10.4.2.2 Reinforcement
The prestressing tendons and the
non-prestressing reinforcement of
the piles including workmanship
shall be as specified under
Sections 11 and 9 respectively of
this Specification and to the
details as shown on the
Drawings.
10.4.2.3 End Plates
Details of end plates of each
length of pile shall be as shown
on the Drawings.
Each end plate shall be machinefinished and provided with a
chamfer to accommodate the
welding when two lengths of pile
are jointed.

10.4.2.4 Pile Shoes
If specified, the type of pile shoes
to be used shall be as shown on
the Drawings and shall be in
10.3.2.3.
10.4.3 Manufacture and Storage of
Prestressed Spun Concrete Piles
10.4.3.1 Casting
The length of piles to be cast
Drawings, subject to revision by
on the site, the S.O. may from
Piles shall be hollow cylinders
manufactured by the centrifugal
casting process. Moulds shall be
of metal, well braced and
stiffened against deformations
caused by the hydrostatic
pressure of the wet concrete
while spinning. The metal forms
shall have smooth joints and
inside surfaces. The forms shall
be accessible for adequate
cleaning.
The spiral reinforcement shall be
securely held to the longitudinal
reinforcement during casting and
spinning. Any welding used shall
not affect the strength of the pre
stressing tendons.
The pile shall not be removed
from the moulds until after the
specified transfer strength is
achieved.
The external diameter and the
thickness of the pile shall not be
Page 250
less than that shown on the

Drawings and shall be constant
over the entire length of the pile
and coaxial with the end plate at
each end.
After a pile has been cast, the
date of casting, reference number
and length shall be clearly
marked with indeletable marking
on the top surface and on the
head of the pile. In addition, each
pile shall be marked at intervals
of 0.5 m along its length before
being driven.

The method and sequence of
lifting, handling, transporting and
storing piles shall be such that
piles are not damaged. Only the
designed lifting and support
points shall be used.

Where lengthening of piles is
required, the details of the joint
Drawings. When two lengths of
pile are jointed, the end plates
shall bear over their complete
areas. Shims for packing shall not
be accepted.
Heads
the required set or depth, the
head of the pile shall be cut off to
the level specified or shown on
the Drawings. The Contractor
shall submit to the S.O. for
approval, his proposed method
for cutting of piles. Pile heads
shall be constructed to details as
All piles within a stack shall be in

groups of the same length.
Packings of uniform thicknessess
shall be provided between piles at
the lifting points.
10.4.4 Installation of Prestressed Spun
Concrete Piles
10.4.4.1 Pitching and Driving of Piles
Pitching and driving of piles shall
be in accordance with SubSections 10.3.4.1 and 10.3.4.2.
Piles shall not be driven until the
concrete has achieved the
specified characteristic strength.
Page 251
10.5 BORED CAST-IN-PLACE

PILES
10.5.1 Description
This work shall comprise the boring
or grabbing, with or without casing,
and subsequently filling the hole
with plain or reinforced concrete to
form bored cast-in-situ piles, all in
Drawings.
10.5.2 Materials
10.5.2.1 Concrete and Reinforcement
The concrete and reinforcement
to be used and workmanship
for bored cast-in-situ piles shall
be as specified under Section 9
of this Specification. The grade
of concrete and the details of
reinforcement to be used shall be

Bentonite shall be mixed
thoroughly with clean fresh water
to make a suspension which will
maintain the stability of the pile
excavation for the period
necessary to place concrete and
complete construction.
Preparation of the suspension
Where saline or chemically
contaminated ground water
occurs, special precautions shall
be taken to modify the bentonite
suspension or prehydrate the
bentonite in fresh water to render
it suitable in all respects for the
construction of piles.
10.5.3 Boring Operations
10.5.3.1 Diameter of Piles
The diameter of piles shall not be
less than the specified designed
diameter at any level throughout
its length.
10.5.2.2 Permanent Casings

10.5.3.2 Boring
Permanent casings which form
part of the designed pile shall be
as specified in the Drawings.
Boring shall be carried down to

the depth as required and
10.5.2.3 Drilling Fluid

Drilling fluid material, bentonite,
shall comply with Specification
No. DF CP4 of the Oil
Companies Materials Association
or its equivalent. A certificate
shall be obtained by the
Contractor from the manufacturer
of the bentonite powder, showing
the properties of each
consignment delivered to the site.
This certificate shall be made
available to the S.O. on request.
When deemed necessary by the

S.O., the Contractor shall take
undisturbed soil samples while
the pile is being bored. The
samples shall be taken to an
approved Laboratory for testing.
Sampling and all subsequent
handling and testing shall be
B.S.5930.
Page 252
Piles shall not be bored close to

other piles which have recently
been cast and which contain
workable or unset concrete, such
that a flow of concrete could be
induced from or damage caused
to any of the piles.

In the event of a rapid loss of
bentonite suspension or water
from the piling excavation, the
excavation shall be backfilled
without delay and the instructions
of the S.O. shall be obtained prior
to resuming boring at that
location.
10.5.3.3 Temporary Casings

10.5.3.5 Spillage and Disposal
Temporary casings of approved
quality or an approved alternative
method shall be used to maintain
the stability of pile excavations
which might otherwise collapse.
Temporary casings shall be free
from significant distortion. They
shall be of uniform cross-section
throughout each continuous
length. During concreting they
shall be free from internal
projections and encrusted
concrete which might prevent the
proper formation of the piles
being cast.
10.5.3.4 Stability of Piling Excavations
Using Drilling Fluid
Where the use of drilling fluid or
a column of water is approved for
maintaining the stability of
boring, the level of fluid or
column of water in the
excavation shall be maintained
such that the fluid pressure
always exceeds the pressure
exerted by the soil and external
ground water and an adequate
temporary casing shall be used in
conjunction with the method to
ensure the stability of the strata
near ground level until concrete
has been placed. The fluid water
level shall be maintained at a
level not less than 1 metre above
the level of the external ground
water.
All reasonable steps shall be

taken to prevent the spillage of
bentonite suspension or water on
the site in areas outside the
immediate vicinity of the boring
operations. Discarded bentonite
water shall be removed from the
site without delay. The disposal
of bentonite water shall comply
with the regulations of the Local
Controlling Authorities.
10.5.3.6 Pumping of Boreholes
Pumping from the borehole shall
not be permitted unless a casing
has been placed into the stable
stratum to prevent the further
ingress of water in significant
quantities from other strata into
the boring, or, unless it can be
shown that pumping will not
have a detrimental effect on the
surrounding soil or its properties.
10.5.3.7 Continuity of Construction
A pile constructed in stable soil,
without the use of temporary
casings or other support, shall be
bored and concreted without
delay to ensure that the soil char
acteristics are not significantly
altered.
Page 253
10.5.3.8 Enlarged Pile Bases

The enlarged pile base shall not
be smaller than the dimensions
specified and shall be concentric
with the pile shaft diameter. A
sloping surface of the frustum
forming the enlargement shall
make an angle to the horizontal
of not less than 55.
10.5.3.9 Cleanliness of Pile Bases
On completion of boring, loose,
disturbed or remoulded soil or
fragments of rock shall be
removed from the base of the
pile.
10.5.3.10 Inspection
For dry boreholes, each hole shall
be inspected prior to the placing
of concrete in it. The inspection
shall be carried out from the
ground surface in the case where
the borehole diameter is less than
750 mm. Where the borehole
diameter exceeds 750 mm,
adequate equipment conforming
to B.S. 5930 shall be provided to
enable the Contractor and the
S.O. to descend into the borehole
for the purpose of inspection.

of the reinforcement during the
construction of the pile and the
spacing of the reinforcing bars
shall be maintained in such a way
that proper concreting shall not
be impeded.
10.5.4.2 Positions of Reinforcement
Adequate spacer blocks, guide
tubes, and lifting wires shall be
provided so as to maintain the
reinforcing steel in the positions
as specified.
Where temporary casings are
employed, the longitudinal
reinforcement shall extend at
least 1.0 metre below the bottom
of the casing so that movement of
the reinforcement during
extraction of the casing is
minimised.
10.5.5 Concreting Operations
10.5.5.1 Placing Concrete
The method of placing and the
workability of concrete shall be
such that a continuous monolithic
concrete shaft of the full crosssection is formed.
10.5.5.2 Workability of Concrete
For wet boreholes, i.e. holes

filled with drilling fluid or water,
a suitable probe shall be provided
to ascertain the evenness and
cleanliness of the pile base.
10.5.4 Placing of Reinforcement
10.5.4.1 Joints in Longitudinal Bars
Reinforcement shall be such that
the full strength of the bar is
effective across the joint and the
joint shall be made so that there
is no relative displacement
The workability of the concrete

shall be determined by the slump
test as described in M.S. 26.
The suggested slump details for
typical concreting situations shall
be as specified in Table 10.1
below. The slump shall be
measured at the time of
discharge into the borehole.
Page 254
TABLE 10.1 - SLUMP RANGE FOR TYPICAL CONCRETING SITUATIONS
Typical Conditions
of Use
Slump Range
(mm)
Placed into water-free unlined bore.

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

enough to give free movement between
bars.
Where casting level of concrete is within
the casing.
Where pile diameter is less than 600 mm.
Where concrete is to be placed by tremie

under water or drilling fluid.
10.5.5.3 Compaction
Internal vibrators shall not be
used to compact concrete unless
it can be satisfied that they will
not cause segregation or arching
of the concrete.
10.5.5.4 Placing Concrete In Dry Borings
Approved measures shall be
taken to avoid segregation and
bleeding and to ensure that the
concrete at the bottom of the pile
is not deficient in grout.
Where piles are vertical, concrete
may be poured through a funnel
with a length of tube so that the
flow is directed and does not hit
reinforcement bars or the side of
the hole. Chutes extending to
near the base shall be employed
for raking piles of large diameter.
For raking piles of small
100 to 175
150 to collapse
diameter, an enriched mix shall

be used in the first few batches of
concrete to minimise segregation.
10.5.5.5 Placing Concrete Under Water or
Drilling Fluid
Concrete to be placed under
water or drilling fluid shall be
placed by tremie unless otherwise
approved and shall not be
discharged freely into the water
or drilling fluid.
Before placing concrete,
measures shall be taken to ensure
that there is no accumulation of
silt or other material at the base
of the boring.
Page 255
The hopper and pipe of the

tremie shall be clean and
watertight throughout. The pipe
shall extend to the base of the
boring and a sliding plug or
barrier shall be placed in the pipe
to prevent direct contact between
the first charge of concrete in the
pipe of the tremie and the water
or drilling fluid. The tremie pipe
shall at all times penetrate the
concrete which has previously
been placed and shall not be
withdrawn from the concrete
until the completion of
concreting. At all times, a
sufficient quantity of concrete
shall be maintained within the
tremie pipe to ensure that the
pressure from it exceeds that
from the water or drilling fluid.
The internal diameter of the
tremie pipe shall not be less than
150 mm for concrete made with
20 mm aggregate and not less
than 200 mm for concrete made
with 40 mm aggregate. The
tremie pipe shall be so designed
that external projections are
minimised, allowing the tremie
pipe to pass through the
reinforcing cage without causing
damage or uplifting. The internal
face of the tremie pipe shall be
from projections.
10.5.6 Extraction of Casing
10.5.6.1 Workability of Concrete
Temporary casings shall be
extracted while the concrete
within them remains sufficiently
workable to ensure that the
concrete is not lifted.

10.5.6.2 Concrete Level
When the casing is being
extracted, a sufficient quantity of
concrete shall be maintained
within it to ensure that the
pressure from external water,
drilling fluid or soil is exceeded
and that the pile is neither
reduced in section nor
contaminated.
No concrete shall be placed in the
boring once the bottom of the
casing has been lifted above the
top of the concrete; it shall be
placed continuously as the casing
is extracted until the desired head
of concrete is obtained.
Adequate precautions shall be
taken in all cases where excess
heads of water or drilling fluid
could be caused as the casing is
withdrawn because of the
displacement of water or fluid by
the concrete as it flows into its
final position against the wall of
the pile shaft. Where double
casings are used in the boring, the
proposed method of working
shall be with the approval of the
S.O.
10.5.6.3 Vibrating Extractors
The use of vibrating extractors
shall be permitted subject to the
condition that work shall be
carried out in such a manner and
at such times as to minimise
nuisance and disturbance.
Page 256
10.5.7 Construction of Pile Heads

10.5.7.1 Water Levels
In the event of the ground water
level being higher than the
required pile head casting level
shown on the Drawings, the
Contractor shall submit his
proposals for approval prior to
placing concrete. The pile head
shall not be left below the ground
water level unless approved
precautions are taken.

10.6.2 Materials
All steel H-section piles shall
comply with B.S. 4 with regard to
sectional dimensions and the steel
shall comply with the requirements
of B.S. 4360. The sections and
grades to be used shall be as
specified or as shown on the
Drawings.
Steel H-Section Piles
10.6.3.1 Manufacture

Heads
The top of the pile shall be
brought above the cut-off level of
the pile to permit all laitance and
weak concrete to be removed and
to ensure that it can be properly
keyed into the pile cap. Pile
heads shall be constructed to the
details shown on the Drawings.
10.5.7.3 Temporary Backfilling Above
Pile Casting Level
After each pile has been cast, any
empty bore remaining shall be
protected and shall be carefully
backfilled as soon as possible
with approved materials.
10.6 STEEL H-SECTION PILES
10.6.1 Description
and installation of steel H-section
piles, inclusive of pitching and
driving, lengthening and preparation
of pile heads, all in accordance with
this Specification and to the details

S.O. the strengthening of the toe
in lieu of a shoe or the
strengthening of the head of a
pile shall be made from material
of the same grade as the pile and
to the details as shown on the
Drawings.
For standard rolled sections the
deviation from straightness in
millimetres shall not exceed 1.04
(L-4.5) where L is the length of
the pile in metres.
For proprietary sections made up
from rolled sections the deviation
from straightness shall not exceed
1/1000 of the length of the pile.
Each pile shall be clearly marked
with white indeletable marking at
the flanged head showing its
reference number and overall
length. In addition, each pile
shall be marked at intervals of
0.5 m along its length before
being driven.
Page 257
The length of piles to be supplied

Drawings subject to revision by
on the Site, the S.O. may from
All operations such as handling
and transporting of piles shall be
damage to piles and their
coatings is minimised. Piles
that are damaged during handling
and transporting shall be replaced
by the Contractor at his own
expense. All damaged and
rejected piles shall be removed
from the Site forthwith.
Piles within a stack shall be in
groups of the same length and on
approved supports.
10.6.4 Installation of Steel H-Section Piles

Heads
the required set or depth and
before encasing in concrete, the
piles shall be cut to within 20
mm of the levels shown on the
Drawings. Pile heads shall be
constructed to the details as
The remaining section which can
be reused for lengthening of piles
shall be stored and protected as
10.7 STEEL PIPE PILES
10.7.1 Description
and installation of steel pipe piles,
inclusive of pitching and driving,
lengthening and preparation of pile
heads, all in accordance with this
Specification and to the details

10.7.2 Materials
Where lengthening of piles is
required, the piles shall be jointed
by butt welding. Butt welded
joints shall be stiffened with
plates fillet welded on all four
sides as detailed on the Drawings.
All weldings shall be continuous
and complying with B.S. 638,
B.S. 5135 and B.S. 5950 for arc
welding and B.S. 4577 for
resistance welding as appropriate.
The type and size of weld shall
be as detailed on the Drawings.
All steel pipes shall comply with

B.S. 6323 with regard to sectional
dimensions and the steel shall
B.S. 4360.
Steel Pipe Piles
10.7.3.1 Welding
Unless otherwise specified, all
welds shall be full penetration
butt welds complying with the
requirements of B.S. 5153.
Page 258
10.7.3.2 Fabrication of Piles

The root edge or root face lengths
of piles that are to be butt welded
shall not differ by more than 25%
from the thickness of piles not
exceeding 12 mm in thickness; or
by more than 3 mm for piles
exceeding 12 mm in thickness.
When piles of unequal thickness
are to be butt welded together, the
thickness of the thinner material
shall be the criterion.
Pile lengths shall be set up so that
the differences in dimensions are
matched as evenly as possible.
10.7.3.3 Matching of Pile Lengths
Longitudinal seam welds and
spiral seam welds of lengths of
pipe piles forming a completed
pile shall, whenever possible, be
evenly staggered. However, if in
order to obtain a satisfactory
match of the ends of piles or the
specified straightness, the
longitudinal seams or spiral
seams are brought closely to one
alignment at the joint, then they
shall be staggered by at least
100 mm.

10.7.3.4 Straightness of Piles
Unless otherwise approved, the
deviation from straightness shall
not exceed 1/600 of a length not
exceeding 10 m. When two or
more such lengths are joined, the
deviation from straightness shall
not exceed 1/960 of the
completed length.
10.7.3.5 Fabrication of Piles on Site
When pile lengths are to be made
up on Site, all test procedures and
dimensional tolerances shall
conform to the Specification
for the supply of pipe materials.
Adequate facilities shall be
provided for supporting and
aligning the lengths of pile.
All piles within a stack shall be in
groups of the same length and on
approved supports. All
operations such as handling,
transporting and pitching of piles
shall be carried out in a manner
such that damage to piles and
their coatings is minimised. Piles
that are damaged during handling
and transporting shall be replaced
by the Contractor at his own
expense. All damaged and
rejected piles shall be removed
from the Site forthwith.
10.7.3.7 Marking of Piles
Each pile shall be clearly marked
with white indeletable marking
showing its reference number and
overall length. In addition, each
pile shall be marked at intervals
of 0.5 metre along its length
before being driven.
Page 259
10.7.4 Workmanship
10.7.4.1 Welding Procedures
The Contractor shall submit for
approval, full details of the
welding procedures and
electrodes with drawings and
schedules as may be necessary.
Tests shall be undertaken as may
be required by the S.O. and shall
be in accordance with the
requirements of B.S. 4870.
10.7.4.2 Welders' Qualifications
Only welders who are qualified
in the approved welding
procedure shall be employed.
Copies of certificates relating to
welders' tests shall be made
available to the S.O. on request.
10.7.4.3 Radiographs
During production of welded
tube piles, at least one radiograph
approximately 300 mm long shall
be required on each completed
length as a spot check on weld
quality. This shall be taken on a
circumferential or longitudinal
weld and its position shall be as
For spirally welded piles, one of
the following tests shall be
carried out :i) for tubes of wall thickness 12
mm or less, three spot check
radiographs, one at each end
of each length of the tube as
manufactured and one at a
position to be chosen at the
time of testing by the S.O.;
and spot check radiographs as
required by the S.O. on the
weld joints between strip
lengths;

ii) for tubes of any wall
thickness, continuous
ultra-sonic examination over
the whole weld, supplemented
where necessary by
radiographs to investigate
defects revealed by the
ultrasonic examination.
10.7.4.4 Acceptance Standards
If the results of any weld test do
not conform to the specified
requirements, two additional
specimens from the same length
of pile shall be tested. In the case
of failure of one or both of
these additional tests, the length
of pile covered by the test shall
be rejected.
10.7.5 Protective Coatings
If protective coatings are specified,
the preparation of surfaces and the
application of the coatings shall be
carried out by skilled labour having
experience in the preparation of the
coatings specified.
10.7.5.1 Surface Preparation
Unless otherwise specified, all
surfaces to be coated shall be
blast cleaned with an approved
abrasive in accordance with B.S.
4232 or SIS 05 59 00 to remove
rust, mill scale and other adhering
materials, to provide a finish to
second quality (near white) of
B.S. 4232 or SIS 05 59 00 grade
Sa 2 1/2.
10.7.5.2 Application and Type of Primer
Immediately after surface
preparation, the surface shall be
coated with an approved primer
or the specified coating to avoid
recontamination. No coat shall be
Page 260
applied to a metal surface which

is not thoroughly dry.

10.7.6 Installation of Steel Pipe Piles
The primer shall be compatible

with the specified coating.
10.7.5.3 Part to be Welded
The coating within 200 mm of a
weld shall be applied after
welding.
10.7.5.4 Thickness, Number and Colour
of Coats
The minimum dry film thickness
of the finished coating, including
the minimum dry film thickness
of each coat and the minimum
number of coats that are to be
applied, shall be as specified and
Coatings shall be applied in
accordance with the
10.7.5.5 Inspection of Coatings and
Acceptibility
The finished coating shall be
generally smooth, of a dense and
uniform texture and free from
sharp protuberances or pin holes.

Unless otherwise approved,
where lengthening of piles is
required, the piles shall be jointed
by butt welding along the entire
periphery as detailed on the
Drawings.
10.7.6.3 Cutting and Preparation of
Pile Heads
the required set or depth and
before encasing in concrete, the
pile shall be cut to within 20 mm
of the levels shown on the
Drawings and protective coatings
shall be removed from the
surfaces of the pile head 100 mm
above the soffit of the concrete.
Pile heads shall be constructed to
details as shown on the
Drawings.
10.7.6.4 Concreting of Pile Shaft
Any coat damaged by subsequent

processes or which has
deteriorated to an extent such that
proper adhesion of the coating
may not be obtained or
maintained, shall be recleaned to
the original standard and recoated
with the specified sequence of
coats.
The completed coating shall be
checked for thickness and
continuity by an approved
magnetic gauge or detector. Areas
where the thickness is less than
that specified shall receive
approved additional treatment.
If concreting is specified or
shown on the Drawings after the
pile has been cut off to the
specified level, the shaft shall be
filled with concrete in a
continuous operation. The
method of placing shall be
The reinforcement cage in the
pile shall be made sufficiently
rigid and kept in its correct
position during concreting.
Page 261
The length of the reinforcing bars

projecting above the pile cut off
level shall be as shown on the
Drawings.
10.8 MICROPILES
10.8.1 Description
This work shall comprise the drilling
of a hole, placing of reinforcement
unit and subsequently filling the hole
with grout to form micropiles, all in
Drawings.
10.8.2 Materials
10.8.2.1 Reinforcement Unit
The type of reinforcement unit to
be used, the diameter and/or
thickness, grade, yield strength
and working stress shall be as
specified or as shown on the
Drawings.
10.8.2.2 Grout
grout shall be non-shrink cement
grout. The grout mix design such
as the water-cement ratio, the
minimum cement and grout
strength at 7 and 28 days shall be
as specified and shown on the
Drawings.
If admixtures are used, details of
admixtures shall be submitted to
the S.O. for approval before
commencement of works. The
use of the admixture shall fully
comply with the manufacturer's
instructions.

10.8.3 Drilling Operations
10.8.3.1 Diameter of Piles
The diameter of piles shall not be
less than the specified/designed
diameter at any level throughout
its length.
10.8.3.2 Drilling
the S.O. details of drilling
equipment and drilling procedure
for approval before
commencement of works.
Drilling operations shall be
relevant requirements of SubSection 10.5.3.
10.8.4 Grouting Operations
10.8.4.1 Mixing and Placing Grout
details of the method and
equipment used in grout mixing.
Further information such as
grouting pressure, grouting
procedure, grouting equipment
and techniques employed in
grouting underwater shall also be
furnished for approval.
Grout shall be mixed on Site and
shall be free from segregation,
slumping and bleeding. Grout
shall be pumped into its final
position in one continuous
operation as soon as possible and
in no case more than half an hour
after mixing.
10.8.4.2 Testing Grout
Grout shall be tested in
B.S. 4550.
Page 262
10.8.5 Construction of Pile Heads

Where lengthening is required,
the pile reinforcement unit shall
be connected on Site to the
details shown on the Drawings.
Other means of jointing
reinforcement shall be to the

Heads
Pile heads shall be constructed to
the details as shown on the
Drawings.
10.9 PRESSURE-TREATED TIMBER

PILES
10.9.1 Description
and installation of pressure-treated
timber piles, inclusive of pitching
and driving, lengthening and
preparation of pile heads, all in
Drawings. The timber terms used in
this Specification shall have the
meanings assigned to them in M.S.
229.
10.9.2 Materials
S.O., Kempas (Koompassia
Malaccensis) shall be used and this
shall not be of a lesser quality than
the grading specified in Appendix A
of M.S. 822.

Pressure-treated timber piles shall
conform to M.S. 822 and shall be
approved by SIRIM.
Pressure-Treated Timber Piles
10.9.3.1 Manufacture
Before commencement of work
the Contractor shall notify the
S.O. of the name of the supplier
and manufacturer for approval.
The method of preservative
treatment for timber piles shall be
the full-cell process as described
in M.S. 360. The preservative
used shall comply with M.S. 733.
The depth of penetration of
preservative shall be a minimum
of 25 mm and the net dry salt
retention in the treated part of the
timber shall be a minimum of 16
kg/cu.m.
Piles shall be within -2 mm and
+6 mm of their specified crosssectional dimensions. The
centroid of any cross-section of a
pile shall not deviate by more
than 25 mm from the straight line
connecting the centroids of the
end faces of the pile.
Before the treated timber pile is
accepted for the work the
Contractor shall obtain from the
manufacturer of the treated piles
a warranty on an approved form
which provides, that for a ten
year period, the treated piles shall
be free from fungus and insect
attack.
Page 263
Each treated pile shall be

permanently marked with
identifications which indicate that
they comply with this
Specification, manufacturer's
trade mark, type of treatment,
charge number and date of
treatment and the length of the
pile. The end plates of each pile
shall have SIRIM Control Labels.
The S.O. may require inspection
and testing at the treatment plant
to observe and ensure that the
manufacturing process and
control testings of the piles are
this Specification. Records of the
actual treatment schedule shall be
kept during the treatment process,
and the Contractor shall furnish
such records for the piles
supplied when requested by the
S.O.

10.9.4 Installation of Pressure-Treated
Timber Piles
Pitching and driving shall be in
accordance with Sub-Sections
10.3.4.1 and 10.3.4.2.
Piles shall be provided in one
single length of 6.0 m each unless
otherwise approved. Any pile
driven to the required set at a
depth of 6.0 m or less shall be in
one continuous length.
10.9.3.2 Delivery and Storage

The Contractor shall notify the
S.O. of the delivery of timber
piles to the Site, and provide the
necessary facilities to enable the
S.O. to inspect each pile and take
random sampling for
determination of depth of
penetration and the net dry salt
retention.
Accepted piles shall be marked
and stacked in lengths on drained
hard ground. Each pile shall be
stacked clear of the ground and
have an air space around it. The
piles shall be separated by sticks
or blocks placed vertically one
above the other and closely
spaced horizontally to avoid
sagging of the piles. All rejected
piles shall be removed from the
Site forthwith.
The pile head shall be adequately

protected during driving, so that
brooming and splitting do not
occur. The pile head shall be
fitted with toothed metal plates as
approved by the S.O. during
normal driving.
In the case of hard driving, unless
otherwise approved by the S.O., a
metal helmet shall be fitted to the
top of the pile. The top of the
pile shall first be trimmed to fit
closely into the recess of the
underside of the helmet. A hard
wood dolly and, if necessary, a
packing piece shall be used above
the helmet.
If during driving the head of the
pile becomes excessively
broomed or otherwise damaged,
the damaged part shall be cut off
and the helmet refitted.
Page 264
When fissures appear in a pile

during driving, which in the
opinion of the S.O. will affect its
strength, the pile shall be rejected
and replaced at the Contractor's
expense.
i) the cut-offs or bored holes

shall be given two flood coats
of 10% m/v solution of the
preservative, or as specified in
accordance with M.S. 360,
allowing each application to
soak thoroughly into the cut
or bored surface;

If jointing is required, pile joints
shall be made by using Mild
Steel Welded Boxes 450 mm
long fabricated from 5 mm thick
plates unless otherwise shown on
the Drawings. Joint boxes shall
be painted with red lead paint or
otherwise protected against
corrosion to the satisfaction of the
S.O. The internal dimensions of
the box shall be 3 mm undersize
of the pile cross-sectional
dimensions. The joint and the
ends of the piles to be jointed
shall be constructed so that the
necessary strength and stiffness
are developed at the joint.
ii) immediately after the

preservative solution has
dried, the pile heads shall be
heavily coated with a
bituminous compound which
conforms to B.S. 3416 for the
whole depth that the pile is to
be enclosed in the pile cap.
10.10
10.10.1
When piles are cut-off at the pile

cap level, all cut-offs and bored
holes shall be treated as follows :-
Description
This work shall comprise the
supply and installation of bakau
piles, inclusive of pitching and
driving, lengthening and
preparation of pile heads, all in
Specification and to the details

Heads
the required set or depth, the head
of the piles shall be cut off square
to sound wood and treated with
an approved preservative and a
waterproof coating all in
accordance with M.S. 822. The
pile head shall be embedded for a
depth of not less than 150 mm in
the concrete cap which shall be at
least 150 mm thick round the
piles.
BAKAU PILES
10.10.2
Materials
S.O. only Bakau Minyak
(Rhizophora Apiculapa) or Bakau
Kurap (Rhizophora Mucronata)
shall be used. Bakau piles shall
be provided in one single length
of not less than 5.0 m each. The
diameter of piles at the small end
shall not be less than 75 mm
unless otherwise specified.
Page 265
All bakau piles shall be free from

rot, fungal or pest attack and any
other defects. The piles shall be
reasonably straight and circular in
cross-section with all branch
joints trimmed off to the general
outline of the piles but leaving
the bark intact on the piles.
10.10.3
Delivery and Inspection of Bakau

Piles
The Contractor shall notify the
S.O. of the delivery of piles to the
Site and provide labour and
facilities to enable the S.O. to
inspect and measure each pile at
the time of unloading. Accepted
piles shall be stacked on an
approved surface in an approved
area and kept constantly in a
damp condition. Rejected piles
shall be removed from the Site
forthwith.
10.10.4
Installation of Bakau Piles
10.10.4.1Pitching of Piles
Piles shall be pitched accurately
in the positions and at spacings as
10.10.4.2Driving of Piles
The length of piles to be driven
Drawings. Based on the results
of pile driving resistance and/or
load tests carried out on piles
driven on the site, the S.O. may,
from time to time order the
lengths or spacing of piles to be
modified.

Unless otherwise approved,
bakau piles shall be driven by
means of a drop hammer of at
least 250 kg in mass, suspended
from a shear-leg or approved
pile-frame.
Piles shall be driven in an
approved sequence to minimise
the detrimental effects of heave
and lateral displacement of the
ground. When required, levels
and measurements shall be taken
to determine the movement of the
ground or any pile resulting from
the driving process. If any pile
rise occurs as a result of adjacent
piles being driven, the Contractor
shall submit to the S.O. for
approval, his proposals for
correcting this and to avoid the
same in subsequent work.
The pile head shall be flat and at
right angles to the axis of the pile,
its edges chamfered to minimise
splitting during driving. The
Contractor shall take precautions
to avoid damage to the pile head
during hard driving by providing
a suitable metal helmet. A hard
wood dolly and, if necessary, a
packing piece shall be used above
the helmet. If during driving the
head of the pile becomes
excessively broomed or
otherwise damaged, the damaged
part shall be cut off, the head
retrimmed and the helmet
refitted.
Page 266
10.10.4.3
Where a pile has to be jointed,
it shall be to the details as
shown on the Drawings. Only
one joint shall be allowed.
The two pile ends to be
jointed shall be of the same
diameter and each shall be cut
at right angles to its axis to
make contact over the whole
cross-section when the two
timbers are co-axial. A mild
steel tube connector of No. 9
gauge to B.S. 6323 shall be
used to join the two pile ends.
The steel tube connector shall
be painted with red lead paint
or otherwise protected against
corrosion all to the
satisfaction of the S.O. The
pile ends shall be trimmed or
packed in the connector to
provide a tight fit.
10.10.4.4
Cutting and Preparation of

Pile Heads

10.11.2 Preliminary Pile Load Tests
Preliminary pile load tests shall be
carried out before the S.O. issues to
the Contractor, in writing,
instructions on the pile length and
pile length combinations for the
manufacture and supply of the piles.
The Contractor shall not proceed to
manufacture or supply the piles until
he has received instructions in
writing to do so from the S.O.
The lengths of the piles for the
preliminary load tests shall be
determined by the S.O.
10.11.3 Production Pile Load Tests
Load tests shall also be carried out
during the installation of piles for the
permanent Works. Such pile load
tests shall be referred to as
production pile load tests.
10.11.4 Testing Procedure
10.11.4.1Preparation of Test Pile
When the piles have been

driven to the required depth,
the top of the piles shall be
cut off to a uniform level.
The cut-off level shall be
below the lowest dry season
ground water level as shown
on the Drawings or as
10.11
The pile head shall be cut off or

built up to the necessary elevation
and shall be capped appropriately
to produce a bearing surface
perpendicular to the axis of the
pile. The arrangement shall be
such that none of the test load is
carried by the ground under the
cap.
PILE TESTING
10.11.4.2Method of Loading
10.11.1 Test Piles

In order to determine the required
length of pile at each location, the
Contractor shall drive test piles as
instructed by the S.O. Test piles
shall be driven with the same
hammer that is used for driving
foundation piles.
The test load shall be applied in

one of the following ways :i) by means of a jack which
obtains its reaction from
kentledge heavier than the
required load;
Page 267
ii) by means of a jack which

obtains its reaction from
tension piles or other suitable
anchors.
The load shall be measured
using a calibrated load gauge
and also a calibrated pressure
gauge in the hydraulic system.
The jack and load gauge shall
be carefully aligned so that
the load applied is co-axial
with the pile.
When method (i) is used, care
shall be taken to ensure that
the centre of gravity of the
kentledge is on the axis of the
pile. The nearest edge of the
crib supporting the kentledge
stack shall not be closer than
1.3 m to the surface of the test
pile. Kentledge shall not be
used for testing raked piles.
When method (ii) is used, all
anchor piles shall be at a
distance of at least three (3)
pile shaft diameters from the
test pile, centre to centre, and
in no case shall they be less
than 2 m from the test pile.
If the anchor piles are to be
permanent working piles,
their levels shall be observed
during application of the test
load to ensure no residual
uplift occurs.
10.11.4.3Measurement of Settlement
Settlements shall be measured by
use of a reference beam or wire
supported independantly of the
load test pile, reaction pile or
piles supporting reaction loads.
Settlements shall be measured to
the nearest 0.1 mm for reference
beams or 0.5 mm for reference

wires. The reference beam
supports shall be located at least
3 m from the load test pile,
reaction pile or piles supporting
reaction loads. The reference
beams or wires shall be protected
from the effects of temperature
changes.
10.11.5 Method of Testing
10.11.5.1General
Maintained Load Tests shall be
conducted on test piles as
selected by the S.O. The
loading tests shall be carried out
in accordance with Sub-Section
10.11.5.2.
When instructed or approved by
the S.O., Constant Rate of
Penetration Tests shall also be
conducted on other piles. The
tests shall be carried out in
10.11.5.3.
Prior to the performance of any
load test, the Contractor shall
submit to the S.O. for his
approval, working drawings
showing the method and
equipment he proposes to use in
the performance of the load test
and the measurement of
settlements. Such submission
shall include design calculations
of lateral supports or other
methods to be used in ensuring
against buckling. Horizontal
supports to ensure buckling
stability shall be provided to the
pile to be loaded whenever the
ratio of the unsupported height to
the least cross-sectional
dimension is 20 or more.
Horizontal supports shall provide
full support without restraining
the vertical movement of the pile
in any way.
Page 268
10.11.5.2Maintained Load Test

The Maintained Load Test shall
be carried out as follows :i) the full test load on a pile
shall be twice the design load
noted on the Drawings and it
shall be applied in twelve
equal increments. At least two
hours shall elapse between the
addition of each load
increment, i.e. until the rate of
settlement is reduced to less
than 0.25 mm/hour and
slowing down;
ii) the full test load shall be
maintained on the pile for at
least 48 hours and settlements
shall be recorded at
intervals of not more than 12
hours. The test pile shall
then be unloaded in four
equal increments at one hour
intervals until the full load
is removed. Settlement
readings shall be made
immediately after and before
every load increment is
applied or removed.
10.11.5.3Constant Rate of Penetration
(CRP) Test
For each pile load test, three
cycles of pile loading test at a
constant rate of penetration shall
be carried out to a full test load
equal to twice the design load.
The rate of loading shall be such
that a constant rate of penetration
is maintained throughout the test
insofar as is practicable. The rate
of movement of each pile to be
tested shall be agreed upon with
the S.O. prior to the start of the
test. At least twelve readings of
settlements and their

corresponding loads shall be
made in the loading process.
After attaining a test load equal to
twice the design load, the load
shall gradually be released and at
least four readings of settlement
and their corresponding loads
shall be made during the
unloading process. The
settlement obtained when the
load has been completely
released shall also be recorded.
An interval of at least 15 minutes
shall elapse before the next CRP
test is commenced.
10.11.6 Submission of Results
Full test data and results shall be
jointly signed by the S.O.'s
representative and the Contractor's
authorised agent immediately upon
completion of the test, and shall
consist of the following :-
i) for the Maintained Load Test, for

each stage of loading, the period
for which the load was held, the
load and the maximum
settlement. These are to be
plotted as time-settlement graphs.
ii) for the CRP test, the maximum
load reached and a graph of load
against penetration;
10.11.7 Interpretation of Test Results
The S.O.'s interpretation and
conclusions on the test results shall
be final. Unless otherwise specified,
the pile so tested shall be deemed to
have failed if :i) the residual settlement after
removal of the test load exceeds
6.50 mm; or
Page 269
ii) the total settlement under the

Working Load exceeds 12.50
mm; or
iii) the total settlement under
twice the Working Load
exceeds 38.0 mm, or 10% of
pile diameter/width whichever
is the lower value.
10.11.8 Load Testing of Bakau Piles
In general, all relevant Sub-Sections
stated hereinbefore shall apply to the
load testing of bakau piles, except
that what is understood as single test
piles in these Sub-Sections shall
mean a group of test piles for bakau
piles.
The load testing of bakau piles shall
be carried out on a group of nine
bakau piles, made up of three rows
of piles, three in a row.
An approved reinforced concrete pile
cap with a loading pedestal shall be
cast centrally over the group of piles
to be tested. The loading pedestal
shall be short to ensure stability, and
it shall have an approved mild steel
bearing plate cast on top. The load
shall be applied centrally on to the
steel plate.

Bakau piles shall be tested to
failure by the Maintained Load
Test as described hereinbefore.
The load on the pile group shall
be applied in 2 to 4 equal
increments as directed by the
S.O. until the failure load is
reached. The failure load (i.e.
ultimate load) is that load at
which the piles continue to settle
at a constant rate without further
increase of applied load.
For each increment of load, the
settlement readings shall be
recorded at 15 minute intervals
until the rate of settlement is less
than 0.25 mm per hour. The load
at each increment shall be
maintained at a constant value
throughout the test.
Graphs of time-settlement, loadtime and load-settlement, to a
suitable scale, shall be plotted
and submitted to the S.O. with all
records of the readings.
Page 270

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The flurescent orange wide angle prismatic

Minimum Coefficient of Retroreflection RA

Cawangan Jalan, Ibu Pejabat JKR, K.L

Standard Specification For Road Works

FOR INTERNAL USE ONLY

The value shall be determined on a HunterLab

Maximum spectral radiance factor, new : 110%, min.

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

iv) Resistance to Accelerated Weathering.

Standard Specification For Road Works

vii) Field Performance

FOR INTERNAL USE ONLY

Standard Specification For Road Works

STANDARD SPECIFICATION FOR ROADS WORKS

Portland Cement Concrete Pavement

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

Standard Specification For Road Works

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

Standard Specification For Road Works

GENERAL DESCRIPTION OF THE PROJECT

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

Standard Specification For Road Works

GENERAL DESCRIPTION OF PROJECT

VEHICLES FOR S.O. AND HIS STAFF

LIST OF LABORATORY EQUIPMENT

Soil Testing Equipment

APERTURE CARD FOR MICROFILM

Cawangan Jalan, Ibu Pejabat JKR, K.L

FOR INTERNAL USE ONLY

Standard Specification For Road Works

The general description of the project is as

The Works covered in this Contract comprise

NOTES, ABBREVIATIONS AND

a) M.S. means Malaysian Standards

Any clause in this Specification which

e) M.D.D. means Maximum Dry

ii) Unless stated to the contrary, any

g) C.B.R. means California Bearing

iii) All Standards and Codes of Practice

i) B.Q. means Bill of Quantities.

In the event of any discrepancy between

h) S.O. means Superintending Officer.

1.3.3 Units of Measurement