Specification

Section 6 - Sub-Base and Roadbase

*601: Construction Requirements for Sub-base and Roadbase Materials Transport vehicles carrying plant mixed material shall have a capacity suited to the output of the mixing plant and the site conditions. Materials when mixed shall be removed at once from the mixer, transported directly to the point where they are to be laid and protected from the weather both during transit from the mixer to the laying site and whilst awaiting tipping. All material shall be placed and spread evenly, spreading taking place concurrently with placing or without delay. Bitumen bound and wet mix roadbase material shall be spread using a paving machine or spreader box operated with a mechanism which levels off the material to an even depth. Except where otherwise specified the material shall be spread in one layer so that after compaction the total thickness is as specified. For cement treated materials the Developer shall avoid longitudinal joint of such material so far as possible. Before work proceeds against a longitudinal joint of such material the edge compacted earlier shall, if it has been exposed for more than one hour, be cut back vertically to produce a face of the specified thickness of layer and of properly compacted material. Compaction shall be carried out as specified in Clauses 606 for cement bound macadam, respectively and in accordance with Table 6 for material to Clauses 602 to 604 inclusive and shall be completed as soon as possible after the material has been spread. Compacting equipment shall not bear directly on hardened or partially hardened cement treated material previously laid other than that necessary for achieving the specified compaction at the joint. Special care shall be taken to ensure full compaction in the vicinity of joints and any loose material shall be removed and replaced with fresh material. The surface of any layer of material shall on completion of compaction be well closed, free from movement under compaction plant and from compaction planes, ridges, cracks or loose material. In the case of cement treated material, if this cannot be done within 2 hours of mixing, the making good shall comprise the material being broken out to the full thickness of layer, removed and replaced with freshly mixed material compacted to Specification. Any layer of cement treated material not covered within 2 hours either by another layer of such material or by another pavement course shall, immediately on completion be cured for a period of not less than 7 days. Curing of the surface of the layer shall be achieved by spraying with a bitumen road emulsion Class 1 to BS. 434 at the rate of 0.6 to 0.8m per litre. The emulsion shall be blinded with hard clean crushed rock or slag fine aggregate or sand containing not more than 15 per cent retained on the 6.3mm BS sieve, applied at the rate of 5.5 to 6.8 Kg per m. Definitions and requirements relating to compaction plant shall be as described in Clause 407.

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Specification
TABLE 6: Compaction Requirements for Granular Sub-base and Wet-Mix Macadam Type of compaction plant Smooth wheeled roller having a force per 100mm width of more than 5.2kN Vibratory roller having a static force per 100mm width of 1.75 - 3.5kN Vibrating plate compactor having a static force under the base of 17.2 - 20.7kN/m Number of passes 16

602: Granular sub-base material Type 1 Type 1 granular material shall be crushed rock, crushed slag or crushed concrete. The material shall be well graded and be within the grading envelope of Table 7. The material passing the 425um BS sieve shall be non-plastic as defined by BS 1377 and tested in compliance therewith. The material shall be transported, laid and compacted without drying out or segregation. The material shall have a 10% fines value of 50kN or more when tested in compliance with BS 812 except that samples shall be tested in a saturated and surface dried condition. Prior to testing the selected test portions shall be soaked in water at room temperature for 24 hours without previously having been oven dried. All material shall be laid in layers not exceeding 175mm thickness after full compaction. TABLE 7: Sub-base Type 1 Range of Grading BS sieve size 75mm 37.5mm 10mm 5mm 600um 75um Percentage by mass passing 100 85 - 100 40 - 70 25 - 45 8 - 22 0 - 10

The particle size shall be determined by the washing and sieving method of BS 812 Part 103.

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Specification

Specification
603: Granular Sub-Base Material Type 2 Type 2 granular material shall be natural sands, gravels crushed rock, crushed slag, or crushed concrete. The material shall be well-graded and be within the grading envelope of Table 8. The material passing the 425 um BS sieve when tested in compliance with BS 1377 shall have a plasticity index of less than 6. The material shall be transported, laid and compacted at a moist content within the range 1% above to 2% below the optimum moisture content determined in compliance with BS 5835, and without drying out or segregation. The material shall have a 10% fines value of 50 kN or more when tested in compliance with BS 812 except that the samples shall be tested in a saturated and surface dried condition. Prior to testing the selected test portions shall be soaked in water at room temperature for 24 hours without previously having been oven dried. TABLE 8: Sub base Type 2 Range of Grading BS sieve size 75mm 37.5mm 10mm 5mm 600um 75um Percentage by mass passing 100 85 - 100 45 - 100 25 - 85 8 - 45 0 - 10*

The particle size shall be determined by the washing and sieving method of BS 812 Part 103. * For material containing mainly Jurassic limestone particles the limits shall be 0-5%. Such material with between 5 and 10% passing the BS 75um sieve may be used only if it is nonfrost susceptible when tested in compliance with TRRL report LR 829. 604: Granular Sub-base Material Type 4 Type 4 granular sub-base material shall be derived from asphalt arisings. The asphalt arisings shallbe either asphalt road planings or granulated asphalt, but excluding material containing tar or tar-bitumen binders.
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Asphalt planings are defined as materials derived from the asphalt layers of the pavement using a mobile machine fitted with milling cutters. Granulated asphalt is defined as asphalt bound material recycled from roads under reconstruction or surplus asphalt material destined for bound pavement layers, but unused, which has been granulated.

Type 4 granular sub-base material shall have an upper limit on recovered bitumen content of 10% when tested in accordance with BS 598 : Part 102.

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Specification
1 Type 4 granular sub-base material shall, at the time of placing, lie within the lump size grading envelope of Table 8/5 and not be gap graded. TABLE 8/5: Type 4 Granular Sub-base Material Range of Lump-size Grading BS sieve size 75mm 37.5mm 20mm 10mm 5mm 600 micron 75 micron Percentage by mass passing 100 85 - 100 60 - 90 30 - 70 15 - 45 0 - 22 0 - 10

The lump size distribution shall be determined either by the washing and sieving method or by the dry sieving method of BS 812 : Part 103 : 1985 (see Note 1). Note 1: The planings should be oven dried (prior to sieving) at a temperature of 45 to 50C. Sieving shall be carried out at 20 5C to reduce the tendency of the bitumen to soften and particles to adhere to each other. The material shall be transported, laid and compacted at a moisture content within the range optimum moisture content to 2% below the optimum moisture content determined in compliance with BS5835 and without drying out or segregation. Measurement of moisture content both for control purposes and for optimum moisture content determination shall be according to BS 812 : Part 109 using a conventional oven on a reduced temperature setting of 45 to 50C. When required by Appendix 7/1, the Contractor shall undertake a Trafficking Trial incorporating the Type 4 granular sub-base material proposed for use in the Works. A trial area shall be constructed, trafficked and assessed in accordance with the procedure described in sub-Clauses 6 to 11 of this Clause. The mean vertical deformation after 1000 equivalent standard axles shall be less than 30mm when measured in accordance with the procedure stated in sub-clause 10 of this clause. Proposals for sub-base trials shall be submitted to the Overseeing Organisation 5 days in advance of construction.

The trial area shall be located on a formation prepared in accordance with the Specification. The trial area may be located so that it can be incorporated within the Permanent Works if the resistance to wheel track rutting is demonstrated to comply with sub-Clause 5 of the Clause. The trial area shall be at least 60m long, and of sufficient width that when trafficked, the wheel paths of the test vehicle shall be at least 1m from either edge of the top of the sub-base layer. The sub-base shall be compacted to the thickness specified in Appendix 7/1. The formation shall extend for a further 1m either side of the sub-base layer. 15-35

Specification

Trial Procedure

Specification
A sufficient run off/run on area shall be constructed at each end of the trial area, the same width, and compacted to the same level, as the trial area, to ensure correct tracking by the test vehicle and minimise dynamic effects of the vehicle bouncing on its springs. Suitable guidance shall be given to assist the driver in maintaining the same track on each pass and to achieve channelled trafficking. Examples of suitable guides would be a string or painted line. Materials The sub-base used in the trial shall be transported, laid and compacted using the equipment proposed for use in the Works. Maximum vertical deformation shall be measured in both wheel tracks using optical or laser levels at pre-determined monitoring points on five transverse lines spaced equally along the length of the trial bay. The transverse lines at the ends of the trial area shall be at least 5m from the run off/run on areas. The average vertical deformation of the two wheel tracks after 1000 standard axles shall be recorded. Reporting The Contractor shall provide the Overseeing Organisation with a report on the Trafficking trial. For Type 4 sub-base to be approved for use in the Works the report shall set out the results of the trial, stating how they validate the use of the material. *605: Wet Mix Macadam Wet-mix macadam shall consist of course and fine aggregate from natural sources which shall be crushed rock complying with the requirements of BS.882 or crushed air-cooled blastfurnace slag complying with BS.1047 and complying with the grading requirements of Table 6, Type A. TABLE 9: Range of Grading BS sieve size Percentage by weight passing Type A 100.0mm 75.0mm 63.0mm 50.0mm 37.5mm 20.0mm 10.0mm 5.0mm 2.36mm 600um 75um 100 95 - 100 60 - 80 40 - 60 25 - 40 15 - 30 8 - 22 0-8 Type C 100 10 - 50 0-5 0-2 -

The particle size shall be determined in accordance with the requirements of BS 1377 Test No. 7. The aggregate shall be frost resistant as defined by the Engineer. 15-36

Specification
The moisture content of the wet mix macadam shall be the optimum 0.5 per cent as determined in accordance with the Vibrating Hammer Method in BS.1377 Test No. 13. The material shall be laid and compacted in a single layer in accordance with Clause 601. Any areas of compacted material having a loose surface deficient in fines due to segregation or otherwise shall be made good by removal of the loose material and replacement with properly graded material. 606: Dense Bitumen Macadam Roadbase The material shall be manufactured, transported, laid and compacted in accordance with the requirements of BS 4987, and shall be 40mm size dense roadbase, laid 100mm thick.

The aggregate shall consist of hard, clean durable crushed rock, steel slag, electric furnace slag or blast furnace slag.

The binder shall be petroleum bitumen complying with the requirements of BS 3690 or a mixture of 90 per cent by mass of such bitumen with 10 per cent by mass of tar complying with BS76. The penetration of the binder shall be either 100 pen or 200 pen.
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the truck mixer has been manufactured in accordance with BS 4251, or the mixing performance of the truck mixer, when tested in accordance with BS 3963 is within the limits of Table 6 of BS 1305.

607: Cement Bound Macadam The aggregate for cement bound macadam shall consist of either coarse and fine aggregate batched separately or an all-in aggregate having a maximum nominal size not exceeding 37.5mm nor less than 20mm. Its quality and cleanliness shall comply with the requirements of Clause 1010. The overall grading of the aggregate shall be within the limits shown in Table 7 and additionally the grading of the aggregate passing the 5mm sieve shall be within Zone 2 or Zone 3 of BS 882. Density tests required, three determinations shall be made of the dry density of the compacted base for each 800m or part thereof base laid each day. The method specified in BS 1377 shall be used so that they are representative of the full depth of the base. To ensure accuracy, these tests shall be made only after a period of 4 hours has elapsed since the completion of the compaction and preferably within 24 hours. The results of the density tests shall be treated as successive groups of three and the average density shall be calculated for each group.

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Specification

Specification
TABLE 10: Range of Grading BS sieve size Percentage by weight passing Nominal maximum size 37.5mm 75mm 37.5mm 20mm 5mm 600um 150um 100 95 - 100 45 - 80 30 - 40 8 - 30 0-6 Nominal maximum size 20mm 100 80 - 100 35 - 45 10 - 35 0-6

The ratio by weight of cement to aggregate, expressed in terms of its saturated surface dry condition shall be sufficient to produce average crushing strengths to the requirements of this Clause. The ratio of cement to aggregate by weight shall not, however, be more than 1:15 nor less than 1:20 except with the approval of the Engineer. The materials shall be mixed either in a batch-type mixer manufactured in accordance with BS 1305, or in a batch-type or continuous mixer, specimens of which have been tested in accordance with BS 3963 and having a mixing performance within the limits of Table 6 of BS 1305. A continuous mixer shall be fed with material which has been proportioned wholly by weight. For the purpose of testing a continuous mixer 0.8m of concrete sampled during continuous operation will be taken as a batch as referred to in BS 3963 and the mixer will be assumed to have a batch capacity in excess of 0.55m. Concrete mixed in a batch type mixer shall be mixed for the time included in the manufacturer's prototype test report or in the special test report for the particular mixer for the mix proportions in use and corresponding to the mixing performance limits of Table 6 of BS 1305. A continuous mixer shall be adjusted in respect of mixer speed and rate of feed to correspond with the values on the test report for the mix proportions in use and the mixing performance limits of Table 6 of BS 1305. The drums or pans of all mixers shall revolve at the speed used for testing in accordance with BS 3963 for the mix proportions required within a tolerance of 1 revolution per minute. The mixing blades of a pan mixer shall be maintained within the tolerances specified by the manufacturers of the mixer and blades shall be replaced when this is no longer possible to maintain the tolerances by adjustment. All drums or pans which have been out of use for more than 30 minutes shall be thoroughly cleaned out before any fresh concrete is mixed in them. Such cleaning out shall also be undertaken whenever the mixer is to be used for high alumina cement after Portland cement and vice versa. Concrete in accordance with BS 1926 delivered in truck mixers or in truck agitators shall have been mixed completely in a stationary mixer as specified above except that a truck mixer may be used for mixing provided no water is added in transit. The cement bound macadam shall be transported, laid and cured in accordance with the requirements of Clause 601.

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Specification
Compacting shall be carried out by means of a vibratory roller which applies a static force of more than 1.76kN per 100mm width of vibratory roll or by a vibratory compactor with a static pressure under the base plate of more than 20.7kN/m. Compaction shall be continued until the surface is closed and the density of the compacted base meets the requirements for density in this clause. The maximum period of time between the mixing of the materials and completion of any given material shall be 2 hours. The average 28 day strengths of groups of three cubes shall not be less than 9.6 MN/m. Furthermore, in order to ensure a high probability at an early stage that the above strength will be met, the average 7 day strengths of groups of three cubes should not be less than 6.9 MN/m and if this strength is not met then the cement content shall be increased to such a value as may be approved by the Engineer. The average density obtained from groups of three determinations shall not be less than 95 percent of the theoretical dry density with zero air content. If the ratio of average densities failing to satisfy the above requirements to average densities satisfying the above requirements exceeds 1:5 in not more than five consecutive such averages, the Engineer may require the Developer to make good by removing the layer represented by the low densities and replacing it with further material to requirements of this Clause. All testing shall be carried out in accordance with the requirements of Clause 608. 608: Testing of Cement Bound Macadam Testing of the cement bound macadam base shall be carried out as follows:!

Prior to acceptance of the aggregate for cement bound macadam, results shall be submitted to the Engineer of the gradings and tests for organic impurities and clay, silt and fine dust of three samples taken on separate days within the previous 4 weeks of normal production or from different parts of the area to be worked. Samples of the aggregate taken and tested in these respects in accordance with the methods described in BS 812 shall be submitted to the Engineer. After the beginning of the work the grading of the aggregate shall be determined and the tests for organic impurities and clay silt and fine dust shall be carried out once per week and at such other times as required by the Engineer. During the whole progress of laying lean concrete, test cubes, which shall be of 150mm size, shall be made in pairs at intervals, each pair being from a separate batch of concrete. One cube of each pair shall be tested at 7 days and the other at 28 days. At the start of the work and until such time as the Engineer may order a reduction in the number of cubes required, 3 pairs of cubes shall be made for each 800m of base or part thereof laid each day. The method specified in BS 1377 shall be used so that they are representative of the full depth of the base. To ensure accuracy, these tests shall be made only after a period of 4 hours has elapsed since the completion of the compaction and preferably within 24 hours.

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Specification

Specification
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The results of the cube test shall be treated as successive groups of 3 and the average strength and range, i.e the highest minus the lowest value, shall be calculated for each group. The making, curing and testing of all cubes shall be in accordance with the methods described in BS 1881, except that the cubes shall be compacted by means of an electric or pneumatic hammer. The hammer shall have a square or rectangular foot having an area between 1dm and 1.5dm and sufficient pressure shall be used directly on to each of the three layers of material filled into the mould to result in the material being compacted to refusal.

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