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KUWAIT OIL COMPANY (K.S.C.

STANDARDS PUBLICATION

KOC STANDARD
FOR
MATERIALS AND WORKMANSHIP -
ROADWAYS, PAVING AND HARD STANDING :
PART 2 : MISCELLANEOUS WORKS
& RIGID PAVEMENT

DOC. NO. KOC-C-024 PART-2

I STANDARDS DIVISION I
DOC. NO. KOC-C-024 PT. 2 Page 1 of 41 Rev. 1

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC STANDARD

FOR

MATERIALS AND WORKMANSHIP -


ROADWAYS, PAVING AND HARD STANDING:

PART 2: MISCELLANEOUS WORKS


& RIGID PAVEMENT

STANDARDS DIVISION
11 DOC. NO. KOC-C-024 PT. 2 1 Page 2 of 4 1 Rev. 1

KOC STANDARD

FOR

MATERIALS AND WORKMANSHIP -

ROADWAYS, PAVING AND HARD STANDING:

PART 2: MISCELLANEOUS WORKS


& RIGID PAVEMENT

DOC. NO. KOC-C-024 PART-2

ISSUING AUTHORITY:

STANDARDS DIVISION
TABLE OF CONTENTS
Page No.

FOREWORD 5

SCOPE

APPLICATION

TERMINOLOGY
3.1 Definition of Terms
3.2 Abbreviations

REFERENCE STANDARDS AND CODES


4.1 Conflicts
4.2 List of Standards and Codes

ENVIRONMENTAL CONDITIONS

HEALTH, SAFETY AND ENVIRONMENT

BASIC ENGINEERING INFORMATION


7.1 Horizontal Clearance
7.2 Vertical Clearance
7.3 Culverts and Pipetrack Crossings

IISCELLANEOUS WORKS
1. 1 Concrete Paving
1.2 Walkways
.3 Parking Areas
.4 Rumble Strips
.5 Roundabout
.6 Traffic Island
.7 'U' Turn Dividers
.8 Traffic Barriers
.9 Crash Barriers
.I0 Guard Rails
ROADWAYS AND PAVING DRAINAGE
9.1 General Considerations
9.2 Surface Drainage
9.3 Drainage Inlets
9.4 Storm Sewers

RIGID PAVEMENT (FOR RIG CROSSINGS)


10.1 General
10.2 Sub-base
1 0.3 Material Requirements
10.4 Construction Requirements
10.5 Workmanship
10.6 Joints in Concrete Pavement
REHABILITATION WORKS
1 1 .I General
1 1.2 Asphalt Pavement
DOC. NO. KOC-C-024 PT. 2 Page 4 of 4 1 Rev. 1

1 1.3 Concrete Pavement


1 1.4 Tolerances

MAINTENANCE WORKS
12.1 General
12.2 Crack Repairs

SITE LABORATORIES
13.1 General
13.2 Functions and Requirements
13.3 Approval

TRAFFIC SIGNS
14.1 General
14.2 Classification of Signs
14.3 Sign Panel Requirements
14.4 Sign Panel Erection
14.5 KOC Standard Drawings

TRAFFIC SIGNALS
15.1 General
15.2 Materials
15.3 Installation of Signal Supports
15.4 Painting

FENCING WORKS TO SOLAR PANELS FOR TRAFFIC SIGNALS


16.1 General
16.2 Fencing Materials and Installation

INSPECTION AND TESTING


17.1 General
17.2 Materials and Equipment lnspection
17.3 Visual lnspection
17.4 Testing
17.5 Field Tests

QUALITY ASSURANCE

DOCUMENTATION
19.1 General
19.2 Test Results and Certificates
19.3 Work Records

APPENDICES

Appendix l : Rigid Pavement

Appendix II : RCC Slab for Rig Crossing

Appendix Ill : Expansion and Contraction Joints in Rigid


Pavement

Appendix IV :Transverse Construction Joints in Rigid


Pavement

ACKNOWLEDGMENT
DOC. NO. KOC-C-024 PT. 2 Page 5 of 4 1 Rev. 1

FOREWORD

This document " KOC Standard for Materials and Workmanship - Roadways, Paving
and Hard Standing : Part 2 : Miscellaneous Works & Rigid Pavement " is also
applicable in continuation w i t h KOC Standard KOC-C-024 Part-I for "Flexible
Pavementrr; and is intended in general t o address the miscellaneous Works related
t o the road construction, w i t h provision of Site laboratories for field testing and
installation of traffic signs etc., for all weather roads within KOC areas. Special
cases such as rigid pavements for rig crossings and rehabilitationlmaintenance of
roadways are also dealt w i t h t o meet the specific construction requirements.

This KOC Standard has been approved by the Standards Division in consultation
with Standards Technical Committee (STC) for use throughout the corporate
engineering and operational functions of Kuwait Oil Company (K.S.C).

Part 2 of this Standard sets out t o achieve the following objectives:-

a) To establish the various requirements of miscellaneous works pertaining t o


the construction of roadways as well as rehabilitation and maintenance of
existing roadway Ipavements.

b1 To meet the basic technical requirements s f specially built concrete road


crossings across the field roads for drilling rigs.

c To provide good and reliable field testing facilities by means of Site


laboratories.

d1 To provide general technical guidance of KOC requirements in project


specifications t o ensure better reliability and safety on the roads.

e1 To set out clear requirements of compliance of materials and workmanship


within a contract.

Feedback as well as any comments or suggestions from the application of this


Standard derived at any stage of design, engineering, field construction,
maintenance or operation are encouraged and should be directed to:

The Supdt. Standards Division


(Chairman, Standards Technical Committee)
Loss Prevention Group, KOC
P.O.Box 9758, Ahmadi 6 1 0 0 8
State of Kuwait

Task Force responsible for this Standard

The Standards Technical Committee (STC) has entrusted the preparation of this
Standard t o the Task Force No. (TF-Cl02) comprising of the following members:

Mr. S.Kumar Standards Div - Team Leader Tel. 6 14 0 7


Mr. Mohammad Sami Standards Div. - Member Tel. 61371
Mrs. Sana Ali Talha Engg. Design Div. - Member Tel. 61352
Mr. Mubarak Al-Ahmad Construction Div. - Member Tel. 61249
Mr. Faisal Khorsheed Ahmadi Svcs. Dept. - Member Tel. 67329

-
DOC. NO. KOC-C-024 PT. 2 Page 6 of 4 1 I Rev. 1

1 .O SCOPE

1 .I This KOC Standard (Part 2) specifies the basic requirements for materials
and workmanship of various miscellaneous works associated w i t h
construction of "Roadways, Paving and Hard Standing" at the new and
the existing locations within KOC Facilities, KOC Fields and Ahmadi
areas.

1.2 This Part covers the extent of miscellaneous works as described herein
and includes but not limited only t o the following:-

Construction of walkways, parking areas, traffic barriers, crash


barriers and guard rails.

Construction of rigid pavement (concrete road) for rig crossing.

Roadways and paving drainage.

Rehabilitation and maintenance of existing pavements.

Provision of Site laboratories.

Installation of traffic sign panels.

Installation of fencing t o solar panels for traffic signals.

1.3 Part 2 of this Standard excludes the basic technical requirements for
selection of materials and workmanship related t o the construction of
"Flexible Pavement", which are covered under KOC Standard KOC-C-024
Part-I .

2.0 APPLICATION

2.1 The construction and maintenance of any work related t o all weather
roads and pavements (asphalt 1 concrete) in KOC operational and non-
operational areas shall conform t o the requirements of this Standard and
reference standards I codes mentioned herein.

2.2 Any exceptions or deviations from this Standard, along w i t h their merits
and justifications, shall be brought t o the attention of KOC1s Controlling
Department for their review, consideration and amendments by
Standards Division (if required).

2.3 Compliance w i t h this Standard does not confer immunity from legal or
statutory obligations.
DOC. NO. KOC-C-024 PT. 2 Page 7 of 4 1 Rev. 1

TERMINOLOGY

Definition of Terms

For the purposes of this Standard, the following definitions apply.

Rigid Pavement

A concrete roadlpaving slab of relatively high bending resistance, which


distributes loads t o the sub-grade.

Pavement Maintenance

The preservation of the entire roadway, including surface, shoulders,


roadsides, structures, and such traffic control devices as are necessary
for its safe and efficient utilization.

Pavement Rehabilitation

Work undertaken, by placing additional surfacing material and/or


improving as necessary the conditions of structural or functional
adequacy of an existing roadway including shoulders, t o extend its
service life. This may include the complete removal and replacement of
the existing pavement if required.

Pumping

The ejection of foundation material, either w e t or dry, through joints or


cracks or along edges of rigid slabs resulting from the vertical
movements of the slab under traffic load.

Modulus of Sub-grade Reaction

Westergaardrs modulus of sub-grade reaction for use in rigid pavement


design; and expressed as load in pounds per square inch on a loaded area
of the roadbed soil or sub base divided by the deflection in inches of the
road bed soil or sub-base.

Sub-Base (for rigid pavement)

One or more compacted layers of granular or stabilized material placed


between the sub-grade and the rigid concrete slab t o provide uniform,
stable and reliable support.

The slopelcamber provided on either side of the road t o drain off storm
water on t o the adjacent grade, or into lined swales provided at the side
of the road.
Right-of-way (ROW)

A corridor of land(s) secured and reserved for development of a roadway


and associated structures pertaining t o the road.

Cold-Milling

The process of stripping asphalt pavement material for the purpose of


profiling or cleaning the surface prior t o resurfacing. The milling provides a
surface, free from gouges, ridges and continuous grooves.

Rutting

A groove or depression formed in a surface layer, longitudinal t o the road,


by the wheels of travelling vehicles, also known as channelling.

Paving

Separate blocks or units fitted closely together over a pavement t o serve as


a surface.

Median Strip

A dividing strip in the middle of the roadway.

Abbreviations

AASHTO American Association of State Highways and


Transportation Officials

CBR California Bearing Ratio

HSE Health, Safety and Environment

KOC Kuwait Oil Company

MPW Ministry of Public Works

REFERENCE STANDARDS AND CODES

Conflicts

In the event of conflicts between this Standard and the StandardsICodes


referred herein, or other purchase or contractual requirements, the most
stringent requirement shall apply. In case further clarifications are required,
the subject shall be brought t o the attention of KOC's Controlling
Department.
DOC. NO. KOC-C-024 PT. 2 Page 9 of 4 1 Rev. 1

4.1.2 In general, the sequence of precedence shall be followed as:

a1 Kuwait Government Rules and Regulations


b1 KOC Technical Specifications
c1 This KOC Standard (KOC-C-024 Part-2)
d1 International codes and standards
e) Contractor's standards and specifications

List of Standards and Codes

The latest edition of the following standards, and codes shall apply:

1 National Standards

AASHTO Guide for Design of Pavement Structures

ACI 3 1 5 Details and Detailing of Concrete Reinforcement

ACI 3 1 8 Building Code Requirements for Structural Concrete

ACI 504R Guide t o Sealing Joints in Concrete Structures

ASTM A 5 3 Specification for Pipe, Steel, Black and Hot- Dipped, Zinc
Coated, Welded and Seamless

ASTM A121 Specification for Metallic-Coated Carbon Steel Barbed


Wire

ASTM A 1 2 3 Specification for Zinc (Hot-Dip Galvanized) Coatings on


Iron and Steel Products

ASTM A 3 0 7 Specification for Carbon Steel Bolts and Studs

ASTM A 3 9 2 Specifications for Zinc-Coated Steel Chain-Link Fence


Fabric

ASTM A 6 1 5 Specification for Deformed and Plain Billet-Steel Bars for


Concrete Reinforcement

ASTM C33 Specification for Concrete Aggregates

ASTM C39 Test Method for Compressive Strength of Cylindrical


Concrete Specimens

ASTM C88 Test Method for Soundness of Aggregates by the use of


Sodium Sulphate or Magnesium Sulphate

ASTM C 9 4 Specification for Ready-Mixed Concrete

ASTM C131 Test Method for Resistance t o Degradation' of Small Size


Course Aggregate by Abrasion and Impact in the Los
Angeles Machine

-
ASTM C143 Test Method for Slump of Hydraulic Cement Concrete

ASTM C 1 5 0 Specification for Portland Cement

ASTM C 9 2 0 Specification for Elastomeric Joint Sealant

ASTM D l 1 8 6 Test Methods for Non-destructive Measurement of Dry


Film Thickness of Nonmagnetic Coatings Applied t o a
Ferrous Base

ASTM D l 2 1 2 Test Methods for Measurement of Wet Film Thickness of


Organic Coatings

ASTM D l 5 5 6 Test Method for Density and Unit Weight of Soil in Place
by the Sand Cone Method

ASTM D l 7 5 1 Specification for Preformed Expansion Joint Filler for


Concrete Paving and Structural Construction

ASTM D2697 Test Method for Volume Non-volatile Matter in Clear or


Pigmented Coatings

Specifications for Colours for Identification, Coding and


Special Purposes

Specification for Test Sieve

Methods of Testing Aggregates

Specification for Aggregates from Natural Sources of


Concrete.

BS I 8 8 1 Methods of Testing Concrete

BS 4 4 4 9 Carbon Steel Bars for the Reinforcement of Concrete

BS 4 4 8 3 Steel Fabric for the Reinforcement of Concrete

BS 521 2 Cold Applied Joint Sealant Systems for Concrete


(Parts 1-3) Pavements

BS EN 9 3 4 Admixtures for Concrete, Mortar and Grout


(Parts 2 &6)

BS EN 10244-2 Steel Wire and Wire Products-Non Ferrous Metallic


Coatings on Steel Wire-Part 2

BS EN 2 2 0 6 3 Metallic and Other Inorganic Coatings-Thermal Spraying-


Zinc, Aluminium and Their Alloys

BS EN I S 0 1 4 6 1 Hot Dip Galvanized Coatings on Iron and Steel Articles


DOC. NO. KOC-C-024 PT. 2 Page 1 1 o f 4 1
I Rev. 1

BS EN I S 0 3 2 6 2 Extender for Paints-Specification and Methods of Test


(1 12 843)

4.2.2 KOC Standards

KOC Standard for Geotechnical Investigation (Onshore)

KOC Standard for Materials and Workmanship-Site


Preparation and Earthwork

KOC-C-024 KOC Standard for Materials and Workmanship -


(Part-I) Roadways, Paving and Hard Standing: Part-I : Flexible
Pavement

KOC Standard for Hazardous Area Classification

KOC Standard for Basic Design Data

KOC Recommended Practice for Protection of KOC


Services: Clearance Requirements for Buried Pipelines &
Piping, Cables, Underground Structures and Buildings

KOC Standard for Painting and Coating of Metal Surfaces


- New Construction

General Specification for Civil Engineering and Building


Works

N.B: For Earthworks, Sub-Base and Base Course Materials, Asphalt


Materials and Concrete Works (General), refer t o KOC Standard KOC-
C-024 Part -1 .

4.2.3 KOC Standard Drawings

15-5-80 Security Chainlink Fence Details (2.40 m High)

1 5-1 8-3 Traffic Signs for Diversions

1 5-1 8-5C Warning Signs Face and Arrow Details

15-1 8-6 Sign Mounting Details, Warning Signs

1 5-1 8-7A Sign mounting details, Guide Signs

1 5-1 8-8 Standard Metal Beam, Guard Rail and Concrete Kerb
Details

15-18-1 7 Guide Signs and Arabic Legend

1 5-34-1 9 A Pipe Crash Barrier Detail

-
Kuwait Government Regulations

State of Kuwait - Ministry of Public Works - Road Administration -


General Specifications for Kuwait Motorway/Expressway System

State of Kuwait Traffic Signs Manual -Volumes 1 & 2

Project Specifications

This Standard also makes reference t o other specification, which should be


designated by the Controlling Department in 1<OC, in the absence of any
KOC Standard and Recommended Practice for the subject listed below:

Reinforced Concrete Materials and Construction.

ENVIRONMENTAL CONDITIONS

The environmental conditions in Kuwait are severe. Refer t o "KOC


Standard for Basic Design Data" (KOC-G-007), which provides the detailed
design information regarding the environmental, site and utility supply
conditions prevailing throughout the KOC facilities.

HEALTH, SAFETY AND ENVIRONMENT

The Contractor shall follow the necessary health and safety procedures,
which are acceptable t o KOC, t o protect its personnel and surrounding
environment during any site works.

All relevant safety requirements of KOC Fire & Safety Regulations, KOC
Health, Safety and Environment (HSE) policy and Health and Environment
(HE) Guidelines shall be adhered to, by the Contractor, while performing
the works within KOC areas.

During execution of work, road diversion if required, shall be developed in


concurrence with KOC Fire & HSE Dept. Proper warning light and notices
shall be provided and Burgan Fire Station shall also be informed about road
closure/diversion.

BASIC ENGINEERING INFORMATION

Horizontal Clearances

A t roads without raised kerbs, a horizontal clearance of 1 0 0 0 m m shall


be maintained between the edge of the shoulder and any structure
projecting above shoulder grade. The minimum horizontal clearance for
lighting poles, guardrails, and traffic signs shall be 6 0 0 mm.

A t roads with raised kerbs, the minimum horizontal clearance shall be 6 0 0


m m from the face of the kerb.
DOC. NO. KOC-C-024 PT. 2 Page 13 of 4 1
A Rev. 1

Vertical Clearances

Minimum vertical clearance of vehicles over main facility access and


primary roads, shall be 5 0 0 0 mm. Over other roads it shall be 4000 mm.
Where access for heavy lift cranes is required, the clearance height shall be
6 5 0 0 mm.

Traffic signs shall be erected with a minimum clearance of 21 00 m m from


ground or footpath level t o the underside of the sign.

Culverts and Pipetrack Crossings

A t culverts and pipetrack crossings, the road width shall be continuous.


The hard shoulders shall generally be terminated on each side of the culvert
or pipe crossing.

Concrete kerbs with minimum height of 1 5 0 m m shall be provided at the


sides of the road over culverts. Heavy duty railing shall be provided, where
the road is raised t o pass over grade pipe tracks. Railings shall be painted
with reflective orange paint.

MISCELLANEOUS WORKS

Concrete Paving

Reinforced concrete slab of Portland cement shall be provided as an area


paving, in areas subject t o possible contaminated spills, vehicular access
ramps t o buildings, footpaths and around pump plinths in accordance with
KOC approved project /construction drawings wherever indicated.

Concrete paved areas shall be laid t o a fall of 1 in 1 0 0 minimum.

Sub-base comprising of granular materials shall not be provided if the sub-


grade material is a well compacted soil with a minimum CBR of 20%.
Refer t o KOC-C-024 Part-I for details of sub-grade and sub-base materials
and workmanship.

Light duty paving slab shall be 1 0 0 m m thick, reinforced with one layer of
high tensile 6 m m diameter 2 0 0 m m square mesh fabric conforming t o BS
ref. No. A 1 4 2 as per BS 4483. The reinforcement shall be placed near the
top of the slab. Paving slab shall be laid over a polyethylene sheet of
1OOOg thickness, placed on the prepared surface (sub-grade or sub-base).

Walkways

Walkways and pathways made of concrete / asphalt / tiles of 1 0 0 0 m m


minimum width around the buildings and 2 0 0 0 m m elsewhere, as indicated
in the KOC approved drawings.

Concrete walkways and pathways shall be light duty paving slab and shall
be constructed in accordance with clause 8.1.4 of this Standard. A

Asphalt walkways and pathways shall be 1 0 0 m m thick and shall be of


type Ill asphalt concrete in accordance with KOC-C-024 Part 1.
DOC. NO. KOC-C-024 PT. 2 Page 1 4 of 4 1 Rev. 1

Paving tiles, wherever specified as walkways I pathways shall be pre-cast


plain concrete interlocking type, as manufactured by the Cement Products
Factory of the National Industries Company in Kuwait. The tiles shall be
laid over 5 0 m m thick evenly spread layer of sand or compacted gatch. The
tiles shall be protected by the pre-cast kerbstones at the edge of the
walkway.

Parkinn Areas

Open paved parking areas shall have the same specification as for the
asphalt road(s) serving the parking area. However in areas subject t o
excessive hydrocarbon spillage, parking areas should be paved with
Portland cement concrete.

For parking at open places, parking bays shall be provided for passenger
cars on a rectangular layout. The width of parking bay shall be 3 0 0 0 m m
and length shall be 6 0 0 0 m m for parking space of each vehicle. Driveway
width shall be considered not less than 7 0 0 0 mm. Parking bay shall be
marked out w i t h durable white lines, 1 0 0 m m wide for straight and angular
(30" or 45") parking depending on the available space.

Rumble Strips

Rumble strips shall be constructed as indicated in the KOC approved


drawings by cold milling of the completed asphalt pavement. The strips
shall be formed by using removable shutter boards rigidly located on the
binder course before laying the wearing course. The strips formed by this
method shall be re-rolled with a pneumatic tyre roller t o re-compact the
edges.

Roundabout

Roundabout or traffic rotaries shall be provided where t w o or more roads


cross each other. The circular shape roundabout shall be applicable where
all the approaching roads carry equal volume of traffic and intersect equal
angles.

Elliptical or elongated shape shall be used where the angles between the
approach roads are not equal and the traffic volume on the approaching
roads varies.

Reflectorized or lighted signs should be provided well in advance of the


rotary t o warn traffic.

Traffic Island

Traffic island shall be provided in an area designated between traffic lanes


in channelized intersections t o direct traffic into definite paths.

The Island shall consist of curbed medians or areas outlined by paint and
shall generally be either elongated or triangular in shape.
Elongated island should not be less than 1 2 5 0 m m wide and 6 0 0 0 m m
long. Triangular island should not be less than 4 5 0 0 mm, on a side after
the rounding of corners.

' U '-Turn Dividers

U-turn dividers or median openings shall be provided t o accommodate


vehicles making ' U' turns.

The width of the road including the median should be sufficient t o permit
the vehicle and heavy equipment t o take the turn without encroaching
beyond the outer edges of the pavement. Medians 3 0 0 0 m m to 4 5 0 0 m m
wide shall be used for 'U' turn openings.

Traffic Barriers

Reinforced concrete barriers shall be provided as roadside barriers and


median barriers in accordance with the KOC approved drawings.

The barriers shall be pre-cast in sections with the maximum length not
greater than 6 0 0 0 mm. The method of casting, handling, placing barrier
sections and details of reinforcement required t o facilitate handling shall be
followed as per KOC approval. The barrier minimum height as
recommended by AASHTO shall be 8 0 0 m m from the bottom of the
pavement.

Crash Barriers

Crash barriers (bollards) shall be provided for the protection of the fire
hydrants w i t h 6" (1 5 0 mm) carbon steel pipes. Crash barriers shall be
installed as per the details indicated in KOC Standard drawing 15-34-19A.

The barriers shall be painted in compliance with KOC Standard for Painting
and Coating of Metal Surfaces - New Construction (KOC-P-001).

Guard Rails

Guard rails shall be installed at the location of process equipmentlpiping in


close proximity t o the edge of roadway.

Guard rails shall be made of un-tensioned steel corrugated profile beams on


steel posts in accordance w i t h KOC Standard drawing 15-18-8. All
steelwork shall be hot dip galvanized in accordance w i t h BS EN I S 0 1461.
DOC. NO. KOC-C-024 PT. 2 Page 16 of 4 1 Rev. 1

ROADWAYS AND PAVING DRAINAGE

General Considerations

Drainage facility for roadways and paved areas shall be provided t o remove
surface runoff by gravity as quickly as possible in order t o avoid flooding
and minimize the risk of traffic hazards.

The drainage facility should consider the anticipated surface run off, as
comprised of annual rainfall intensity as per" KOC Standard for Basic
Design Data" (KOC-G-007) on roadways including shoulders if any; as well
as flow(s) of clean water from other paved areas, not subject t o
contamination.

This drainage system shall be simple, easy t o maintain, utilising the natural
slope of the surrounding areas as far as practicable and should consider the
optimum depths t o maintain the flows where drainage channels are
provided. Generally, velocities of flow shall be kept in such a way as t o
prevent siltation as well as scouring of the bed and sides of the channels.

Surface Drainage

Roadways except single carriageway road shall be crowned t o drain water


away from both sides on t o the adjacent grade for KOC accesslfield roads,
where natural ground is below the road level. However if the natural
ground surrounding the road is above the crown, water should be drained
t o drainage channels, where provided as open ditches and1 or lined swales.

The channels should be located and shaped t o minimize traffic hazards and
should be as shown in the KOC approved project1construction drawings.
Wherever required, drainage inlets shall be provided t o prevent ponding and
limit the spread of water into traffic lanes.

Open Ditches (Unlined)

a) Open unlined ditches shall be provided, wherever local soil conditions


permit, with side slopes of 4:l (horizontal t o vertical) or flatter on
both sides and shall have the adequate capacity/cross section t o
remove storm water without any overflooding.

b) The minimum depth should be kept not less than 4 5 0 m m below the
edge of the shoulder. However, the depth of ditch shall be such as t o
prevent any saturation of the pavement sub-grade.

C) The bottom of ditches shall be generally graded t o maintain a


longitudinal slope of 1 in 250.

Lined Swales (Asphalt1 Concrete)

a) Swales shall be generally asphalt lined and shall be trapezoidal in


cross section, with the sides slopes protected by a prime coat and
wearing course as specified for the roadways.
DOC. NO. KOC-C-024 PT. 2 Page 17 of 4 1 Rev. 1

b) Bottom of the swales shall be left unpaved t o provide some seepage


of storm water into the ground.

C) Depth of swale shall be adequate t o accommodate the anticipated


flow of storm water and shall be maintained by suitably grading the
adjacent ground.

d) However, swales shall be concrete lined at sharp bendshurves or at


locations where the flow of water is restricted, t o prevent erosion of
the bed and sides of the drainage channels.

Paved Areas

Paved area(s) shall be divided into several catchment areas t o contain


water using gradients and kerbinglbunds for efficient drainage.

Paving should be sloped at a gradient not flatter than 1 in 8 0 in large


open areas and 1 in 6 0 in restricted areas.

The maximum vertical fall across paving should not be greater than
2 5 0 mm.

Drainage Inlets

Drainage inlets, wherever required on the roadways inside the KOC


facilities or residential areas, shall be provided t o receive rainwater at grade
and permit water t o flow downward into underground storm drains. Inlets
should be capable of passing the flow without clogging with debris.
The entrance t o inlets shall be protected with grating, which shall be flush
with the surface of medians, so as not be hazard t o traffic.

The distance apart for placing inlets, which mainly depends on the
longitudinal fall and cross fall, shall generally be between 45 m t o 9 0 m
and each inlet shall drain an area of about 2 0 0 m 2 t o 2 5 0 m 2 . This spacing
shall be applicable t o the road width of approximately 4.6 m. For wider
roads, spacing of the inlets should be proportionally reduced.

Storm Sewers

Wherever storm water sewers or underground pipes (to receive surface


runoff from the roadside inlets) are t o be provided, they shall be connected
t o an existing drainage system.

The direction of storm water pipes shall be changed only at inlet or


manhole locations.

The manholes should provide maintenance access t o pipes at about every


1 5 0 m.
DOC. NO. KOC-C-024 PT. 2 Page 18 of 41 Rev. 1

RIGID PAVEMENT (FOR RIG CROSSINGS)

General

Reinforced concrete rigid pavement shall be generally provided for the


crossing of drilling rigs across the field roads.

Rigid pavement shall be made of a Portland cement concrete slab resting


on a sub-base course or directly on sub-grade, if the sub-grade is a well
compacted soil with minimum CBR value of 25%.

Concrete slab shall be designed in accordance with AASHTO " Guide for
Design of Pavement Structures" with the Westergaard's modulus of sub-
grade reaction, as recommended from the geotechnical investigation at
Site. Concrete slab shall have adequate thickness and t o be so rigid that all
the anticipated loads shall be transferred t o the base without any
deformation of the slab, but shall not be less than 2 5 0 m m thick.

Refer t o Appendices I and II for details of rigid pavement and RCC slab for
rig crossing respectively.

Sub-base
-

Sub-base for the concrete pavement shall be compacted layers of granular


or stabilised material, placed between the sub-grade and the rigid slab.
Refer t o KOC-C-Q24 Part-I for materials, workmanship and testing of sub-
base construction.

Material Requirements

The selected materials of in-situ concrete for the rigid pavement


construction shall comply with the following clauses.

Cement

a) Unless otherwise mentioned, Portland cement conforming t o ASTM


C 1 5 0 Type I or V shall be used.

b) Only a single brand of cement shall be used throughout the Work;


change of brand shall be subject t o KOC approval.

Aggregates

Aggregates shall comply with BS 8 8 2 or ASTM C33 and conform t o the


following:-

a) It shall be clean, free from oil, grease or any contamination; hard,


sound and mixture of well-graded coarse and fine particles.

b) All particles shall pass a 2 0 m m (314 in) BS 4 1 0 sieve size and the
fineness modulus of fine aggregates shall be neither less than 2.3 nor
more than 3.1
C) Fine aggregate shall be free from organic/inorganic impurities and shall
not contain other deleterious substance more than 5 % by weight.

d) The aggregates for in-situ concrete shall be composed of maximum


2 0 m m single sized coarse aggregates in accordance with Table 3 of
BS 8 8 2 with fine aggregates conforming t o Grading C or M of Table 4
of BS 882.

e) All aggregates shall meet the testing requirements in accordance with


BS 8 1 2, ASTM C88 and ASTM C l 3 l .

Reinforcing Steel

Steel wire fabric complying with BS 4 4 8 3 shall be used as reinforcing steel


in pavement. As a minimum, one layer of high tensile 7 m m diameter 2 0 0
m m square mesh fabric conforming t o BS ref. No. A 1 9 3 shall be provided.

However in Sabka areas, fusion bonded epoxy (FBE) coated reinforcing bar
shall be provided in the concrete pavement t o minimise corrosion of
reinforcement.

Admixtures

Normal water reducing admixtures complying with BS EN 9 3 4 shall be


added t o in-situ concrete t o maintain sufficient workability at the minimum
water cement ratio. The type of admixture shall be subject t o KO6
approval and the dosage and mixing shall be strictly in compliance with
manufacturer's instructions. The admixture containing chlorides or other
corrosive agents shall not be used under any circumstances.

In-situ Concrete Mix.

The concrete mix shall comply with ACI 3 1 8 and shall have minimum
cement content of 3 8 0 kg/m3 of ordinary Portland cement (Type 1) or
sulphate resisting Portland cement (Type V) for structural concrete. The
minimum characteristic strength of structural concrete (Grade 30) at 2 8
days shall be 3 0 N/mm2.

Ready-Mixed Concrete

a) Ready-mixed concrete shall be permitted provided i t complies with the


following:

I) ASTM C94;

ii) it is centrally mixed off the site and approved by KOC;

iii) it is transported in an agitator truck (truck mixing not


permitted);

iv) plant is certified by the Kuwait Ministry of Public Works.

b) Before discharging the concrete at the point of delivery, for each


batch of concrete, the Contractor shall provide t o KOC, a delivery
DOC. NO. KOC-C-024 PT. 2 Page 2 0 of 4 1 I Rev. 1

ticket on which is printed, stamped or written the following minimum


information:

Name or number of concrete depot


Serial number of ticket
Data
Truck number
Name of Supplier
Grade or mix description of concrete
Type of cement
Cement content
Water cement ratio
Nominal maximum size of aggregate
Source of aggregates
Type or name of admixture, if included
Quantity of concrete in cubic metres

10.4 Construction Requirements

10.4.1 General

a) The Contractor shall provide all materials in conformity w i t h clause


10.3 of this Standard and equipment, tools and experienced
manpower necessary for executing the Work.

b) All equipment, tools and machines used by the Contractor in the


proper execution of the Work shall be subject t o KOC approval and
shall be maintained in good condition till the completion of the Work.

10.4.2 Earthwork

a) The earthworks shall be carried out in accordance with the


requirements specified in clauses 8.0 through 10.0 of KOC Standard
for Materials and Workmanship-"Roadways, Paving and Hard
Standing" (KOC-C-024 Part -1).

b) The area(s) t o be graded shall be properly finished t o the required


elevations and surfaces as shown on the KOC approved construction
drawings.

C) The elevation of any point, the line of any edge or centre of earth
works shall conform t o those established in the KOC approved
construction drawings within the tolerances as specified in KOC
Standard KOC-C-024 Part-I .

10.4.3 Weather Limitations

Concrete shall neither be mixed nor placed when the ambient temperature
is below 2OC (35OF) nor when the air temperature in the shade is 40°C
(104OF) or above. No concrete shall be placed during high sand storm or
rain unless adequately protected or unless otherwise directed by KOC. The
temperature of concrete when placed shall not exceed 32OC.
DOC. NO. KOC-C-024 PT. 2 Page 2 1 of 4 1 Rev. 1

Workmanship

Concrete Works

Concrete Works for the construction of rigid pavement as well as for


miscellaneous Works where concrete is used, shall be carried out in
accordance with designated Project Specification "Reinforced
Concrete Materials and Construction".

Concrete shall be produced by weigh batching and mixed in mixer


machine for pouring. The water cement ratio of the concrete mix
shall be maintained for good workability and any adjustment needed
shall be made for the aggregate moisture content at the time of
mixing.

Concrete shall be evenly spread and compacted by vibrator t o


produce a dense finish free from honeycombing, sags, bulges, thick or
thin areas and any other visible defects.

All reinforcements shall be cut, bent, placed in the formwork and


checked by KOC before concreting in accordance with ACI 3 1 5 and
ACI 3 1 8.

Curing

a) Curing for concrete shall be continued for at least seven (7) days by
use of one of the following methods:-

i) Being kept damp by a continuous water spray.

ii) Being covered with continuously wet burlap or fabric pads.

iii) Being sprayed with water and immediately covered with a layer
of waterproof paper meant for curing of concrete.

b) The accelerators shall not be used as curing aids.

The concrete surfaces below the grade level shall be painted with three
coats of modified bituminous paint, the total DFT being 1 0 0 0 microns,
then covered with 1000g polyethylene membranes.

Joints in Concrete Pavement

General

a) Joints (expansion and contraction) shall be formed in the concrete


pavement t o reduce the adverse thermal effects of expansion and
contraction. Construction joints shall be provided, when placement of
concrete is being interrupted or discontinued.

b) Joint location, spacing, and other details together w i t h thematerials


t o be used shall be provided as per the KOC approved construction
drawings. However, the recommended spacing should not exceed
more than 1 0 m between transverse contraction joints in the
pavement.
DOC. NO. KOC-C-024 PT. 2 Page 2 2 of 4 1 I Rev. 1

c) Joints in concrete shall be positioned in such a way so that saline


water from any source cannot collect and pond over them.

10.6.2 Expansion and Contraction Joints (transverse joints)

a) Expansion and contraction joints shall be formed in accordance with


ACI 504R. Reinforcement shall not extend across joints.

b) Expansion joint shall be formed using filler material such as rubber,


bitumen or cork and polysulphide sealant. Filler and sealant shall
comply with ASTM D l 7 5 1 and ASTM C920 respectively.

c) Contraction joint shall be formed by sawing into the hardened


concrete, by inserting plastic inserts at joint locations before concrete
is cast, or by tooling the concrete after placement but before concrete
has fully hardened

d) Refer t o Appendix Ill for typical details of expansion and contraction


joints.

10.6.3 Construction Joints (transverse joints)

Transverse construction joints shall be formed at regular joint spacing


for planned interruptions at the end of the day concreting (butt joint)
or at irregular spacing for emergency interruptions due t o inclement
weather or emergency breakdown (keyed & tied joint).
A vertical face with a header board shall be formed at the end of the
slab being cast. The header board shall be equipped with a protrusion
that, when formed into the concrete, creates a key way for load
transfer between the adjoining slab sections.

The joint surface shall be roughened t o remove laitance without


disturbing the course aggregate, by pressure jetting with air and water
or wire brushing. The new concrete shall be well worked against the
old surface t o ensure a good joint.

Care shall be taken not t o break the concrete-steel bond at any time.

The use of expanded metal or other perforated material, as stop- end


at vertical face shall not be accepted.

Refer t o Appendix IV for typical details of construction joints.


REHABILITATION WORKS

General

Rehabilitation Works comprising of majorlminor repairs such as resurfacing,


restoration and/or reconstruction shall be carried out t o extend the service
life of roadways and pavements as well as t o ensure safety, when they
develop potholes of varying sizes, failures and depressions on the surfaces
as described below.

As~haltPavement

Repair of Potholes (Isolated holes of less than 1.0 m 2 )

The failed pavement shall be cut back t o solid material with


pneumatic asphalt cutting tools. Cut shall be made square or
rectangular with faces straight and vertical. One pair of face shall be
at right angles t o the direction of traffic.

The cut pavement and loose material shall be removed from the holes
and shall be carted away t o a location approved by KOC.

Cut holes shall be then filled with a premixed materials of sand- gravel
in accordance with clause 8.4.3 of KOC-C-024 Part-1 .The sand gravel
material shall be placed in1 5 0 m m lifts and each lift shall be
compacted t o 95% modified Proctor density w i t h mechanical
compactors; similar treatment shall be given t o subsoil before filling
the excavation with sand gravel.

The cut edges of the pavement shall be cleaned with a wirebroom


and shall be painted with bituminous emulsion.

The compacted soil or the upper surface of the sand gravel shall be
primed with a light coating of MC-70, as per KOC instructions.

The holes shall be filled w i t h appropriate hot asphalt concrete mix


and shall be compacted in lifts not exceeding 7 0 m m t o the same
level as the adjacent surface. Vibratory compactor shall be used t o
compact the hot asphalt concrete.

Level of the patch shall be checked with a straight edge and


necessary corrections shall be made.

Repair of Failed Pavement (Deep Patch)

a) Refer t o clause 1 1.2.1 (a) of this Standard for cutting the area.

b) The cut pavement shall be removed and underlying soil shall be


excavated t o a minimum depth of 3 0 0 mm. All the cut pavement
material and excavated soil shall be carted away t o a KOC approved
location.

C) The subsoil shall be thoroughly compacted w i t h mechanical


compactor t o 95% of modified Proctor density (in the presence of
the patch the optimum moisture content shall not be exceeded).
DOC. NO. KOC-C-024 PT. 2 Page 2 4 of 4 1 Rev. 1

d) Refer t o clause 1 1.2.1 (c) of this Standard for filling and compaction.

e) Refer t o clause 1 1.2.1 (d) of this Standard for cleaning.

f) The compacted soil shall be primed lightly w i t h MC-70, as per KOC


instructions.

g) Asphalt concrete of the same type as used conforming t o KOC-C-


024,Part-1 shall be placed and compacted in the excavated area in
7 0 m m lifts t o the same level as the adjacent surface.

h) The lower lift shall be compacted w i t h a vibratory compactor and


the t o p lift shall be compacted w i t h a steel wheeled roller:-

(i) first by compacting the hot asphalt concrete 1 5 0 m m from the


t w o traffic edges; and

(ii) then by rolling in the traffic direction.

The drive wheel of the roller shall be in the forward position.


Pneumatic roller shall be used for final compacted surface.

i) The use of an asphalt concrete pavement finisher should depend on


the size of the area being patched.

Repair of Depressed Pavement (Skin patch)

In case where the pavement has depressed but the asphalt concrete has
not fractured and the pavement appears stable, the following repair
procedure shall be applied:

a) Upper 3 0 m m of the pavement, starting just behind the depression


shall be cut and removed. The removed pavement shall be carted
away t o a location approved by KOC.

b) The surface shall be cleaned with a wire broom and tack coat shall be
applied lightly. The edges of the cut shall be painted with bituminous
emulsion (not exceeding 0.23 litres/m2 of tack coat).

c) The cut shall be filled w i t h the appropriate hot mix asphalt concrete
and shall be compacted w i t h a steel wheeled roller:

(i) first by compacting the hot asphalt concrete 1 5 0 m m from the


t w o traffic edges; and

(ii) then by rolling in the traffic direction.

The drive wheel of the roller shall be in the forward position.


Pneumatic roller shall be used for final compacted surface.

d) Level of the patch shall be checked with a straight edge and


necessary corrections shall be made.
Concrete Pavement

Repair of Shallow Patches (not exceeding 1 2 mm)

Repair of this type of patches shall be carried out by coating the surface
w i t h a cut back asphalt or emulsion, after they have been cleaned and
well brushed and covering w i t h coarse sand. Where the pavement is
badly cracked, it shall be broken into small pieces, compacted thoroughly
and grouted w i t h bitumen.

Repair of Patches or Potholes (exceeding 2 5 m m in depth)

Repair of this type of patches or potholes shall be carried out w i t h


concrete. The damaged portion shall be cut out t o a rectangular shape.
The faces of the old concrete shall be thoroughly cleaned and wetted and
brushed w i t h neat cement grout. The new concrete shall be made as
close as possible t o the mix of the existing one and t o the consistency
that will allow thorough tamping and ramming.

Repair of Slab Due t o Settlement

Where the slabs have settled due t o defective sub-grades, the repair
work shall be carried out by grouting under pressure. Cement sand grout
or bituminous mixture shall be pumped through a series of drilled holes of
maximum 40 m m in diameter t o fill up the voids in between the sub-
grade and the slab.

Tolerances

The milled surface shall not vary from a three (3) meter straight edge
placed on the surface by more than six (6) m m and the discontinuity of
surfaces of adjacent passes shall be limited t o + 3 mm.

The transverse slope of the milled surfaces shall conform t o the specified
slope within six ( 6 ) m m per 3 metre. Transitions between different depths
of cuts shall be at a uniform rate of three (3) m m of depth per eight (8)
metre of travel. The entire roadway width, where applicable, shall be
milled uniformly so the cross section of the new surface forms a straight
line.
MAINTENANCE WORKS

General

Periodic maintenance shall be conducted t o repair the minor defects


forming out of various types of cracks developed in the
roadways/pavements due t o traffic and weather. In order t o maintain them
in good and original condition, the following repair works should be carried
out.

Crack Repairs

Asphalt Pavement

a) "Alligator" cracks, which form out of small interlocking rectangular


shaped cracks due t o soft sub-grade or failure of an untreated granular
sub-base, shall be repaired by removing all w e t material and patching
w i t h full depth hot mix asphalt.

b) "Edge" cracks, which extend longitudinally and located near the


edges of pavement due t o settlement or inadequate support of
pavement, shall be repaired by filling the cracks with cut back asphalt
mixed with sand.

c) "Joint" cracks, which occur at the interface between a pavement and


adjacent shoulder due t o thermal movement or inadequate drainage
causing intrusion of water shall be repaired by filling cracks with an
asphalt emulsion slurry.

d) "Crescent" shaped cracks or "slippage"cracks which are caused by


insufficient bond between the surface layer and the underlying course,
shall be repaired by removing the surface crack t o locations where
adequate bond is present. The area from which the surface course
was removed shall be patched with hot mix asphalt.

e) Other than above, minor cracks wherever visible on the road surfaces,
shall be removed by cutting the area around the cracks and then shall
be filled with hot mix asphalt.

Concrete Pavement

a) Deteriorated concrete pavements of Portland cement develop various


forms of cracking (longitudinal, transverse & diagonal) on the surface
due t o variety of reasons such as overloading, failure of soft patch of
underlying soil, lack of proper joints or concrete shrinkage.

b) Concrete pavements are also prone t o distortions due t o pumping


action and faults at the joints or along a major crack.

C) The concrete pavement shall be restored t o the good condition by the


corrective maintenance Works as follows:-

i) Repair of distorted concrete pavement due t o pumping shall be


carried out by injecting asphalt or Portland cement grout under
the slab.
ii) Repair of cracks (perpendicular, parallel and diagonal t o the
pavement) shall be carried out by cleaning the cracks of all loose
material by means of compressed air or sand blasting. Cracks
then shall be filled with an approved rubber asphalt sealer.

SITE LABORATORY

General

Site laboratory shall be provided by Contractor t o comply with various field


testing requirements specified in KOC Standards KOC-C-024 Parts I & 2;
and shall comprise of all sampling and test equipment as necessary,
including trained laboratory personnel, building and utilities. Generally, Site
laboratory(s) shall be of the following types:-

a) Soil Laboratory.

b) Asphalt Laboratory.

c) Concrete Laboratory (where required).

The laboratory shall have a minimum useable floor area of 35 rn2 excluding
circulation space and health and safety accommodation.

The laboratory shall be located at a KOC approved place, as close as


possible, t o the Works and shall not be removed from the Site, nor the
laboratory personnel demobilized without the prior approval of KOC.

Functions and Requirements

The laboratory shall have all necessary testing equipment and storage
equipment and shall meet the minimum requirements as below:-

facilities for sample preparation for soils, aggregates, asphalt mixes,


cut back asphalt and the like;

facilities for storage of field sampling equipment(s) such as sand


cone density apparatus, aggregate stock pile sampling tools, soil
sampling tools and the like;

facilities and equipment for soil and aggregate testing such as


gradation, liquid limit, plasticity index, Proctor density, aggregate
flakiness and elongation, calibration of sand for density test, speedy
moisture, CBR and the like;

facilities and equipment for testing of asphalt mixes such as density


of compacted samples, extraction gradation, bitumenometer, ash
correction aggregate specific gravity, compacting of Marshall moulds
and the like.

The laboratory shall be maintained in a good condition throughout the


execution period of the Works. Adequate laboratory supplies including but
not limited t o filter paper, trichloroethylene, speedy moisture reagent, stock
solution and the like shall be constantly ensured.
Provision of all the necessary qualified personnel shall be made t o ensure
the complete operation of the laboratory, which shall include a materials
and testing engineer w h o shall be in-charge of the laboratory personnel
and supervise their day t o day duties. Such personnel shall be subject t o
prior approval of KOC and shall not be removed or replaced without the
consent of KOC.

Approval

Prior t o the commencement of the Works and during the continuance


thereof, KOC approval shall be obtained on laboratory t o ensure its
compliance in accordance with clause 13.2 above.

In the case of non compliance with clause 13.2 above, any time during the
course of the works, KOC may order :-

a) partial or complete stoppage of the work until all the requirements


have been complied with and/or;

b) stoppage of sampling and testing and the transferring of such


activities for their performance t o any other designated laboratory.

TRAFFIC SIGNS

General

All traffic sign panel materials, manufacturing and installation works shall
be in accordance with MPW General Specifications for Kuwait Motorway1
Expressway System, Kuwait Traffic Signs Manual, and designated Project
Specification" Reinforced Concrete Materials and Construction".

All signs shall be approved by KOC Fire and HSE Dept. before
manufacturing. The Contractor shall submit samples of all required
materials t o KOC for approval prior t o fabrication.

Classification of Signs

Traffic signs are classified as regulatory, warning and guide signs.


Regulatory signs shall be used t o indicate the required method of traffic
movement e.g. 'STOP' and 'GIVE WAY'. Warning signs such, as
'CAUTION-ROAD WORK IN PROGRESS' shall be used t o indicate
hazardous conditions. Guide signs such as 'TO GC-15' shall be used t o
indicate the direction.

Sign Panel Requirements

Sign panels shall be of steel with reflective sheeting or as indicated in the


approved project drawing.

Sign panels shall be prefabricated sheet steel blanks galvanized with a


minimum of 2 m m thick continuous coating conforming t o ASTM A1 23.
Zinc coating shall be designation G90 and in addition all sheet shall be mill
phosphated t o a thickness of 1.0 glm2 k 0 . 5 g/m2 of surface area.
DOC. NO. KOC-C-024 PT. 2 Page 29 of 4 1 Rev. 1

Sign panels shall be covered with approved high intensity grade scotchlite
reflective sheeting, which shall have adhesive properties t o a minimum
duration of five (5) years and shall be fixed t o the sign by means of a
pressure machine.

Each sign panel shall have appropriate reflectorized lettering or insignia.

The posts shall be fabricated from steel pipe conforming t o ASTM A 5 3


Grade B.

The posts shall be painted with KOC approved reflectorized yellow or white
and black bands.

Sign Panels Erection

Proper arrangement of KOC approved pattern shall be used t o fix the sign
panel t o the post.

Edge of signs shall be at 6 0 0 m m from the edge of kerbstone or as


indicated in the approved project drawing. The panels shall be mounted at
right angles t o the face of the traffic flow.

Where mirror reflection from the sign face is encountered such as t o reduce
legibility, the sign shall be slightly turned (approximately 1 0 % of the
normal size of the sign) away from the road.

The size and number of posts required t o support each sign panel
installation shall be as per the KOC approved project drawing(s). The post
or posts shall be vertical.

When t w o posts support the same panel, they shall be erected vertical and
parallel with each other with the tops of the posts at the same height.

All concrete works at sign foundations, including reinforcing steel, shall be


in accordance with KOC Standard 3811022" General Specifications for
Civil Engineering and Building Works".

The footings for the ground mounted signs shall not exceed more than 1 0 0
m m above the finished grade.

KOC Standard Drawings

Refer t o KOC Standard drawings mentioned in clause 4.2.3 of this


Standard for miscellaneous details of sign panels.

-
DOC. NO. KOC-C-024 PT. 2 Page 30 of 4 1 Rev. 1

TRAFFIC SIGNALS

General

Traffic signals shall be installed t o assign the right of way at intersections


and control the flow of vehicular and pedestrian traffic for road safety.

Traffic signal system shall be pre-timed and traffic actuated t o control the
assigned movements and shall be as specified by KOC and/or Govt.
Authority.

Materials

Contractor shall supply all accessories, components and materials required


for the satisfactory completion of the traffic signal system. Contractor
shall also be responsible for storage of all materials, delivery t o the site
and installation.

Installation of Signal Supports

The footings for signal poles, pedestals and overhead masts shall be
constructed in accordance with KOC Standard for Materials and
Workmanship-"Site Preparation and Earthworks"(K0C-C-005) and
3 8 1 I 0 2 2 "General Specification for Civil Engineering and Building Works."

Anchor bolts conforming t o ASTM A 3 0 7 shall be accurately fixed with a


steel template supplied by the manufacturer.

Nuts shall be screwed onto the anchor bolts and adjusted t o the preliminary
level for the support base.

The support shall be set in position and the nuts adjusted t o set the
support t o the final and correct level. The use of shims or any other
levelling device shall not be permitted.

After the signal support has been installed t o the correct level, the space
between the concrete base and the pole base plate shall be filled with
approved cementhand grout, neatly finished and chamfered.

Painting

After installation the outer surface of each pole, pedestal, etc. shall be
painted with t w o coats of grey paint as per BS 3 8 1 C or equivalent and
approved by KOC.

FENCING WORKS TO SOLAR PANELS FOR TRAFFIC SIGNALS

General

Wherever solar panels are specified for traffic signals in remote and desert
locations, they shall be protected by fencing works for safety. .

Contractor shall supply all materials and provide security fence 2 4 0 0 m m


high with the provision of personnel gate together with lock. The size of
DOC. NO. KOC-C-024 PT. 2
I Page 3 1 of 4 1 Rev. 1

the fencing enclosure shall be as per approved project drawing of solar


panels for traffic signals.

The location of enclosure fence and gate shall be marked on site by the
Contractor as per KOC approved location. Location of fence foundation
shall be adjusted, in case of any underground obstruction. The revised
drawing, incorporating the changes shall be submitted t o KOC approval.

Fencing Materials and Installation

The fence shall comprise of galvanized chainlink fence fabric and fittings.
Fabric shall be minimum of 2 4 0 0 m m height. The fence shall have t w o
rows of tension wire, six rows of barbed strands and one row of concertina
barbed wire on top supported by extension arms and a continuous top and
bottom rail.

The fence posts shall be placed at 3 0 0 0 mrn apart and shall be cast in
concrete foundations. The fence shall be adequately braced at panels
adjacent t o gates and removable panels.

Fence centreline markers shall be steel pins of 1 2 m m diameter and


minimum length 1 0 0 0 m m set vertically in concrete blocks of minimum
size 5 0 0 m m x 5 0 0 m m x 5 0 0 mm. Top face of block shall be
approximately 2 0 0 m m above existing ground level.

The bottom rail shall be installed on a straight grade between posts. The
chainlink fabric shall be fastened on the side of the post. The chainlink
fence fabric shall be galvanized conforming t o ASTM A392, Class 2.

Fencing material shall be made from steel wire helically wound and
interwoven in such a manner as t o provide a continuous mesh without
knots or ties except in the form of knuckling or of twisting the end of wires
t o form the selvage of the fabric.

Steel wire of fencing material shall be woven throughout in the form of


approximately uniform square mesh. The mesh shall have parallel sides.

Fence fabric shall be 5 0 m m mesh x 3 m m thickness. The permissible


variation from the specified size of mesh shall be +
32 mm. Fence tension
wire shall be woven from galvanized wire 4.0 m m diameter. The wires
shall have a minimum zinc coating weight of 61 0 g/m2 and the fabric shall
have twisted and barbed selvage on both sides.

Chain link fence fabric with excessive roughness, blisters, bruises and
flaking shall not be used.

Galvanized barbed wire (barbed strands) shall conform t o ASTM A121.


Strand wire shall be 2.5 m m diameter with minimum zinc coating weight of
2 4 5 g/m2 and barbing wire shall be 2.0 m m diameter with minimum zinc
coating weight of 2 0 0 g/m2. The spacing between the barbs shall be 1 0 2
mm.

Concertina barbed wire shall be fabricated from single high tensile steel
wire of minimum 3.0 m m diameter with tensile strength of 1 2 3 5 N/mm2.
Barbs shall be fabricated from galvanized mild steel wire of 2.0 m m
diameter with tensile strength of 3 5 0 t o 9 2 5 N/mm2.

The spacing between the concertina barbs shall be 6 0 m m w i t h a variation


of + 16mm. Concertina shall be approximately 1 0 0 0 m m diameter with a
variation of k 5 0 mm. The approximate extended length of the coil shall be
1 0 meters and spacing between t w o spirals shall be 2 9 5 mm.
Galvanization shall be as per BS EN 10244-2.

Foundation shall be cast for fence posts, access gate, and solar panel
complete with required pipes, base plates, sockets and the like using
sulphate resistant cement in accordance with KOC General Specification
for Civil Engineering and Building Works (3811022). Reinforcing bars shall
conform t o ASTM A 6 1 5 Grade 6 0 or BS 4449.

Contractor shall provide a well-compacted surface inside the fence line and
2 0 0 0 m m wide all around the fence outside

Refer t o KOC Standard drawing 15-5-80 for chainlink fencing details.

INSPECTION AND TESTING

General

KOC shall have the right t o inspect all tools and equipment; materials and
workmanship involved in the construction of rigid pavement, installation of
traffic and guide signs, signals, fencing and miscellaneous works described
in this Standard.

Contractor shall submit for KOC approvai a Quality Plan and an lnspection
& Test Plan that will provide the detailed activities of the Work in a
chronological way. The lnspection and Test Plan shall have the columns
indicating the activity, the contractual and specification requirements, the
method of verification, the acceptance criteria, the document (test
certificate or report) that will be generated as well as columns for indicating
KOC markings for witness (W), hold (H), review (R) etc.

Contractor shall perform at all stages of the Works all the inspections and
appropriate tests that are necessary t o assure that the materials and
workmanship meet fully the requirements of this Standard.

Materials and Equipment lnspection

All materials shall be inspected t o ensure conformance w i t h this Standard.

All equipment t o be used in the earth filling & compaction and laying of
asphalt concrete or in-situ concrete shall be inspected t o ensure compliance
w i t h the KOC Fire and Safety Regulations.

Visual lnspection

Compacted Earth Surfaces

After the earth surfaces have been compacted and trimmed t o the actual
profile, a visual inspection shall be carried out by the Contractor jointly with
DOC. NO. KOC-C-024 PT. 2 Page 33 of 41 Rev. 1

KOC t o ensure that no soft patches, uneven surfaces or loose dust are left
on the surfaces prior t o commencing the application of asphalt concrete or
in-situ concrete (as applicable).

Asphalt Concrete

After application of asphalt concrete materials and proper drying, it shall be


inspected t o assure that the final surfaces shall be free from any defect
such as thin spots, voids, cracks, blisters etc.

Concrete Works

Concrete works shall be inspected by KOC t o assure that the surfaces are
free from any visible defects described in clause 10.5.1 of this Standard.
All repair and rectification Work shall be executed by the KOC approved
method statements.

Paint Works

The painted surfaces (crash barriers, sign panel posts etc.) shall be visually
inspected t o ensure the absence of over spray, sags, air pockets and any
other paint defects. The repair of damagedldefective coating shall be
carried out in accordance with clause 9.8 of KOC Standard KOC-P-001.

Fencing Works

Sample rolls of selected chainlink fence fabric shall be inspected for weave,
size of mesh, diamond count, wire size, height of fabric, selvage and
length.

Testing

All the tests required for the proper execution of Works shall be conducted
by the Contractor in the KOC approved Site laboratory in accordance with
the relevant BS & ASTM standards listed in clause 4.2.1 of this Standard,
and as and when instructed by KOC.

All the laboratory tests on the soil samples for selection of suitable fill
materials shall be carried out in accordance with clauses 14.2.2 through
14.2.4 of KOC Standard KOC-C-005.

Field Tests

Earthworks

Field in-place density tests shall be performed in accordance with ASTM D


1 5 5 6 and as per KOC-C-024 Part I,clause 10.5.

Structural Concrete

a) Prior t o commencing the concrete work, the Contractor shall prepare


three (3) Nos. test cubes of 1 5 0 m m sizes in the Standard moulds,
conforming t o the grade specified. The test cubes shall be made,
cured, preserved, and tested in compliance with BS 1 8 8 1 or ASTM C39
DOC. NO. KOC-C-024 PT. 2 Page 34 of 41
I Rev. 1

after 7 days t o indicate a compressive strength of not less than 7 0 %


of the compressive strength at 2 8 days.

b) Six (6) Nos. of representative test cubes of above sizes shall be made
for every 2 0 m3 of concrete during the course of concrete pouring,
cured, stored; and tested, three (3) after 7 & 2 8 days respectively t o
confirm the specified compressive strength as indicated in the
approved drawings.

C) Final evaluation and acceptance of concrete shall be based on 2 8 days


compressive strength and shall be in accordance with ACI 3 1 8 and
ASTM C94. If tests prove that the concrete is unsatisfactory and/or
below the required strength or as per KOC judgement, any section of
concrete Works is defective, then the defective parts of concrete shall
be cut, removed and replaced by the Contractor.

Asphalt Concrete

For all testing and acceptance requirements, refer t o the relevant clauses
in KOC Standard KOC-C-024 Part -1.

Paint Works

a) Random samples of paints shall be tested in the KOC approved


laboratory t o ensure compliance with the manufacturer's specification
and BS EN I S 0 3 2 6 2 Parts 1 t o 3.

b) Paint materials for metal surfaces shall conform t o ASTM D2697 and
BS EN 2 2 0 6 3 and shall be KOC approved,

C) Paint film wet and dry thickness shall be tested as per ASTM D 1212
and ASTM D 1 18 6 respectively.

QUALITY ASSURANCE

The Contractor shall operate a quality system preferably based on I S 0


9 0 0 0 series of standards t o satisfy the requirements of this Standard. The
Contractor shall demonstrate compliance by providing a copy of the
accredited certificate or its quality manual. Verification of the Contractor
quality system is normally part of the pre-qualification procedure and is
therefore, not detailed in the text of this Standard.

DOCUMENTATION

General

All correspondence, instructions, data sheets, drawings, calculations or any


other written information shall be in English language. In case of dual
languages, one language shall be English.

All dimensions, units of measurement, physical constants etc. shall be in SI


units, unless otherwise specified. (Pipe sizes t o be generally mentioned in
inches)
DOC. NO. KOC-C-024 PT. 2 Page 35 of 4 1 Rev. 1

All documents (texts, specifications, data sheets, drawings, etc.) shall be


provided in the form of electronic files in the approved software formats
(latest version of Microsoft Word, Excel and Autocad). All calculations
shall be submitted in approved and widely used softwareb) agreed upon
by KOC.

Test Results and Certificates

All test results and certificates of materials required for satisfactory


execution of the Works shall be submitted t o KOC for review and approval
within the stipulated period as specified in the Contract documents.

All test results for asphalt concrete reconstruction Works or for concrete
Works shall be furnished t o KOC for review and approval within 4 8 hours
of completion of tests prior t o commencement of any Work.

All field test results shall be reported t o KOC for review and acceptance of
Works within 2 4 hours of completion of tests.

Work Records

The Contractor shall operate a detailed recording and reporting system,


associated with all aspects of Works and shall be able t o furnish all
relevant Site information t o KOC as and when directed.
DOC. NO. KOC-C-024 PT. 2 Page 36 of 41 Rev. 1
1
20.0 APPENDICES

APPENDIX I: RIGID PAVEMENT

1. SUBGRADE 7. SHOULDER SLOPE


2. SUBBASE 8. DITCH SIDE SLOPE
3. PAVEMENT SLAB 9. PAVEMENT (TOTAL DEPTH)
4. SHOULDER BASE , 10. CARRIAGEWAY
5. DRAINAGE DITCH 1 1. SHOULDERS
6. CROWN SLOPE 12. ROADWAY (TOTAL WIDTH)

TYPICAL SECTION FOR RIGID PAVEMENT


DOC. NO. KOC-C-024 PT. 2 Page 37 of 4 1 Rev. 1

APPENDIX II: RCC SLAB FOR RIG CROSSING

SHOULDER

CARRIAGEWAY -
WI ' 1 '

el
Ll
M
DISTRIBUTION STEEL

SHOULDER 4IIIIIIIIIIIIIIIIIIIIII SHOULDER

I
0
PLAN

OF ROAD

AS PER DESIGN COMPACTED CATCH

TYPICAL DETAILS OF RIGID PAVEMENT (RCC SLAB)


FOR RIG CROSSING
DOC. NO. KOC-C-024 PT. 2 Page 38 of 41 Rev. 1

APPENDIX II: RCC SLAB FOR RIG CROSSING (Contd.)

I 7 COVER (TYP.1
,- STEEL FABRIC MESH
A103(TYP.)

SECTION X-X

JOINT SEALANT
STEEL FABRIC MESH BOND BREAKER MATERIAL
A193 (TYP.)
1 ,COVER r ASPHALT LAYERS (mp.)

COMPACTED GATCH 200 1-


I
150

SECTION Y-Y

NOTES:
1. ALL DIMENSIONS SHALL BE IN MILLIMETERS.
2. DIMENSIONS "A", "B", "C" AND "Dn SHALL BE AS PER DESIGN.
3. THE DISTRIBUTION REINFORCEMENT SHOWN I S INDICATIVE ONLY, ACTUAL REINFORCEMENT
SHALL BE AS PER DESIGN.
4. DISTRIBUTION STEEL SHALL BE MINIMUM WIRE MESH FABRIC A193 (7@@ZOO C/C) WITH
3 0 0 MINIMUM LAP.
5. DOWEL BARS SHALL BE 450 LONG PLAIN MILD STEEL 18$ @ 2 5 0 C/C.
DOC. NO. KOC-C-024 PT. 2 Page 39 of 4 1 Rev. 1

APPENDIX Ill: EXPANSION AND CONTRACTION JOINTS IN RIGID PAVEMENT

,-30 (MIN.)

SLIDING a95
:3->e
(MIN.)

L EXPANSION .CAP
' 4 '
.*,.
..b.
" a A
-IpLzz...
*' * .
4 *

COMPRESSIBLE
FILLER MATERIAL
1 LSMOOTH
DOWEL BAR,
THIS SIDE LUBRICATED

TYPICAL DETAILS O F EXPANSION JOINT

JOINT SEALANT
RESERVOIR -/,q

DISTRKWTION STEEL L s M o o m Dowm Bm,


THIS SIDE LUBRICATED
3mm(MIN.) SAW CUT WIDTH

TYPICAL DETAILS OF CONTRACTION JOINT

NOTE:
1. ALL DIMENSIONS ARE IN MILLIMETERS.
2. DEPTH OF CONCRETE SLAB (h) AS PER DESIGN.
DOC. NO. KOC-C-024 PT. 2 Page 40 of 4 1 Rev. 1

JOINT SEALANT
7

h= DEPTH OF SLAB
/ SMOOTH DOWEL BAR
THlS SlDE LUBRlCATED

TYPICAL BUTT JOINT

JOlNT SEALANT
7

TYPICAL KEYED & TIED JOINT


DOC. NO. KOC-C-024 PT. 2 Page 4 1 of 4 1 Rev. 1

ACKNOWLEDGEMENT

This Standard has been approved by the Standards Technical Committee (STC)
consisting of the following:-

Mr. Ali H. Baba (Standards Div.) Chairman


Mr. Mohd. Emam (Insp. & Corr. Div.) Deputy Chairman
Mr. S. Kumar (Standards Div.) Secretary/Member
Dr. Mohammad llyas (Standard Div.) Member
Mr. Khalid S. AI-Ali (Gen. Proj. Div.) Member
Mr. Henry S. Hill (Opn. Svcs. Dept. S & E) Member

The draft of this Standard has been circulated t o the KOC user departments for their
review and responses were received from the following:-

ENGINEERING GROUP OPNS. GROUP (N&W)

Gen. Supdt. Proj. Mgmt. Dept.(S & E) Gen. Supdt. Opn. Svcs. Dept.(N&W)
Gen. Supdt. Opn. Dept. (N)

MAJOR PROJECTS GROUP OPNS. GROUP (S&E)

Gen. Supdt. Engg. Proj. Dept.(S & W ) Gen. Supdt. Opn. Svcs. Dept.(S&E)
Gen. Supdt. Opn. Dept.(S)
Gen. Supdt. Opn. Dept.(E)
Gen. Supdt. M&EO Dept.

INDUSTRIAL SERVICES GROUP LOSS PREVENTION GROUP

Gen. Supdt. Ahmadi Svcs. Dept. Gen. Supdt. Insp.& Corr. Dept.
Gen. Supdt. Fire & HSE Dept.
DRILLING OPERATIONS GROUP

Gen. Supdt. Drill. Engg. & Supp. Svcs. Dept.

This KOC Standard for Materials and Workmanship " Roadways, Paving and Hard
Standing : Part 2: Miscellaneous Works and Rigid Pavement " has been prepared by
the Task Force (TF-C/02) comprising of the following members:

Mr. S. Kumar Standards Div. - Team Leader Tel. 6 14 0 7


Mr. Mohammad Sami Standards Div. - Member Tel. 61371
Mrs. Sana Ali Talha Engg. Design Div. - Member Tel. 61352
Mr. Mubarak Al-Ahmad Construction Div. - Member Tel. 6?249
Mr. Faisal Khorsheed Ahmadi Svcs. Dept. - Member Tel. 67329