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PAVEMENT CONSTRUCTION BEE-WMS-701(0)

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BESRAYA EASTERN EXTENSION

METHOD STATEMENT
FOR
PAVEMENT CONSTRUCTION

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PAVEMENT CONSTRUCTION BEE-WMS-701(0)
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LIST OF CONTENT
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LIST OF CONTENT

AMENDMENT RECORDS

1.0 INTRODUCTION

2.0 SCOPE

3.0 REFERENCES

4.0 FORMS TO BE USED

5.0 MACHINERY & EQUIPMENT

6.0 MATERIAL

7.0 CONSTRUCTION PROCEDURE

8.0 SAFETY

9.0 ENVIRONMENT

10.0 ANNEXES

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AMENDMENT RECORDS

Pages Revision Details of Amendment Revision


Date

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1.0 INTRODUCTION

Pavement construction involves the construction of lower sub-base, sub-base,


road base, dense bituminous macadam upper road base, asphaltic concrete binder
& wearing course.

2.0 SCOPE

This method statement shall apply for all pavement construction works in the
Besraya Eastern Extension Project. The intention of this method statement is to
give a general guideline for the pavement construction. Details of the procedures
contained herein may be modified based upon actual ground condition and site
requirements. The Engineer will be informed about proposed modifications to the
Method Statement in writing for his approval.

3.0 REFERENCES

• JKR/SPJ/1988 Specifications Sections 4


• Addendum/Additional Specification Section 4
● M308-ITP-501 Pavement Construction
● M308-WMS-601 Roadway Excavation
● Engineer’s Drawings & Specifications

4.0 FORMS TO BE USED

● M308-OPR-FM-501A Bored Piling Record


● M308-OPR-FM-501B Soil Boring & Rock Coring Record
● M308-OPR-FM-501C Record of Bored Piles
● M308-OPR-FM-501D Bored Piles Concreting Details
● M308-OPR-FM-501E Bored Pile Concreting Graph
● M308-OPR-FM-501F Bentonite Tests Record
● M308-OPR-FM-601C Concrete Pour Record
● M308-OPR-FM-601D Concrete Pour Summary Record

5.0 MACHINERY & EQUIPMENT

• Paver
• Motor Grader
• Back Pusher
• Vibratory Steel Roller
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• Pneumatic Tyre Roller
• Power Brooms
• Air Compressor
• Pressure Distributor for Bituminous Material
• Tipper Lorries

6.0 MATERIAL
• Crusher Run / Granular Material
• Crushed Aggregate
• Dense Bituminous Macadam
• Asphaltic Concrete ACB 25
• Asphaltic Concrete ACW 20
• Bituminous Prime Coat
• Bituminous Tack Coat

7.0 CONSTRUCTION PROCEDURE

7.1 General

7.1.1 Pavement construction works shall only be allowed to commence


on site upon the approval & acceptance of the sub-grade layer.

7.1.2 The Surveyor shall counter check again the alignment & all
dipping pegs and confirm with the Engineer before pavement
construction commence.

7.1.3 The pavement construction are divided as follows:-

i) Construction of Lower Granular Sub-base


ii) Construction of Granular Sub-base Type B
iii) Construction of Crushed Aggregate Lower Road Base
iv) Construction of Dense Bituminous Macadam Upper Road
Base
v) Construction of Asphaltic Concrete ACB 28 binder course
vi) Construction of Asphaltic Concrete ACW 20 wearing
course

7.1.4 Section Head / Project Engineer will prepare a programme


containing schedules and works sequence.

7.2 Lower Granular Sub-base


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7.2.1 The materials will be delivered to the site by tipper lorries and
spread and leveled by means of a motor-grader for the full width of
the pavement and shoulder. The material shall be filled &
compacted to the required thickness as specified in the drawing.

7.2.2 Compaction of the lower granular sub-base layer shall be carried


out by using vibratory roller to achieve relative dry density as per
Drawing Specifications.

7.2.3 Periodic testing for grading and field densities will be carried out
in accordance to the Specification.

7.2.4 Alignment, level and surface regularity will be checked in


accordance to Technical Specification.

7.2.5 The final surface of the lower granular sub-base layer shall be
regulated and trimmed by motor grader to the required level and
cross fall within the specified vertical tolerances.

7.3 Granular Sub- base Type B

7.3.1 The materials will be delivered to the site by tipper lorries and
spread and leveled by means of a motor-grader for the full width of
the pavement and shoulder. The material shall be filled &
compacted to the required thickness as specified in the drawing.

7.3.2 Compaction of the granular sub-base layer shall be carried out by


using vibratory roller to achieve relative dry density as per
Drawing Specifications.

7.3.3 Periodic testing for grading and field densities will be carried out
in accordance to the Specification.

7.3.4 Alignment, level and surface regularity will be checked in


accordance to Technical Specification.

7.3.5 The final surface of the granular sub-base layer shall be regulated
and trimmed by motor grader to the required level and cross fall
within the specified vertical tolerances.

7.4 Crushed Aggregate Lower Road Base

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7.4.1 The materials will be delivered to the site by tipper lorries and
spread and leveled by means of a motor-grader for the full width of
the pavement and shoulder. The material shall be filled &
compacted in two layers until to the required thickness as specified
in the drawing.

7.4.2 Compaction of the crushed aggregate lower road base layer shall
be carried out by using vibratory roller to achieve relative dry
density as per Drawing Specifications.

7.4.3 Periodic testing for grading and field densities will be carried out
in accordance to the Specification.

7.4.4 Alignment, level and surface regularity will be checked in


accordance to Technical Specification.

7.4.5 The final surface of the granular sub-base layer shall be regulated
and trimmed by motor grader to the required level and cross fall
within the specified vertical tolerances.

7.5 Dense Bituminous Macadam Upper Road Base

General Description

DBM consists of the following materials:

1) Road base material complying with JKR / SPJ / 1988 Section 4


and the grading shall be as follows:

B.S. Sieve Size Percentage by Weight Passing


50 mm 100
37.5 mm 95 – 100
28 mm 70 – 94
20 mm –
14 mm 56 – 76
10 mm –
6.3 mm 44 – 60
3.35 mm 32 - 46
1.18 mm -
300 um 7 - 21
75 um 2–8

2) Bitumen - (80 - 100) Penetration Grade

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3) Filler - Portland Cement or Lime filler

4) Binder Content - 3.5 +/- 0.5%

Temperature of Materials

The aggregates shall be surface dry and shall be mixed at an appropriate


temperature. The mixed material as delivered to the laying site shall be
between 120 degrees Celsius to 160 degrees Celsius.

Laying Procedure

7.5.1 Work shall commence on site upon approval and acceptance


of the crushed aggregate lower road base and prime coating.
The prime coating shall be sprayed well in advance & leave
for 24hrs for curing.

7.5.2 The dense bituminous macadam shall be plant-mixed with


binder content of 3.5 +/- 0.5 %.

7.5.3 The approved dense bituminous macadam shall be delivered


to site by tipper trucks. To prevent the loss of heat, the
mixture shall be covered by tarpaulin.

7.5.4 The dense bituminous macadam shall be laid by a Paver in


single layer and in the manner described below

7.5.5 If the laid surface is open-textured, back casting shall be


carried out and the bigger sized aggregates removed before
rolling.

7.5.6 At the end of the paving operation, the transverse joint shall
be feathered down. Lap joint shall be provided for the next
operation of paving.

7.5.7 Compaction shall be carried out using the specified /


equivalent type of compactors and the rolling pattern shall be
as per established during the trial lay.

7.5.8 Rolling shall always commence from the lower to the higher
side of the carriageway. The minimum rolling temperature
shall be 80 degrees Celsius.

7.5.9 The surface of the dense bituminous macadam shall be

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finished to the line and grade as required by the Drawings.

7.5.10 Upon completion of laying and compaction, joint survey


shall be carried out to check for compliance with the
specified requirement.

7.5.11 After all the above works is completed, the supervisor is to ensure
that the site is to be tidied up & all excess materials are to be
discarded away from the site.

Field Control

Plant Trial Mix and Trial Lay

1) These shall be carried out to assess the suitability of the


mixing, laying and compaction plant and to establish the
sequence of the laying operation.

2) The approval of the dense bituminous macadam shall be based


on the following criteria:

a) Application of the required rolling pattern using the


specified equivalent type of compactor as established
during the trial lay.

b) Joint survey to check compliance of finished surface


with levels and tolerances specified.

Site Records

A senior staff and the Engineer's Representative must be present during


the laying of premix. All records shall consists of:

a) Date, Time of laying


b) Source of Dense Bituminous Macadam
c) Weather report
d) Temperature
e) Lists of Machineries/Manpower
f) Location of work (Chainage)
g) Lorry numbers

7.6 Asphaltic Concrete ACB 28

General Description
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ACB 28 consists of the following materials:

1) Binder Course material complying with JKR / SPJ / 1988


Addendum No. 1 and the grading shall be as follows:

B.S. Sieve Size Percentage by Weight Passing


37.5 mm 100
28.0 mm 80 – 100
20.0 mm 72 – 93
14.0 mm 58 – 82
10.0 mm 50 – 75
5.0 mm 36 – 58
3.35 mm 30 – 52
1.18 mm 18 – 38
425 um 11 - 25
150 um 5 – 14
75 um 3–8

2) Bitumen - (80 - 100) Penetration Grade

3) Filler - Portland Cement or Lime filler

4) Binder Content - 4.0 – 6.0 %

Temperature of Materials

The aggregates shall be surface dry and shall be mixed at an appropriate


temperature. The mixed material as delivered to the laying site shall be
between 140 degrees Celsius to 160 degrees Celsius.

Laying Procedure

7.6.1 Work shall commence on site upon approval and acceptance


of the dense bituminous macadam upper road base.

7.6.2 The surface to receive the asphaltic concrete binder course


shall be free of all damage, loose materials and standing
water by sweeping.

7.6.3 Tack coat of approved bitumen emulsion shall be applied as


per Specifications on the prepared surface prior to laying of
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the asphaltic concrete binder course.

7.6.4 The asphaltic concrete binder course shall be plant-mixed


with bitumen content as established in the Job Standard
Mixture.

7.6.5 The approved asphaltic concrete binder course shall be


delivered to site by tipper trucks. To prevent the loss of heat,
the mixture shall be covered by tarpaulin.

7.6.6 The asphaltic concrete binder course shall be laid by a paver


in single layer and in 2 runs.

7.6.7 If the laid surface is open-textured, back casting shall be


carried out and the bigger sized aggregates removed before
rolling.

7.6.8 At the end of the paving operation, the transverse joint shall
be feathered down. Vertical joint shall be provided for the
next operation of paving.

7.6.9 Compaction shall be carried out using the specified


equivalent type of compactors and the rolling pattern shall be
as per established during the trial lay.

7.6.10 Rolling shall always commence from the lower to the higher
side of the carriageway. The minimum rolling temperature
shall be 125 degrees Celsius.

7.6.11 The surface of the asphaltic concrete binder course shall be


finished to the line and grade as required by the Drawings.

7.6.12 Upon completion of laying and compaction, joint survey


shall be carried out to check for compliance with the
specified requirement.

7.6.13 After all the above works is completed, the supervisor is to ensure
that the site is to be tidied up & all excess materials are to be
discarded away from the site.

Field Control

Plant Trial Mix and Trial Lay

1) These shall be carried out to assess the suitability of the


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mixing, laying and compaction plant and to establish the
sequence of the laying operation.

2) The approval of the asphaltic concrete binder course shall be


based on the following criteria:

a) Application of the required rolling pattern to achieve


field density of not less than 92 % of the absolute
density of the Job Standard Mixture.

b) Joint survey to check compliance of finished surface


with levels and tolerances specified.

Site Records

A senior staff and the Engineer's Representative must be present during


the laying of premix. All records shall consists of:

a) Date, Time of laying


b) Source of Asphaltic Concrete ACB 28
c) Weather report
d) Temperature
e) Lists of Machineries/Manpower
f) Location of work (Chainage)
g) Lorry numbers

7.7 Asphaltic Concrete ACW 20

General Description

ACW 20 consists of the following materials:

1) Wearing Course material complying with JKR / SPJ / 1988


Addendum No. 1 and the grading shall be as follows:

B.S. Sieve Size Percentage by Weight Passing


37.5 mm -
28.0 mm 100
20.0 mm 76 – 100
14.0 mm 64 – 89

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10.0 mm 56 – 81
5.0 mm 46 – 71
3.35 mm 32 – 58
1.18 mm 20 – 42
425 um 12 – 28
150 um 6 – 16
75 um 4–8

2) Bitumen - (80 - 100) Penetration Grade

3) Filler - Portland Cement or Lime filler

4) Binder Content - 4.5 – 6.5 %

Temperature of Materials

The aggregates shall be surface dry and shall be mixed at an appropriate


temperature. The mixed material as delivered to the laying site shall be
between 140 degrees Celsius to 160 degrees Celsius.

Laying Procedure

7.7.1 Work shall commence on site upon approval and acceptance


of the asphaltic concrete binder course.

7.7.2 The surface to receive the asphaltic concrete wearing course


shall be free of all damage, loose materials and standing
water by sweeping.

7.7.3 Tack coat of approved bitumen emulsion shall be applied as


per Specifications on the prepared surface prior to laying of
the asphaltic concrete wearing course.

7.7.4 The asphaltic concrete wearing course shall be plant-mixed


with bitumen content as established in the Job Standard
Mixture.

7.7.5 The approved asphaltic concrete wearing course shall be


delivered to site by tipper trucks. To prevent the loss of heat,
the mixture shall be covered by tarpaulin.

7.7.6 The asphaltic concrete wearing course shall be laid by a


paver in single layer and in 2 runs.

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7.7.7 If the laid surface is open-textured, back casting shall be
carried out and the bigger sized aggregates removed before
rolling.

7.7.8 At the end of the paving operation, the transverse joint shall
be feathered down. Vertical joint shall be provided for the
next operation of paving.

7.7.9 Compaction shall be carried out using the specified


equivalent type of compactors and the rolling pattern shall be
as per established during the trial lay.

7.7.10 Rolling shall always commence from the lower to the higher
side of the carriageway. The minimum rolling temperature
shall be 125 degrees Celsius.

7.7.11 The surface of the asphaltic concrete wearing course shall be


finished to the line and grade as required by the Drawings.

7.7.12 Upon completion of laying and compaction, joint survey


shall be carried out to check for compliance with the
specified requirement.

7.7.13 After all the above works is completed, the supervisor is to ensure
that the site is to be tidied up & all excess materials are to be
discarded away from the site.

Field Control

Plant Trial Mix and Trial Lay

1) These shall be carried out to assess the suitability of the


mixing, laying and compaction plant and to establish the sequence of the
laying operation.

2) The approval of the asphaltic concrete wearing course


shall be based on the following criteria:

a) Application of the required rolling pattern to achieve field


density of not less than 92 % of the absolute density of the
Job Standard Mixture.

b) Joint survey to check compliance of finished surface with


levels and tolerances specified.

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Site Records

A senior staff and the Engineer's Representative must be present during


the laying of premix. All records shall consists of:

a) Date, Time of laying


b) Source of Asphaltic Concrete ACW 20
c) Weather report
d) Temperature
e) Lists of Machineries/Manpower
f) Location of work (Chainage)
g) Lorry numbers

8.0 SAFETY

8.1 General Safety

The Section Head, will have overall responsibility for safety.

As the construction area will be isolated and fenced, the danger of injury
to members of the general public is minimal. All site visitors within the
construction area will be accompanied by a member of the Site Team.

The following general safety issues will be addressed on site:

● All lifting appliances and lifting gear shall be inspected by a


competent person (eg. By Main Contractor Safety Officer or
suitably experienced Plant Manager) and certified as having
adequate capacity for their intended purpose.

● All lifting gear should be regularly inspected for damage that may
effect capacity.

● Lifting appliances shall only operate on a firm base of adequate


bearing capacity.

8.2 Personnel and Safety

All new workers and staff will attend the Safety Induction Course before
commencing on site work.

All personnel will wear safety helmet and safety boots. Eye protection
shall be worn by all welders.
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All workers must attend the weekly toolbox meetings held on site.

Any unsafe acts or conditions to be identified and corrected promptly or


referred to the respective supervisor. Any accident or incident to be
reported immediately so preventative action can be taken to prevent re-
occurrence.

8.3 Training

All staff members will be briefed on the importance of monitoring on site


safety by the Safety Manager.

9.0 ENVIRONMENT

The Section Head will have overall responsibility for the environment.

All new workers and staff will attend the Environmental Induction Course before
commencing on site.

Typical environmental management measures will be monitored in accordance


with the following documents:

● The Project Environmental Plan


● The Project Management Plan

10.0 ANNEXES

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