R: ROAD PAVEMENT LAYERWORKS

R: ROAD PAVEMENT LAYERWORKS

1. SCOPE

This specification covers the requirements for sub-base and gravel wearing courses plus the
requirements for bases for roads, shoulders and paved areas. It covers procuring, furnishing,
classification, placing, compacting and finishing of approved natural gravel, stabilized gravel or
crushed stone.

2. MATERIALS

2.1 Classification for excavation purposes

The provision of sub-clause 2.1 of the earthworks specification E shall apply to the method of
classifying and the classes of excavation of material excavated from cuts and borrow pits for use in
the road pavement.

2.2 Physical Properties

a) Materials specified for use in the pavement are classed according to their quality (Class 2,4;
Class 2,6 etc), and should conform to the specifications for these classes given in table R1.
Should treatment with lime or cement be specified the material's properties should conform
to those set out in table R2 or as instructed by the Engineer.

In no case shall the maximum dimension of coarse aggregate exceed two-thirds of the thickness of
the compacted layer.

b) Where graded crushed stone is specified, and where the nature of the rock is such that the
material is deficient in fine aggregate, the Engineer may allow the admixture of approved
soil fines, crusher fines, or sand, in limited quantities. The total amount of such admixed
fines and sands shall not exceed 15% by mass of the aggregate.

Further the soils fines shall comply with the following:

i) Liquid limit less than 25

ii) Plastic Limit less than 6
iii) Linear shrinkage less than 3

c) Wearing course gravels shall conform to the following requirements:-

i) Grading modulus (GM) not less than 1,5 and not greater than 2,5
ii) The percentage passing the 75 m sieve should not exceed 70% of the percentage passing
the 425 m sieve.
iii) Reject index (IR) less than 10%
iv) Maximum plasticity index (PI) = 15(GM-0,25)
v) Minimum plasticity index (P1) = 10(GM-0,25)

2.3 Stabilizing Agents

a) General

The stabilizing agent or agents shall be one or more of the following, as required in terms of
the schedule or as ordered.

b) Lime

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Lime for stabilization will be hydrated lime complying with the latest C.A.S. No. A19.
Any variation must be authorised in writing by the engineer.

c) Cement

Cement for stabilization will normally be Portland Blast Furnace Cement, but the use of
other cement types may be directed or authorised by the Engineer in writing. All cement
used shall comply with the latest CAS No. A46.

d) Storage

Separate storage facilities shall be provided on the Site for each type of stabilizing agent
used:
A stabilizing agent that is stored on the Site shall be kept under a cover that provides proper
protection from moisture and other factors that may promote deterioration.
Storage of a stabilizing agent in bulk in weather-proof silos or similar containers will be
permitted provided that the measurement of stabilizing agent drawn for use is by mass and
not by volume. The storage capacity provided and the amount of stabilizing agent stored
shall be sufficient to ensure that no interruption to the progress of the work is occasioned by
lack of materials.

Except where otherwise approved in the case of lime, no stabilizing agent shall be stored for
longer than 3 months.
Stabilizing agent that has deteriorated or that has been contaminated shall not be used in the
Works and shall be removed from the Site without delay.

2.4 Water

Only water that is of good quality and has been approved may be used.

2.5 Selection

The Contractor shall be responsible for locating suitable sources of material and for
ensuring that the materials from such services comply with the requirements of 2.2. In
addition he shall obtain approval for the materials and the sources

a) before commencing construction; and

b) during construction whenever the physical properties of the materials being exposed
in borrow pits or obtained from commercial sources differ appreciably from the
properties of the material previously approved.

3.0 PLANT

3.1 General

The requirements of Subclause 3.0 of the Earthworks Specification E shall apply.

3.2 Stabilization

As an alternative to graders, disc harrows or rotary mixers may be used for stabilization. The
Engineer may, if he is satisfied with the results obtained from the use of such machines, allow the
use of "one-pass" stabilizing machines that are capable of applying the stabilizing agent and water
in the required metered amounts.

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4. CONSTRUCTION

4.1 Precautions

The relevant requirements of Subclause 4.1 of the earthworks specification E shall apply.

4.2 Excavation

4.2.1 Cuts

Where pavement layer material is obtained from designated cuts, the relevant requirements of
subclause 4.0 of the earthworks specification E shall apply.

4.2.2 Borrow Pits

Where pavement layer material is excavated from borrow pits established by the Contractor, the
requirements of subclause 4.0 of the earthworks specification shall apply.

4.2.3 Overburden

Where overburden has to be excavated in order to obtain suitable material, the Contractor shall
advise the Engineer in good time of the extent of the area of overburden he proposes to remove, so
that an agreement can be reached on the quantity of overburden that is required to be removed. No
excavation at the particular borrow area shall be commenced before such an agreement has been
signed by the Engineer and the Contractor. Overburden shall be removed and stockpiled
separately from any topsoil. On completion of operations at a borrow area the overburden shall be
spread back over the area excavated.

4.3 Processing

Where specified or ordered the material shall be processed by one or more of the following
methods.

a) Heavy grid rolling:

Material placed on the road shall be subjected to heavy grid rolling. The following
procedure shall be deemed to constitute heavy grid rolling:

1) The material shall be evenly spread over the full width of the road.
2) Rolling shall be so carried out with a grid roller of mass at least 13 t and travelling
at a speed of at least 12 km/h, that every portion of the layer is covered by four
passes of the roller.

3) The material shall be windrowed to one side of the road, shall be checked for
oversize material, and the oversize material shall be removed. The material shall
then be respread and again grid rolled as in (2) above. This process shall be
repeated until all oversize material is broken down or removed.

b) Mechanical Modification

Materials from different sources shall be thoroughly mixed together on the road by means
of motor graders disc harrows, ploughs, rotary mixers, or similar means by working over
the full width and depth of the layer to obtain a uniform mixture.

c) Stabilization

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The procedure given in 4.5 shall be used.

4.4 Placing and Compaction

4.4.1 Placing

Before the construction of the pavement layers the Contractor shall ensure that the underlying
subgrade if any, complies with the requirements of the earthworks specification E.

The material shall be dumped on the road and then spread by means of motor graders over the full
width of the layer shown on the drawings and to such depth that after compaction the thickness of
the layer complies with the requirements of the project specification and the surface of the layer is
true to elevation, grade, and cross-section.

4.4.2 Spreading

The material shall be spread away from the area on which it has been dumped in such a manner as
to minimize segregation of the various sizes of aggregate in the material. If processing in terms of
4.3 is ordered, material that is oversize in terms of the requirements for size of 2.2 and that remains
after processing or spreading or both shall be handknapped or bladed off the road, or removed to a
site as directed and graded, but not compacted.

4.4.3 Watering

Where necessary, in order to increase the moisture content of the material to the optimum value for
the compaction equipment employed and the density required, not more than the requisite quantity
of water shall be added uniformly over the area to be compacted. The water shall be thoroughly
mixed into the material until a homogeneous mixture is obtained.

4.4.4 Compaction

Material that is too wet shall be allowed to dry out to the correct moisture content before
compaction proceeds.

Compaction shall be carried out as specified under Controlled Compaction in continuous operations
over the full width and length of the area being compacted until the specified density has been
achieved.

Any weak spots that become apparent during compaction shall be cut out and repaired with sound
material at the Contractor's expense.

4.5 Stabilization

4.5.1 Rate of Application

This shall be as specified on the drawings or as ordered by the Engineer. If no rate is shown a
nominal rate of 2% by mass shall be used.

4.5.2 Preparation of Layer

The material to be stabilized shall be spread as specified in 4.4.2 The layer shall be shaped true to
designated lines, grades and cross sections.

4.5.3 Application of Stabilizing Agent

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The stabilizing agent shall be uniformly spread over the full width of the prepared layer at the
specified rate of application. Where hand spreading is used the bags or pockets shall be
systematically placed down the centre line or edge of the section to be stabilized, so as to ensure the
proper percentage of stabilizing agent will be added.

4.5.4 Mixing-in of Stabilizing Agent, Watering and Compaction

a) Immediately after the stabilizing agent has been applied and spread, it shall be uniformly
mixed with the material to be stabilized for the full depth and width specified. Care shall be
exercised to avoid disturbing the compacted layer underneath. Mixing shall continue for as
long as is necessary to ensure a thorough uniform homogeneous mix.

b) Immediately after the stabilizing agent has been properly mixed in the moisture content
shall be determined, and if necessary, water shall be added as specified in 4.4.3. The
material shall then be compacted as specified in 4.4.4.

4.5.5 Construction Limitations

a) Where the stabilizing agent is cement all compaction and finishing shall be completed
within six hours of addition of water, and within 10 hours of the addition of cement.

b) Where the stabilization agent is lime all compaction and finishing shall be completed within
48 hours of the addition of water or lime.

4.5.6 Curing

The stabilized layer shall be cured after completion of compaction by keeping the surface damp for
a period of five days, by regular application of water.

a) Lower pavement layers shall be covered by the next layer of spread material immediately
after the five day curing period.

b) Base pavement layers shall be kept damp until sealed by a prime coat. The prime coat shall
be applied not sooner than 24 hours nor later than seven days following the curing process.

c) Construction traffic, except that essential for curing the layer, shall not travel on any
stabilized layer within five days of completing compaction.

4.5.7 Layer Failure

The Engineer may direct the Contractor to make good any stabilized section which fails in either
density or tolerance by reworking that section with the addition of a quantity of fresh stabilizer
being not less than 50 per cent of the quantity originally specified.

Should however a lime-stabilized layer not attain the specified density, it may be reworked within
the 48 hours permitted in 4.5.5.

4.6 Protection and Maintenance

The Contractor shall protect and maintain the completed pavement layers. He shall without delay
and in a manner as to ensure an even and uniform surface, repair any damage or defects that may
occur. Unless otherwise authorised, no unnecessary construction traffic and no public traffic shall
be allowed on any unsurfaced base.

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4.7 Transport

The freehaul distance shall be 1,0 km. For overhaul the relevant provisions of subclause 4.2.5 of the
earthworks specification E shall apply to haul distances greater than 1,0 km.

5. TOLERANCES

5.1 Each layer shall be within the tolerances given below. All tolerances specified are subject
to the finished layer being free from rutting and or depressions which may hold water and
from any compaction layering caused by bad grading techniques.

BASE I BASE II BASE III

a) Thickness : The average compacted 4 tests every 4 tests 4 tests

thickness from levels taken before 500m² every every
and after construction or from test 1000m² 1500m²
holes may not vary from the +20mm
specified thickness by more than - 15mm +20mm +20mm
.......................... - 20mm -20mm
3 points
levelled 3 points 3 points
b) Level: The level of any point on the evey 20m levelled levelled
finished surface may not vary from +-20mm every 20m every 20m
the level as given or calculated from +-20mm +-20mm
the drawings by more than
..................................

c) Smoothness : When a straight edge

of Length 3,0m is laid on finished
surface parallel with the centre line 10mm
of the road, the distance between the 12mm 14mm
surface and the straight edge shallbe every
nowhere greater than 100m every every
.......................................................... 100m 100m
+1,0%
d) Width: The width of the layer shall +1,0% +1,0%
be not less than that specified on the
drawings

e) Moisture Content : OMC in the field

during compacion may not vary by
more than

f) Density: the density shall not vary

from that specified by more than that
indicated in Clause 6.2

5.2 Moisture Content and Density

The provisions of sub clause 5.1.1 of the earthworks specification E shall apply.

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6. TESTING

6.1 General
Sampling and testing procedures shall comply with the applicable requirements of CAS No.
A43.

6.2 Process Control

In addition to the requirements for testing given in Clause 6 of the earthworks specification
E the following shall apply.

The Contractor shall carry out process control tests at a frequency that is not less than that
set out below, and he shall provide the Engineer with the results of such tests, and shall
include the cost of such testing in the rate for the particular layer (Refer Clause 8.2).

TEST Area or Number of Min.Ave Min.Dens.

Volume tests density for any
per Test per set per set% sngl test%

a)Natural gravel, processed gravel and crushed stone:-

Density:

93% Mod AASHTO 1000m2 4 93,7 89,4

95% Unstabilized 1000m2 4 95,7 91,9
95% Stabilized 1000m2 4 95,7 91,0
98% Unstabilized 1000m2 4 98,5 95,3
98% Stabilized 1000m2 4 97,5 93,5

Indicator Tests:
grading analysis
and Atterberg
limits
:- in road 1000m2 2
:- in stockpile 1000m3 4

b) Natural gravel and processed gravel :-

Texas Triaxial Test

California Bearing
Ratio CBR
Unconfined Compressive
Strength U.C.S.
(Cement-stabilized
gravels) 5000m2
:- in road 1000m2 2
:- in stockpile 4

c)Crushed Stone:-
Aggregate Crushing
Value (ACV) 1000m3 2
Flakiness 1000m3 2

6.3 Stabilization

6.3.1 Testing for quality of material and Rate of Application of Agent

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Where the material to be stabilized is not from a designated source and the proportion of stabilizing
agent is not specified by the Engineer, the Contractor shall, at least 4 weeks before commencing the
construction of a stabilized layer, submit to the Engineer representative samples of the material he
proposes to use in the mix, to enable the Engineer to test-check the materials for quality and, if he
considers it necessary, to specify the quantity of stabilizing agent to be added.

6.3.2 Acceptance Control of Stabilizer

For the purpose of acceptance control the quantity of stabilizing agent in a layer will, at the
discretion
of the Engineer, be determined by direct measurement or by counting.

6.3.3 Strength tests for Stabilized Materials

The Contractor shall carry out and pay for tests on the stabilized material at the frequency specified
in 6.2 and check that the material complies with Subclause 2.2 of this specification.

7. MEASUREMENT AND PAYMENT

7.1 Measurement

a) Rates tendered shall cover the cost of locating the sources of supply of the material if such
sources are not designated

b) The provision of material will be paid for once only, i.e.:- where suitable material is
available from excavations, payment for the provision of such material, delivered to
stockpile, will be made under cut to stockpile in Clause 6.2 of the earthworks specification
E. Payment for the uplifting of the material and subsequent operators to complete
construction of the layer will be made in terms of 7.2.2 ....

c) Except as provided for in (d) below freehaul will be 1,0 km

d) In the case of material from a commercial source or from a borrow area, no additional
payment will be made for the class of excavation, method of processing, or overhaul unless
otherwise specified.

7.2 PAYMENT

7.2.1 Construct the pavement layers/shoulders/gravel wearing course with material excavated in all
materials from borrow pits .........................................M3

Separate items will be scheduled for the different pavement layers.

The rate shall cover the cost of locating the material, complying with all precautions in terms of
Clause 4.1, opening up, operating, and rehabilitating the borrow pits, excavation, basic selection,
transporting, spreading, watering, compacting and final grading, complying with tolerances and
testing.

7.2.2 Construct pavement layers/shoulders/gravel wearing course with material from designated
excavations

Separate items will be scheduled for the different pavement layers.

Construct the pavement layer from the stockpile previously excavated and selected from designated
excavations

1) Natural Gravel Material .................... M3

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2) Crushed Stone .................................. M3

The rate shall cover the cost of basic selection, loading from stockpiles, transporting,
spreading, watering, compacting, final grading, complying with tolerances and testing.

7.2.3 Construct Pavement layers with material from commercial source

Separate items will be scheduled for the different pavement layers

a) Natural Gravel material .....................M3

b) Crushed Stone material .....................M3

The rate shall cover the cost of locating the source, complying with all the relevant
precautions required in terms of 4.1, procuring the material, basic selection. Transporting
from source to point of deposition on the road, spreading, watering, compacting, final
grading, complying with the tolerances, and testing.

7.2.4 Process pavement layer material by the following processes and use in pavement layer

a) Heavy grid rolling ...............................M3

b) Mechanical Modification .....................M3

In the case of mechanical modification no allowance will be made in measurement for any
reduction in volume of the combined mixture over that of the individual materials
compacted to the specified density.
Each rate shall cover the costs of processing the material in accordance with the relevant
specified, ordered, or agreed method. In the case of stabilization the rate shall not cover the
supply of the stabilizing agent (See 7.2.5)

7.2.5 Stabilizing Agent

a) Lime ......................................... t
b) Cement ..................................... t

Measurement will be based on the quantity ordered by the Engineer, or actually

incorporated within the layer concerned, whichever is the lesser.

The rates shall cover the cost of providing the stabilizing agent within the pavement layer
irrespective of the rate of application specified or ordered, and shall allow for the variations
in mixing and compaction times of the various stabilizing agents.

7.2.6 Overhaul (haul exceeding 1,0 km) (provisional)....................................................................... m3.km

Volumes will be computed from the designated dimensions. No allowance will be made for
bulking. Distances will be measured to the nearest 0,1 km from the end of the 1 km freehaul, in one
direction only, by the shortest practicable route.
The rate shall cover the cost of transporting the material for the overhaul distance.

7.2.7 Repair existing pavement layer........................................................................................................ m²

The rate shall cover the cost of skimming off contaminated material, importing equivalent, eroded
and lost material, spreading, watering, compacting, final grading, complying with tolerances and
testing.

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