Roadworks and Surfacing

PETRONAS TECHNICAL STANDARDS
Roadworks and Surfacing
PTS 11.12.02
January 2017
© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner.PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
65.225.112.134 nurul.hashim@petrofac.com nurul.hashim@petrofac.com 05/19/2020 00:00:50 GM

PTS 11.12.02
ROADWORKS AND SURFACING January 2017
Page 2 of 45
FOREWORD
PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.
Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.
Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.
In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.
PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.
The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.

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ANNOUNCEMENT
Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 - 2015 which includes revision to numbering system, format and content. As part of this change,
the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition
to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required
make reference to other PTS in its revised numbering to ensure consistency. Users are requested to
refer to PTS 00.01.01 (PTS Index) for mapping between old and revised PTS numbers for clarity. For
further inquiries, contact PTS administrator at ptshelpdesk@petronas.com.my

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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 6
1.1 SCOPE ............................................................................................................................ 6
1.2 GLOSSARY OF TERMS..................................................................................................... 6
1.3 SUMMARY OF CHANGES ............................................................................................... 7
2.0 ROAD CLASSIFICATIONS......................................................................................... 8
2.1 HEAVY DUTY .................................................................................................................. 8
2.2 LIGHT DUTY.................................................................................................................... 8
3.0 PAVEMENT TYPES................................................................................................ 10
3.1 RIGID PAVEMENT (REINFORCED CONCRETE) MATERIALS ........................................... 10
3.2 FLEXIBLE PAVEMENT MATERIALS ................................................................................ 11
4.0 DESIGN OF ROAD GEOMETRY .............................................................................. 13
4.1 TRAFFIC PROJECTION................................................................................................... 13
4.2 DESIGN VEHICLES AND CHARACTERISTICS – TABLE FOR VEHICLE DIMENSION .......... 13
4.3 DESIGN SPEED.............................................................................................................. 14
4.4 SIGHT DISTANCE .......................................................................................................... 14
4.5 HORIZONTAL ALIGNMENT ........................................................................................... 15
4.6 VERTICAL ALIGNMENT ................................................................................................. 15
4.7 LANE WIDTH AND SHOULDER ..................................................................................... 15
4.8 INTERSECTION DESIGN ................................................................................................ 16
4.9 TRANSITION SLAB ........................................................................................................ 16
5.0 DESIGN OF ROAD PAVEMENT .............................................................................. 17
5.1 GENERAL ...................................................................................................................... 17
5.2 RIGID PAVEMENT......................................................................................................... 17
5.3 FLEXIBLE PAVEMENT ................................................................................................... 19
6.0 ROAD FURNITURE ............................................................................................... 20
6.1 CONCRETE KERBS......................................................................................................... 20
6.2 SIDEWALKS .................................................................................................................. 20
6.3 TRAFFIC BARRIERS ....................................................................................................... 20
6.4 PEDESTRIAN CROSSING ............................................................................................... 21
6.5 PIPE BRIDGE AND STRUCTURE CROSSING ................................................................... 21
6.6 CYCLE TRACK ................................................................................................................ 21
6.7 PARKING ...................................................................................................................... 22

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6.8 PAVEMENT FOR MAINTENANCE ACTIVITIES ............................................................... 22

6.9 SIGNAGES AND ROAD MARKINGS ............................................................................... 22
7.0 OTHER ROAD ELEMENTS...................................................................................... 23
7.1 DRAINAGE .................................................................................................................... 23
8.0 UNPAVED AREAS ................................................................................................. 25
8.1 GENERAL ...................................................................................................................... 25
8.2 DESIGN AND REQUIREMENTS ..................................................................................... 25
8.3 MATERIALS................................................................................................................... 26
9.0 MAINTENANCE .................................................................................................... 27
10.0 EROSION PROTECTION FOR EMBANKMENT AND OPEN DRAINS ........................... 28
10.1 GENERAL ...................................................................................................................... 28
10.2 DESIGN AND REQUIREMENTS ..................................................................................... 29
11.0 UNDERGROUND UTILITIES AND CABLES ............................................................... 31
11.2 BACKFILLING ................................................................................................................ 31
11.3 OTHER REQUIREMENTS ............................................................................................... 31
12.0 FENCING ............................................................................................................. 32
12.1 DESIGN STANDARDS .................................................................................................... 32
12.2 SECURITY RISK ASSESSMENT ....................................................................................... 32
12.3 DESIGN SPECIFICATIONS.............................................................................................. 32
12.4 GUARDRAIL BARRIERS ................................................................................................. 33
13.0 BIBLIOGRAPHY .................................................................................................... 35
APPENDIX 1: VERTICAL ALIGNMENT OF ROAD ................................................................ 37
APPENDIX 2: SAFE TURNING RADIUS OF VEHICLES .......................................................... 38
APPENDIX 3: GUARDRAILS .............................................................................................. 41
APPENDIX 4: PARKING BAYS LAYOUT.............................................................................. 44
APPENDIX 5: RISK ASSESSMENT BASED ON THE SITUATIONS........................................... 45

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1.0 INTRODUCTION
This PTS specifies the minimum requirements for road, paving design and general
requirements including surface protection for onshore plant facilities.
This PTS adopts various national standards, international standards with additional
requirements based on PETRONAS lesson learnt and best practices.
1.1 SCOPE
The scope covers road and paving design and general requirement for related facilities which
include slope protection, underground utilities and fencing which are connected to the roads
and paving.
The scope does not cover drainage design for the roadside drain and within paved area. For
drainage design of road surfaces, refer to PTS 11.12.03.
1.2 GLOSSARY OF TERMS
1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.
1.2.2 Specific Definition
None
1.2.3 Specific Abbreviations
No Abbreviations Description
American Association of State Highway and

1 AASHTO Transporatation Official
2 ADT Average Daily Traffic
3 CBR California Bearing Ratio
4 MMS Maintenance Management System
5 MUTCD Manual of Uniform Traffic Control Devices
6 PCA Portland Cement Association
7 QAQC Quality Assurance and Quality Control
8 REAM Road Engineering Association of Malaysia

Table 1.1 : Specific Abbreviations

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1.3 SUMMARY OF CHANGES
This PTS 11.12.02 (January 2017) replaces PTS 11.12.02 (October 2013).
2.0

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2.0 ROAD CLASSIFICATIONS
Roads are classified into two categories namely Heavy Duty roads and Light Duty roads. Both
of these roads shall be designed in accordance with the latest version of AASHTO. The
classification of Heavy Duty roads and Light Duty roads are determined based on the type of
vehicular access required.
2.1 HEAVY DUTY
Heavy Duty roads consist of all roads within and around the processing units, utility areas and
yards, loading facilities including main access roads to the plant.
Figure 2.1: Schematic Drawing showing Typical Axle Loads and Vehicle Dimensions for Heavy
duty Road
2.2 LIGHT DUTY
Light Duty roads consist of patrol roads and maintenance tracks, and roads around the
administration complex, where no vehicle with multiple axles which provide continuous high
load is expected.

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Figure 2.2: Schematic Drawing showing Typical Axle Loads and Vehicle Dimensions for Light Duty
Road

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3.0 PAVEMENT TYPES
Both the heavy duty roads and light duty roads can be designed using rigid pavement or
flexible pavement. The design of the pavements is covered in Sections 4 and 5 of this PTS.
3.1 RIGID PAVEMENT (REINFORCED CONCRETE) MATERIALS
3.1.1 Rigid pavements consist of jointed reinforced concrete pavement (dowelled) and continuously
reinforced concrete pavement. Refer Figures 3.3 and 3.4.
3.1.2 Grade 30 concrete shall be used as the minimum grade for all rigid pavements.
3.1.3 Heavy duty roads with rigid paving shall have a minimum thickness of 250mm while light duty
roads shall have a minimum thickness of 150mm.
3.1.4 Conditions to choose the requirement and types of joint shall be referred to AASHTO.
Figure 3.3: Jointed Reinforced Concrete Pavement (JRCP)

(Source: Huang, Pavement Analysis and Design and REAM – GL 7/2004)
Figure 3.4: Continuously Reinforced Concrete Pavement (CRCP)

(Source: Huang, Pavement Analysis and Design)

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3.2 FLEXIBLE PAVEMENT MATERIALS
3.2.1 These roads consist of bituminous type flexible pavement, and where access to underlying
services is required, interlocking pavers, brickwork, or blockwork could provide a low
maintenance flexible paving system.
3.2.2 The flexible pavement consists of several layers which include the Surface Course (wearing
course, binder course), base course and subbase course.
3.2.3 The materials for the above layers can be refered to latest version of Guide for Design of
Pavement Structures. The road layer classifications are as follows:
Minimum
Road layer Definition
Thickness (mm)
Wearing Course 40
Surface The uppermost layer of the pavement
Course system; composed of hot mix asphalt.
Binder Course 50
Asphalt 50
The layer of material directly beneath
Base or Crushed Stone 100 the hot mix asphalt surface layer. The
Base base may be composed of asphalt,
Course Cement crushed stone, or cement treated
Treated aggregate.
Aggregate 100
That layer of the pavement system

Granular immediately below the base and
Subbase 100
immediately above the subgrade.
Subbases are often composed of
Cement aggregates, gravel, or cement treated
Treated 150 materials.
The layer of soil which supports the

Subgrade pavement system. The subgrade soil
may be a naturally deposited material or
it may be fill material borrowed from
- - another source.
Table 3.1: Road Layer Classifications
(Source: Arahan Teknik (Jalan) 5/85)

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Figure 3.5: Typical Layers of Flexible Bituminous Road

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4.0 DESIGN OF ROAD GEOMETRY
The geometric design for both heavy duty roads and light duty roads shall be in accordance
with the latest version of AASHTO, A Policy on Geometric Design of Highways and Streets.
The cross fall of the heavy duty and light duty roads shall be sufficient to ensure effective run-
off of rainwater and shall comply with the minimum requirements of Clause 4.6 of this PTS.
The designed thickness of the pavement shall comply with the minimum requirements
indicated in Section 5.0.
4.1 TRAFFIC PROJECTION
4.1.1 The roads within the plant shall be designed to an average daily traffic (ADT) of < 1000.
4.2 DESIGN VEHICLES AND CHARACTERISTICS – TABLE FOR VEHICLE DIMENSION
4.2.1 The vehicle dimensions for various vehicle types are shown in Table 4.1. Information in this
table can be used to determine the appropriate turning radius for intersections.
Design Vehicle Dimension in Metres

Turning Radius
Equivalent Overhang (Metres)
Type in Wheel Overall Overall
Type AASHTO Base Front Rear Length Width Height Inner Outer
Passenger
Car P 3.4 0.9 1.5 5.8 2.1 1.3 4.2 7.3
Rigid
Truck SU 6.1 1.2 1.8 9.1 2.6* 4.1 8.5 12.8
Semi-
Trailer WB-15 9.1 0.9 0.6 16.7 2.6* 4.1 5.8 13.7
NOTE(S) : *Maximum alloawable overall width under current Malaysian Legislation is 2.5m.
Table 4.1: Table of Vehicle Dimension
(Source: REAM – GL 2/2002)

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4.3 DESIGN SPEED
4.3.1 The design speed within the plant shall be selected to meet the needs of the road to fulfill its
function. The maximum design speed limits in the plant are as follows:
Area Type Design Speed (km/h)
Non-Process 40
Process 40
Jetty 25
Table 4.2: Design Speed
(Source: Petronas Best Practice)
4.4 SIGHT DISTANCE
4.4.1 The sight distance is the length of road ahead which is visible to the driver. The designer shall
design the road to have sufficient sight distance to avoid collision with obstacles ahead. The
minimum stopping sight distance is the length required to enable a vehicle to stop before
reaching the obstacle in its path. Table 4.3 shows the recommended minimum stopping sight
distance for the relevant design speeds.
Design Speed Minimum Stopping Sight

(km/h) Distance (m)
40 45
25 30
Table 4.3: Minimum Stopping Sight Distance

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4.5 HORIZONTAL ALIGNMENT
4.5.1 In designing the horizontal alignment of roads, consideration should be given to the minimum
radius of the road. The values for the minimum shall be based on the design speed as indicated
in Table 4.4.
Minimum Radius (m)

Design Speed
(km/h) e = 0.06 e = 0.10
40 60 50
25 35 30
Table 4.4: Minimum Radius
*NOTE(S) : e = super elevation
4.6 VERTICAL ALIGNMENT
4.6.1 The maximum longitudinal gradient for Heavy Duty roads shall be 1:20 (or 5%) while Light
Duty Roads shall have a maximum gradient of 1:10 (or 10%.). The vertical alignments of road
for crest and sag curves as well as the gradient indications are indicated in Appendix 1.
4.7 LANE WIDTH AND SHOULDER
4.7.1 The minimum pavement width and shoulder width shall conform to the requirements shown
in Table 4.5 below.
Road Type Definition/ Criteria Road Width (m) Shoulder Width

(m)
Main - All roads outside plant area. 8 2

E.g: around administrative
buildings, around workshop,
around warehouse
- Road leading to plant area and

from one plant to other plant
Plant - All roads in and around 4-6 1.5

processing units, utility areas
and yards
Patrol - To accommodate vehicles with 3 -

a maximum weight of 5t
- Gradient ≤ 1:8.5
- Flexible-type paving

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Road Type Definition/ Criteria Road Width (m) Shoulder Width

(m)
Maintenance - To facilitate access to future to suit -

Track
development areas
- Access to other areas not

mentioned above for
maintenance and inspection
activities
- Gradient ≤ 1:5
Jetty Approach - Including Lay by area 4-6 -

Trestle
Table 4.5: Table of Lane Width and Shoulder Widthrea
(Source: REAM - GL 2/2002 and Petronas Best Practice)
4.7.2 The crossfall gradient of roads shall be 1:50 (2.5%) from the crown of the road or across the
road, where applicable.
4.7.3 Road shoulder is provided to accommodate stopped vehicle, during emergency situation.
Hence, there shall be no element located and installed within road shoulder area.
4.8 INTERSECTION DESIGN
4.8.1 The design of intersections shall be adequate to cater for the safe turning radius of vehicles
as shown in Appendix 2.
4.9 TRANSITION SLAB
4.9.1 The use of below ground, reinforced concrete transition slabs shall be considered at those
locations where differential settlement between paving and/or foundations is expected. This
may be the case at pipe culverts and/or piled objects such as foundations and liquid-light
process plant paving.

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5.0 DESIGN OF ROAD PAVEMENT
This section describes the minimum requirements for paved areas.
5.1 GENERAL
5.1.1 The design of the pavement shall be based on the number of axles throughout the design life
of the road. For heavy duty roads, the recommended number of axles movements is 1.5
million while for light duty roads it is 1.0 million.
5.2 RIGID PAVEMENT
5.2.1 Rigid pavement is used at areas where there is a risk of chemical or hydrocarbon spillage.
5.2.2 The pavement shall comprise of slabs placed side by side connected by flexible joints which
allow for lateral movement. Joints shall be designed to be impermeable to chemicals and
hydrocarbons.
5.2.3 The analysis of the pavement should be based on plate theory instead of layered theory. Plate
theory is a simplified version of layered theory that assumes the concrete slab to be a medium
thick plate with a plane that is maintained before and after bending.
5.2.4 Typical cross sections of light-duty and heavy-duty rigid pavements are shown in Figure 5.1
and 5.2.
Figure 5.1: Cross Section of Heavy-duty Pavement

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Figure 5.2: Cross Section of Light-duty Pavement
5.2.5 The rigid pavement shall be designed using the Modified Portland Cement Associations’s
(PCA) method. However the following criteria shall be met:
i. The minimum thickness of the heavy-duty paving shall be 250mm with two layers
of 7mm steel wire spaced a pitch of 200mm x 200mm. The steel reinforcement
shall have a minimum cover of 40mm.
ii. The minimum thickness of the light duty paving shall be 150mm with one layer of
7mm steel wire spaced a pitch of 200mm x 200mm. The steel reinforcement shall
have a minimum cover of 0.6 times the slab thickness above the bottom of the
slab.
5.2.6 The modulus of sub-grade reaction shall be determined or verified through a standard plate
bearing test, with a 762mm (30 in) diameter plate. Other methods used shall be corrected to
have a comparable value with the standard method. Consequences of short-term settlement
and long-term consolidation and differential settlement shall be taken into consideration.
5.2.7 Steel wire fabric reinforcement is laid within the pavement to prevent thermal and shrinkage
stresses on the pavement due to uncontrolled cracking. The wire mesh design shall consider
the maximum friction forces due to sliding, which are dependent on slab base friction and
weight of slab only. The reinforcement shall not contribute to the tensile strength of the slab.

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5.3 FLEXIBLE PAVEMENT
5.3.1 The design of the pavement thickness shall be in accordance to AASHTO, Guide for Design of
Pavement Structures.
5.3.2 The thickness design of flexible pavement shall be based on the design CBR (California Bearing
Ratio) of the subgrade and the standard axle number indicated in 5.1.
5.3.3 The following parameters shall be considered in the design of flexible pavement:
i. Reliability, R = 75% for heavy duty roads
ii. Reliability, R = 50% for light duty roads,
iii. Standard deviation,So = 0.45
iv. Initial serviceability index, Po= 4.2
5.3.4 The top layer of subgrade course (150mm) shall be scarified and compacted to the desirable
density near the optimum moisture content. Where the subgrade support is insufficient,
economic methods shall be considered based on site trials as indicated in PTS 11.12.01.
5.3.5 The subbase layer is required when the subgrade is not capable of supporting the pavement
and traffic due to insufficient bearing capacity or due to its settlement behavior.

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6.0 ROAD FURNITURE
Road furniture encompasses all roadside objects used for safety and control of traffic in
addition to those for assisting the driver. Road furniture items provide drivers with the
necessary warnings, rules, distance and directional information in order to travel safely.
6.1 CONCRETE KERBS
6.1.1 Concrete kerbs should be constructed at road pavement edge delineation, as a separate unit
or integral unit with road pavement. It is recommended for use in adjacent to footpaths or
pedestrian
6.1.2 The requirements for concrete kerbs shall be as follows;
i. The laying of the kerbs, shall take place before the completion of the rolling
operation of the sub-base and base course.
ii. The kerbs shall be laid on a lean concrete of grade C20 (20N/mm2), with a
thickness not less than 100 mm and width such as to permit a suitable haunch to
be formed providing stability of each element against vehicle wheel loads.
iii. Each element shall have a constant section, and shall be laid as per the drawing
requirements and with the edges perfectly aligned.
iv. The gulley openings shall have such dimensions as to permit, after wearing course
laying, the regular draining of the water.
v. The sealing of the joint shall be made with a suitable cement mortar.
6.2 SIDEWALKS
6.2.1 Sidewalk is a path along the side of a road dedicated for pedestrian walking path. Minimum
width of sidewalk shall be 1.2m. Sidewalk shall be provided in the dedicated route for
pedestrian. Few materials are available for the sidewalks construction such as light-duty
interlocking pavers, concrete and asphalt pavement.
6.3 TRAFFIC BARRIERS
6.3.1 Traffic barriers shall be applied where considered essential to protect personnel, equipment
and piping. Typical locations requiring traffic barriers are road crossings over pipe tracks and
under pipe racks, roads close to pipe racks and pipe tracks, and roads adjacent to steep slopes,
T-junctions and sharp bends.
6.3.2 The preferred traffic barrier system consists of I-beams with steel supports embedded in the
soil at 3 m distances to carry a guard-rail of 0.75 m minimum height. The steel should be
galvanized.
6.3.3 The system shall be designed to absorb the design impact energy by deformation without
collapse.

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6.3.4 Typical section refers to Appendix 3.
6.4 PEDESTRIAN CROSSING
6.4.1 Pedestrian crossing is a designated point on a road at which some means are employed to
assist pedestrians to cross the road. They are designed to keep pedestrians together where
they can be seen by motorists, and where they can cross most safely across the flow of
vehicular traffic.
6.4.2 Detail specifications for pedestrian crossing shall be in accordance to AASHTO Guide for
Planning, Designs and Operation of Pedestrian Facilities
6.5 PIPE BRIDGE AND STRUCTURE CROSSING
6.5.1 Minimum height clearance for pipe bridge and structure overpass shall be as follows:
Road type Minimum clearance (m)
Main Avoid crossing
Plant 5.50
Sloping road 6.00

Table 6.1: Minimum clearance for structure crossing
6.6 CYCLE TRACK
6.6.1 A cycle track can be located within an existing road. Pavement markings define the corridor
set aside for the cycle track and route markings are necessary to define the route and reduce
potential conflicts.
6.6.2 Detail specifications for cycle track shall be in accordance to AASHTO Guide for Development
of Bicycle Facilities

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6.7 PARKING
6.7.1 Below table shows the parking bay minimum size according to orientation of cars:
Bay sizes
Description
(Width x Length)
Parallel Parking bay 5.0m x 2.5m
300 Parking bay 4.8m x 4.2m

Table 6.2: Table of Parking Bay Size
6.7.2 Parking layouts for vehicles refer to Appendix 4.
6.8 PAVEMENT FOR MAINTENANCE ACTIVITIES
6.8.1 Appropriate pavement shall be designed for specific maintenance and lifting designed areas.
6.9 SIGNAGES AND ROAD MARKINGS
6.9.1 Road traffic signs and markings for internal plant roads shall follow the latest revision of
Manual of Uniform Traffic Control Devices (MUTCD). For local roads within the jurisdiction of
the PETRONAS Operating Units, the design of the road traffic signs and markings shall follow
the local authority’s requirement. If such requirements is not available, then reference shall
be made to the highest standard available to ensure conformity and road safety.

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7.0 OTHER ROAD ELEMENTS
7.1 DRAINAGE
7.1.1 Surface drainage
i. The road surface shall have a minimum lateral gradient of 1 in 50 to provide

proper drainage under all weather conditions.
ii. The drainage of road surfaces and plot paving forms an integral part of the
drainage system. For its design, reference is made to PTS 11.12.03.
iii. Surface water run-off from catchment areas outside the site shall be diverted
around the site by means of perimeter ditches, which shall be designed to
accommodate the peak design flows and protected against scour
7.1.2 Groundwater control
i. The ground under the road paving system shall be well drained.
ii. The distance between the underside of the paving and the maximum ground
water level shall be not less than:
Road type Distance to water (m)
Main 0.75
Plant 0.50
Patrol 0.30
Maintenance track Not applicable

Table 7.1: Paving Underside Distance to Groundwater

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7.1.3 Paving gradient
Catchment areas and gradients of paving for process area applications are described in PTS
11.12.03. Where guidance is not covered by the referenced standard, the following minimum
gradients shall apply:
Paving area Minimum gradient
LNG 1:200
LPG sphere 1:50
Furnaces 1:50
Other 1:200
Table 7.2: Paving minimum gradient

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8.0 UNPAVED AREAS
8.1 GENERAL
8.1.1 This section only describes the minimum technical requirements for the design of unpaved
areas.
8.1.2 The unpaved areas are generally classified as the areas in the plant that are not exposed to
the hydrocarbon or chemical spill; low occurrence and the areas that are not designed to cater
loads except for pedestrians and light vehicles.
8.1.3 The classifications of unpaved areas are as below:
i. Low fire hazard
a) Administration and non-process buildings area
b) Road shoulder, area for future development
c) Interfacing area; area near fences
d) Area within pipe racks and pipe tracks that are connected using the
continuously welded piping line with no flange
ii. Fire Hazard
a) Flare area excluding the area that has equipment
b) Crude and gas storage tank areas
c) Area surrounding the process area
d) Area within pipe racks and pipe tracks that contain flange connections,
valve or sampling points including manifolds.
8.2 DESIGN AND REQUIREMENTS
8.2.1 The design considers the classifications of the unpaved area as Low Fire Hazard and Fire
Hazard area. For the Low Fire Hazard area, if the grass is required, the type must be the slow
growing type.
8.2.2 For the Fire Hazard area, the minimal requirements will be as follows;
i. Gravel cover below pipe tracks shall be 100mm thick
ii. The gravel or other inert materials in all areas shall be at least 75mm thick with
the measures of minimizing the growth of vegetation
8.2.3 Requirements for the unpaved areas shall cover the following purpose;
i. To suppress the growth of unusable vegetation

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ii. To prevent soil erosion caused by wind and water
iii. To be able to sustain the light vehicles and pedestrians to pass through
8.3 MATERIALS
8.3.1 The materials for the unpaved areas shall be durable under local conditions especially from
fire and must be low in maintenance. The locations of unpaved area shall have good drainage
system and unpolluted ground water.
8.3.2 Geotextile material that in accordance with ASTM specification should be used for unpaved
areas where presence of vegetation growth are not tolerable.
8.3.3 Application of the geotextile material for unpaved area within process units shall be reviewed
for HSE/process safety requirement.
8.3.4 Maximum gravel size used shall be 20mm to 50mm. Crushed gravel and coarse gravel are
acceptable.

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9.0 MAINTENANCE
A maintenance cycle to ensure assets remain serviceable for the life of the site shall be
implemented for all civil engineering infrastructures. The designer and site operator shall
develop a master plan that shall incorporate a system of reporting results of both routine and
irregular inspections of the assets. The system shall catalogue the condition of assets and
criteria shall be established which shall trigger the requirement for repair or renewal. This
system shall ensure the assets remain serviceable and allow the operating unit to plan for
maintenance that will ensure maintenance costs can be included in annual budget plans and
kept to a minimum.
The internal and external plant road shall be maintained by PETRONAS Operating Units to
ensure the road serves its intended purpose. The structure of the maintenance program can
be referred to AASHTO MMS-1 - Guidelines for Maintenance Management Systems.

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10.0 EROSION PROTECTION FOR EMBANKMENT AND OPEN DRAINS
10.1 GENERAL
10.1.1 This section explains only the erosion protection of slopes including embankments, ditches
and open drains. Slope stability is not considered in this section. Related standards that may
be referred are PTS 11.12.01, PTS 11.13.01 and PTS 11.12.03.
10.1.2 Materials of erosion protection layers include:
i. concrete slabs, blocks or mortar
ii. flexible asphaltic and bituminous products (including sand bitumen mix)
iii. impermeable polyethylene or equivalent sheeting (anchored with tiles,

brickwork, rock, etc.)
iv. layer of crushed rock, gravel, tiles and brickwork (if required in combination with
filter fabric)
v. reinforced mats with geotextiles and geogrids
vi. grass.
10.1.3 The slope protection system selected shall be based on the risk level study, require low
maintenance, high durability, and capable to protect the slopes against erosion, subsequent
damage and failure on a micro scale (wind, water and spillages effects). Other conditions that
may be taken into consideration to select the system are as following:
i. Activities nearby the area of the slopes
ii. Temporary loading from vehicles
iii. Storage of materials
iv. Vibration
10.1.4 In zones where accidental spillage of hazardous chemicals or hydrocarbons may occur, the
cover layer of open drains and ditches shall prevent the spillage seeping into the soil.
Protection system that includes a permeable lining may be adopted if the accidental spillage
flows rapidly through the system and can be cleared away in a short time. On the other hand,
if the cleanup operation will takes some time to be done, an impermeable membrane solution
shall be selected.
10.1.5 Application of filter fabric shall be adopted where there is a possibility of wash out of sandy
material through the erosion protection layers. The risk of cracking in the protection layer or
in brickwork/slabs joints shall also be taken into consideration. Typical slope section is shown
in Figure 10.1.

PTS 11.12.02
Page 29 of 45
Figure 10.1: Typical slope section
10.2 DESIGN AND REQUIREMENTS
10.2.1 The requirements are divided into 2 areas; inside battery limits and outside battery limits.
10.2.2 For materials selection, it shall comply with ASTM Volume 04.03. For concrete and cement
mortar, PTS 11.15.03 shall be referred.
10.2.3 Prior to the installation of erosion protection layers, slopes shall be compacted and trimmed
to protect the system from local failure.
10.2.4 The design of the erosion protection system shall meet the requirements under operational
conditions and able to withstand the sliding or floatation of the system that may occur due to
temperature fluctuations or changes in pore water pressure. The behavioral process including
long term superficial settlement, erosion, etc. shall be taken into consideration in the design
of slope protection.
10.2.5 Drainage holes or weep holes shall not be included in the design if impermeable erosion
protection system is selected. Accumulation of pore pressures may lead to slope failures,
therefore it is important to record the peak level of ground water together with the lowest
drain water level.
10.2.6 Process Unit Areas
For process unit areas, the design requirements are classified into 2 locations; inside battery
limits and outside battery limits:
i. Inside battery limits
a) All slopes, embankments, open drains and ditches shall include concrete
lining. The design of the concrete shall comply with PTS 11.15.03. The
layer thickness of the concrete lining shall be at least 80 mm with a 7 mm

PTS 11.12.02
Page 30 of 45
steel wire reinforcement mesh at a spacing of 200 mm x 200 mm pitch or

equivalent. The size of concrete slabs shall be 5 m x 5 m maximum.
b) Slopes greater than 1 m shall include drainage points or weep holes if the
risk of pollution is considered low. This could facilitate to prevent the
accumulation of pore water pressures.
c) Filter cloth may be applied to prevent wash out of sandy material through
these drainage points and also to avoid soil erosion through joints
between panels.
d) The possibility of long-term behaviour such as gradual clogging shall also

be considered.
ii. Outside battery limits
a) In areas where there is a requirement to reduce the possibility of fire

hazards, grass shall not be adopted as erosion protection, e.g. flare areas,
major pipe tracks, pump pits, etc.
b) Any suitable erosion protection layers, except grass, shall be acceptable

to be adopted in areas where the risk of contamination is not expected.
c) The minimum requirements for concrete panels shall be similar to inside

battery limits requirements.
d) For flexible erosion protection systems, drainage points or weep holes

shall be included at slopes. The requirements of drainage regarding
drainage points or weep holes as discussed above (inside battery limits)
shall be taken into consideration where low permeable erosion
protection layers are required.
e) Where there is a risk of hazardous accidental spillage of chemicals or

hydrocarbons that is potentially harmful to the environment, concrete
slabs with size of 5 m x 5 m maximum shall be adopted. Another option is
to use an impermeable sealing membrane for major drains. This
membrane layer shall be applied at minimum 0.5 m above design water
level.

PTS 11.12.02
Page 31 of 45
11.0 UNDERGROUND UTILITIES AND CABLES
11.1.1 For minimum cover of soil from top of buried pipe, refer to Piping General Arrangement
Requirement, PTS 12.30.02, Clause 3.4.
11.1.2 Cables shall be protected by cable tiles at a minimum of 350 mm deep below final grade for
both paved and unpaved areas. Location of trenches in paved areas shall be indicated by
colour codes while for unpaved areas, the location shall be shown by signs, both on the
surface. For detail of typical arrangement of cable trenches, refer to PTS Electrical Standard
drawing no S68.009-C.
11.1.3 Cables shall be laid cross underneath buried pipelines and shall have distance of at least 0.3m
to the pipelines. The pipe shall be insulated in hot lines. Where the depth measured at the top
of the pipeline is more than 1 metre, cables should cross above them.
11.2 BACKFILLING
11.2.1 The backfill materials for trenches shall be well drained and graded sand and free from
deleterious materials.
11.2.2 The selection of backfill materials and its design depth shall consider the effects of frost and
sub-zero temperature conditions.
11.2.3 If access is required, trenches in paved area shall be covered with removable concrete panels.
However, permanent paving shall be continuous if access is not required.
11.3 OTHER REQUIREMENTS
11.3.1 The design requirements of drainage system shall also be taken into consideration for cable
trenches design. The upper cable trench shall have a bridge comprising full concrete bottom
slab in order to ease the excavation of the lower trench. The lowest level of trenches shall be
above the constant ground water table.
11.3.2 For instrument trenches, they shall always cross 90 degrees with power and lighting cables
and in spacing of at least 0.6 m and up to 2 m for minimum of 10% distance over which they
run in parallel with trenches supporting power and lighting cables.
11.3.3 Typical cross sections and layouts of cable trenches shall be referred to Standard Drawing
D11.92.020 and D11.92.021.

PTS 11.12.02
Page 32 of 45
12.0 FENCING
12.1 DESIGN STANDARDS
12.1.1 The scope of this section is limited to the minimum requirements for permanent fences and
gates design. The design requirements shall conform to ASTM, BS 1722 and local authority
requirements whichever is more stringent.
12.2 SECURITY RISK ASSESSMENT
12.2.1 Prior to fence installation, a security risk assessment shall be implemented for developments
of green field and extensions of existing facilities. Appendix 5 identifies the risk categories and
the situations that shall be evaluated in the assessment. Typically, the type of fence installed
is standard for the whole facility; however, other fence type shall be installed if particular risk
areas are identified.
12.3 DESIGN SPECIFICATIONS
12.3.1 The erection of permanent fencing system shall be done before all other construction
activities.
12.3.2 The purpose of the fences and gates system installation is mainly to prevent unauthorized
entry into the site.
12.3.3 The recommended fencing system includes bracing, chain link fence fabric, barbed wire,
tension wire, gates and all posts for line, corner and end have a buried concrete footing and
inclined top. The top of the outer boundary fence shall be 45° outward inclined section of 0.7
m length within the property limits. Reference shall be made to Standard Drawings
D11.92.008, D11.92.009, D11.92.010 and D11.92.11. for typical fencing details.
12.3.4 The view along the length of fence shall be clear from any obstructions as this may aid the
plant security to identify any intruders. Maintenance tracks or patrol road are required along
the boundary. Fences shall have a minimum number of bends.
12.3.5 Gates shall be installed at which the locations could satisfy operational requirements. The
design of gates height shall be as similar as the design of fences. The number of gates required
shall be lowest possible.
12.3.6 Site Preparation
Site preparation shall be done prior to the erection of fences. Embankment may be required
for the system and shall be within the site boundary. Erosion protection of the embankment
shall be adequate for it to be stable. Embankments shall have a slope of 1:5 maximum and a
minimum shoulder of 0.5 m between the fence foundation and the external embankment
slope. The dry density of the fill material shall be at least 85% modified AASHTO (ASTM D 1557
or AASHTO T180).

PTS 11.12.02
Page 33 of 45
12.3.7 Fence Design Requirements
The design of fence system shall comply with BS 1722-10. Fence design shall fulfill the
following requirements:
i. Able to withstand any extreme load that may occur (e.g. gale force wind loads,
thermal movement from extreme climatic conditions, etc.)
ii. The height of the fences and gates shall be at least 2 m and the gap between the
fence and the ground shall not exceed 0.1 m
iii. Ground beam and anchors may be used to avoid the bottom of fence from lifting
up
iv. The weight of the concrete footing of a fence post shall be at least similar weight
as the post with a minimum 0f 25 kg
v. The concrete footing shall be minimum 0.6 m deep in the ground
vi. Metal parts shall not be in contact with the ground (except the chain link fence
fabric)
vii. The type of gates should be the swinging type or sliding type
viii. For drainage, a removable bar screen shall be installed at crossings of the fence
with any drainage channels.
ix. Steel fencing and steel gates posts shall be earth grounded. All fencing and gate
components shall be bonded by an approved electrical bonding method.
x. The selection of materials shall be based on local availability, require minimum

maintenance with low capital costs, high durability, and compatible and not easily
corroded when assembled. Galvanized or aluminium-coated steel, aluminium and
concrete are generally acceptable. PVC-coated chain link fence fabric and tension
wire may be used at non corrosive environment and subject to owner approval.
xi. Welded wire mesh shall be for security fencing shall be of polyester powder
coated 50mm x 150mm mesh size maximum of 5mm core wire diameter all in
accordance with BS 4102.
xii. All posts for line, corner and end have of security fencing shall have a buried
concrete footing and v-shaped extension top.
12.4 GUARDRAIL BARRIERS
12.4.1 Guardrail barriers shall be provided on the side of roads (road shoulder) especially on steep
road, high embankments, obscure curves, sharp corners. It will minimize severity of potential
accident and prevent vehicles from riding out from traveled way.
12.4.2 Guardrail shall be made of galvanized steel, in accordance with REAM - GL 2/2002

PTS 11.12.02
Page 34 of 45
requirement. The quardrail system shall be installed with C Section posts,W beam, post and
bolts and other component to complete. Refer to Appendix 3 for details of Guardrail system
requirement.

PTS 11.12.02
Page 35 of 45
13.0 BIBLIOGRAPHY
In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:
PETRONAS STANDARDS
Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms & Reading Guide PTS 00.01.03
Site Preparation and Earthworks Including Tank Foundations and Tank PTS 11.12.01
Farms
Drainage and Primary Treatment Facilities PTS 11.12.03
Geotechnical and Foundation Engineering PTS 11.13.01
Design and Construction of Reinforced Concrete Foundations and PTS 11.15.03
Structures
Piping General Requirements PTS 12.30.02
STANDARD DRAWINGS
Fence Construction Type "A" with Reinforced Concrete Post D11.92.008
Fence Construction "Type B" with Tee Posts and Horizontal Tubing D11.92.009
13002a00.pdf
Fence Construction Type "C" with Tee Posts D11.92.010
Fence Construction Type "D" with Tubular Posts D11.92.011
Electrical and Instrument Cable Trenches in Concrete Paved Areas D11.92.020
Cable Routing in Unpaved, Brick Paved, or Tiled Areas and Crossing D11.92.021
Roads
MALAYSIAN STANDARDS
Manual On Pavement Design Arahan Teknik
(Jalan) 5/85
A Guide on Geometric Design of Roads REAM – GL 2/2002
Guidelines To The Design of Plain Concrete Pavement REAM – GL 7/2004
INTERNATIONAL STANDARDS
Guide for the Development of Bicycle Facilities, 4th Edition AASHTO GBF-4

PTS 11.12.02
Page 36 of 45
Guide for Design of Pavement Structures, 4th Edition with 1998 AASHTO GDHS-5
Supplement
A Policy on Geometric Design of Highways and Streets, 6th Edition AASHTO GDPS-4-M
Guide for the Planning, Design, and Operation of Pedestrian Facilities AASHTO GPF-1
Guidelines for Maintenance Management Systems AASHTO MMS-1
Road & Paving Materials ASTM Vol 4.03
Specification for Anti-Intruder Fences in Chain Link and Welded Mesh BS 1722-10
Manual of Uniform Traffic Control Devices (MUTCD) MUTCD Rev 2
Huang,Y.H., 2004. “Pavement Analysis and Design”, Pearson Prentice
Hall, New Jersey

PTS 11.12.02
Page 37 of 45
APPENDIX 1: VERTICAL ALIGNMENT OF ROAD
Note:
V.I.P – Vertical Intersection Point
B.V.C – Tangent Point; Beginning of vertical curve
E.V.C – Tangent Point; Ending of vertical curve
G – Gradient (%)
V.C.L – Vertical curve Length
Mo – Middle point offset
A – Algebraic Difference in Grade
Figure A1.1: Vertical Alignment of Road

PTS 11.12.02
Page 38 of 45
APPENDIX 2: SAFE TURNING RADIUS OF VEHICLES
Figure A2.1: Turning Radius for P Design Vehicle

(Source: REAM A Guide on Geometric Design of Roads)

PTS 11.12.02
Page 39 of 45
Figure A2.2: Turning Radius for SU Design Vehicle


PTS 11.12.02
Page 40 of 45
Figure A2.3: Turning Radius for WB-15 Design Vehicle


PTS 11.12.02
Page 41 of 45
APPENDIX 3: GUARDRAILS
Table A3.1: Blocked-out Steel W-Beam Guardrail

(Source: REAM Guidelines on Design and Selection of Longitudinal Traffic Safety Barriers)

PTS 11.12.02
Page 42 of 45
Figure A3.2: W-Beam Guardrail Assembly – General Arrangement

(Source: Safety Barriers, Considerations for the Provision of Safety Barriers on Rural Roads, National Association of Australian Safe Road
Authorities, 1987)
Figure A3.3: Guard Rail Location- Barrier or Semi-Barrier Kerb

Authorities, 1987)

PTS 11.12.02
Page 43 of 45
Figure A3.4: Guard Rail Location- Mountable or Semi-Mountable Kerb
Authorities, 1987)
Figure A3.5: Minimum Lateral Earth Clearance Required behind W-Beam Guardrail
(Source: Designed for Malaysia Road Conditions, REAM 2004)

PTS 11.12.02
Page 44 of 45
APPENDIX 4: PARKING BAYS LAYOUT
Figure A4.1: Parking Bay Layout

PTS 11.12.02
Page 45 of 45
APPENDIX 5: RISK ASSESSMENT BASED ON THE SITUATIONS
Risk Category Description
Insignificant  Very low level of crime
 Basic personal and company precautions are needed
 An effective public security infrastructure is provided
Low  Frequent incidents of minor crime
 Limited possibility of activism and terrorism
 Good quality public security infrastructure
 Basic personal and company security are required
Medium  Frequent incidents of crime
 Criminals, terrorists or guerrillas acting violence
 Possibility of small-scale internal unrest
 Limited quality of public security infrastructure
 Must pay attention to good personal and company security precautions
High  Frequent petty, serious and organized crime
 Critical terrorist problem
 Medium-scale internal unrest is expected
 Low quality public service infrastructure
 Require stringent personal and company security precautions
Critical  The security authorities lost control of law and order
 Personal and company need to have a maximum level of security

protection
Table A5.1: Risk Assessment based on the Situation

Roadworks and Surfacing

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PETRONAS TECHNICAL STANDARDS

Roadworks and Surfacing

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

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6.8 PAVEMENT FOR MAINTENANCE ACTIVITIES ............................................................... 22

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1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

1.2.2 Specific Definition

1.2.3 Specific Abbreviations

American Association of State Highway and

2 ADT Average Daily Traffic

3 CBR California Bearing Ratio

4 MMS Maintenance Management System

5 MUTCD Manual of Uniform Traffic Control Devices

6 PCA Portland Cement Association

7 QAQC Quality Assurance and Quality Control

8 REAM Road Engineering Association of Malaysia

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1.3 SUMMARY OF CHANGES

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2.0 ROAD CLASSIFICATIONS

2.1 HEAVY DUTY

2.2 LIGHT DUTY

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3.0 PAVEMENT TYPES

3.1 RIGID PAVEMENT (REINFORCED CONCRETE) MATERIALS

Figure 3.3: Jointed Reinforced Concrete Pavement (JRCP)

Figure 3.4: Continuously Reinforced Concrete Pavement (CRCP)

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3.2 FLEXIBLE PAVEMENT MATERIALS

That layer of the pavement system

The layer of soil which supports the

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Figure 3.5: Typical Layers of Flexible Bituminous Road

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4.0 DESIGN OF ROAD GEOMETRY

4.1 TRAFFIC PROJECTION

4.2 DESIGN VEHICLES AND CHARACTERISTICS – TABLE FOR VEHICLE DIMENSION

Design Vehicle Dimension in Metres

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4.3 DESIGN SPEED

Area Type Design Speed (km/h)

4.4 SIGHT DISTANCE

Design Speed Minimum Stopping Sight

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4.5 HORIZONTAL ALIGNMENT

Minimum Radius (m)

4.6 VERTICAL ALIGNMENT

4.7 LANE WIDTH AND SHOULDER

Road Type Definition/ Criteria Road Width (m) Shoulder Width

Main - All roads outside plant area. 8 2

- Road leading to plant area and

Plant - All roads in and around 4-6 1.5

Patrol - To accommodate vehicles with 3 -

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Road Type Definition/ Criteria Road Width (m) Shoulder Width

Maintenance - To facilitate access to future to suit -

- Access to other areas not